Stairmaster 4400 PT/CL manual General Troubleshooting Guidelines, Electrical Troubleshooting

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TROUBLESHOOTING

GENERAL TROUBLESHOOTING GUIDELINES

This troubleshooting section is organized into three basic problem sections: electrical troubleshooting, console diagnostic tests, and mechanical trouble- shooting. Once you have identified the problem section, perform all the tests in the same order as written. To order a replacement part or for help with trouble- shooting, contact our Customer Service Department. Refer to the Appendix for the appropriate phone number.

ELECTRICAL TROUBLESHOOTING

The 4600/4400 PT electrical system has four major components: the alterna- tor, the power supply, the power cables, and the console. The 4600/4400 CL has five major components: the alternator, the power board, the battery, the power cables, and the console. The console, power board, and power supply are not serviceable by the owner. If any of these parts are inoperable, they must be replaced. Opening the console or the power supply will void the warranty.

4600/4400 PT

1.Use a voltmeter set on VAC to verify that the AC wall outlet has 100 to 120 VAC (or 220 to 240 VAC, if applicable). If you do not have a voltmeter plug in an alternate AC-powered device (e.g., a lamp). If the device does not work when plugged into the electrical outlet, consult an electrician for further assistance and then retest the electrical outlet.

2.Plug the power supply into the wall outlet. The green Light Emitting Diode (LED) on the power supply should be on. If the LED does not light up, replace the power supply.

3.Disconnect the DC cable from the left side panel. Set the voltmeter to VDC and test for 12 to 19 VDC in pins #1 (+) and #2 (-). Replace the power supply if the voltage reading is outside the specified range.

4.Remove the bottom cover and connect the DC cable to the power connector on the left side of the frame. Locate the black and white wires on the backside of the power connector.

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Contents 4200 PT, 4400 PT/CL 4600 PT/CL Willows Road N.E., Suite Kirkland, WA 800 425 Fax 425 Corporate HeadquartersWarranty Preface What is in this MANUAL?What is the Stairmaster Freeclimber Exercise SYSTEM? Contents Pretest Screening Alternator Test Parts Removal and ReplacementAppendices Dimensions and Specifications forList of Tables List of IllustrationsDrive Shaft Assembly & Eccentric Hub Assembly ContentsSafety Guidelines Important Safety InstructionsDo not use the machine outdoors Major Parts 4600 PT/CL IntroductionMajor Parts 4200 PT and 4400 PT/CL Internal Battery Power Supply SpecificationsBattery Charger Specifications Level Adjusting End Caps Installation InstructionsDC Power Connector Your Machine Must be Properly Grounded General Guidelines for Safe Operation Basic Operating InstructionsIf AT ANY Time During Your Workout YOU Feel Chest Pain Begin ExercisingCool Down Program starts at level threeRest Periods Correct Exercise Position Locked/Non-locked Option Heart Rate MonitoringHeart Rate Input Error Messages Telemetry Heart Rate 4600/4400 PT/CL only Using the Transmitter BeltTelemetry Heart Rate StairMaster Transmitter Belt Maintaining the Transmitter BeltContact Heart Rate Using Contact Heart RateContact Heart Rate Display Window Workout Options Freeclimber 4400/4600 PT/CL ConsoleWorkout Statistics StopEntertainment Keypad Numeric KeypadIntensity Level Keys Stop KEY PromptWorkout Statistics Exercise Program Keypad Weight 175 lbsIntensity Level Quick Start ProgramSpeed Intervals Program Fat Burner ProgramAerobic Training Program Constant Heart Rate Program Rest IntervalFitness Test Programs Understanding Submaximal Exercise TestingIndividuals Minus age low estimateStairMaster Submaximal Fit Test Pretest ScreeningFreeclimber 4400/4600 PT/CL Console StairMaster Fitness Protocol Women Freeclimber 4600/4400 PT/CL ConsoleMEN Turning on the Nycfd Stair Climb Test Turning on the Cpat Stair Climb TestConsole Codes Quick Scan Programming Machine Status Codes Xxxx Resetting the Maintenance Hour CounterConfiguration Code TOP Window Workout SetupFreeclimber 4200 PT Console TimerKeypad Bottom WindowQuick Start Option Maintenance Records Maintenance InstructionsHelpful Hints Tool ListPreventive Maintenance Initial ServiceCleaning InspectingLubrication Battery Disposal Battery ChargeFrequency Cleaner Recommended Preventive Maintenance ScheduleGeneral Troubleshooting Guidelines TroubleshootingElectrical Troubleshooting 4600/4400 PTAlternator Test Electrical TroubleshootingResistor Test 4600/4400 CL Battery TestDiode Test Electrical Troubleshooting Diagnostic Codes 4600/4400 PT/CL Console Diagnostic TestsDisplay Test Keypad TestSerial Port Test Press Level , 6 , 1 , to start the testTach Test Error ReportingContact Heart Rate Test 4600/4400 PT/CL Console Diagnostic TestsTelemetry Polar Heart Rate Test Unplug the machine and remove the bottom side covers Mechanical TroubleshootingAs applicable Mechanical Troubleshooting Covers Parts Removal and ReplacementMid Cover Top CoverRemove the mid cover Shield 4600 PT/CLBottom Cover POLY-V and HTD Belt Console AdjustmentConsole Pedal ARM Return Spring Step Chain RetainerRemove the bottom cover Remove the bottom cover Remove the step chain retainers Reinstall the coversStep Chain Drive Chain Spring PulleyRemove the snap ring from the left end of the drive shaft Drive Shaft AssemblyParts Removal and Replacement Leveling ARM PedalPedal ARM Reverse the removal procedures to reinstall the pedal armSlide or gently tap the pedal arm off the mounting shaft Pedal PADHandlebar 4400 PT/CL ,4200 PT Eccentric HUB AssemblyFirst Reduction Shaft Assembly Side Handrails 4600 PT/CL Upper Handles 4600 PT/CLAlternator Reverse the removal procedures to reinstall the handrailGrounding Instructions This may vary for International power suppliesCanadian DOC Class B Compliance FCC ComplianceAppendices State Address Phone Number Battery RecyclingNew York Corporate Circle 315 New Jersey Industrial Ave 201Syracuse, NY Ohio, Central Rickenbacker ANG 513 Bldg Columbus, OH Ohio, North Hamilton Ave 216Parts Needing Periodic Maintenance Final Assembly Left, 4600 PT Final Assembly Right,4600 PT Final Assembly Left, 4600 CL Final Assembly Right, 4600 CL Covers 4600 PT/CL Appendices Appendices Final Assembly Left, 4400/4200 PT Final Assembly Right, 4400/4200 PT Final Assembly Left, 4400 CL Final Assembly Right, 4400 CL Covers 4400 PT/CL, 4200 PT Cover Removal Cover fasteners Drive Chain tensioning Belt Tension