Stairmaster 4600 PT/CL, 4200 PT, 4400 PT/CL manual As applicable

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MECHANICAL TROUBLESHOOTING

Do not reinstall the Poly-V belt if performing step #4. Plug in the connector at position J4 or reconnect the DC power cable,

as applicable.

4.Remove the drive and step chains. Check the condition of the chains by flexing each link up and down. Each link should move freely. Re- place the chain if any stiff or inflexible links are found or if the chain is rusty, corroded, or otherwise damaged. Do not reinstall the chains.

5.Remove the pedals. Clean any corrosion off the pedal shaft with an oil-dampened rag. Apply a thin coat of multi-purpose grease to the shaft. If the noise persists, go to step 6.

6.Check the step chain connection point. Clean and grease the master link and bushing. Replace damaged parts.

7.Check the drive hub assembly.

Check the condition of the drive sprocket teeth. The teeth should not be unevenly worn. Replace the worn sprocket(s).

The drive sprockets work independently of one another. Each sprocket should turn freely in one direction and lock when turned in the other direction. Replace an inoperable drive sprocket.

Remove the drive shaft. Inspect the bearings in the drive hub. Replace the drive hub assembly if the shaft does not spin freely or if there is excessive radial play at the shaft. Be careful not to get dirt into the hub.

Inspect the ends of the drive shaft (at the sprocket attachment points) for signs of wear or scoring. Replace the shaft if it is excessively worn.

8.Check the pedal arm and leveling arm shafts by removing both the right and left pedal and leveling arms. Inspect the shafts and the bushings for signs of wear and corrosion. Replace the bushing(s) if worn.

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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 What is in this MANUAL? What is the Stairmaster Freeclimber Exercise SYSTEM?Preface Contents Pretest Screening Alternator Test Parts Removal and ReplacementList of Illustrations Dimensions and Specifications forAppendices List of TablesDrive 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 Power Supply Specifications Battery Charger SpecificationsInternal Battery 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 ExercisingProgram starts at level three Rest PeriodsCool Down Correct Exercise Position Heart Rate Monitoring Heart Rate InputLocked/Non-locked Option Error Messages Using the Transmitter Belt Telemetry Heart RateTelemetry Heart Rate 4600/4400 PT/CL only StairMaster Transmitter Belt Maintaining the Transmitter BeltUsing Contact Heart Rate Contact Heart RateContact Heart Rate Stop Freeclimber 4400/4600 PT/CL ConsoleDisplay Window Workout Options Workout StatisticsPrompt Numeric KeypadEntertainment Keypad Intensity Level Keys Stop KEYWorkout Statistics Quick Start Program Weight 175 lbsExercise Program Keypad Intensity LevelFat Burner Program Aerobic Training ProgramSpeed Intervals 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 Freeclimber 4600/4400 PT/CL Console MENWomen Turning on the Nycfd Stair Climb Test Turning on the Cpat Stair Climb TestConsole Codes Quick Scan Programming Machine Status Codes Resetting the Maintenance Hour Counter Configuration CodeXxxx TOP Window Workout SetupFreeclimber 4200 PT Console TimerKeypad Bottom WindowQuick Start Option Tool List Maintenance InstructionsMaintenance Records Helpful HintsInspecting Initial ServicePreventive Maintenance CleaningLubrication Battery Disposal Battery ChargeFrequency Cleaner Recommended Preventive Maintenance Schedule4600/4400 PT TroubleshootingGeneral Troubleshooting Guidelines Electrical TroubleshootingAlternator Test Electrical Troubleshooting4600/4400 CL Battery Test Diode TestResistor Test Electrical Troubleshooting Keypad Test 4600/4400 PT/CL Console Diagnostic TestsDiagnostic Codes Display 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 Top Cover Parts Removal and ReplacementCovers Mid CoverShield 4600 PT/CL Bottom CoverRemove the mid cover Console Adjustment ConsolePOLY-V and HTD Belt Step Chain Retainer Remove the bottom coverPedal ARM Return Spring Reinstall the covers Step ChainRemove the bottom cover Remove the step chain retainers Drive Chain Spring PulleyRemove the snap ring from the left end of the drive shaft Drive Shaft AssemblyParts Removal and Replacement Leveling ARM PedalPedal PAD Reverse the removal procedures to reinstall the pedal armPedal ARM Slide or gently tap the pedal arm off the mounting shaftEccentric HUB Assembly First Reduction Shaft AssemblyHandlebar 4400 PT/CL ,4200 PT 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 RecyclingBldg Columbus, OH Ohio, North Hamilton Ave 216 New Jersey Industrial Ave 201New York Corporate Circle 315 Syracuse, NY Ohio, Central Rickenbacker ANG 513Parts 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