Stratus Systems Owner`s Manual
Stratus Systems
Owner’s Manual
Printed in the United States.
© 1997, 2000 StairMaster Health & Fitness Products™
All rights reserved.
Corporate Headquarters
12421 Willows Road N.E., Suite 100
Kirkland, WA 98034
(800) 635-2936
(425) 823-1825
Fax (425) 823-9490
www.stairmaster.com
P/N 21442-H
©1997, 2000 StairMaster Health & Fitness Products™ and StairMaster are either a registered
trademark or trademark of StairMaster Health & Fitness Products™ in the
United States and/or other countries. StairMaster is a Rutledge Capital company.
Page iii
WARRANTY
This is to certify that the StairMaster® Stratus systems cycle ergometer is
warranted for a period of three years by StairMaster Health & Fitness Products™
to be free of all defects in materials and workmanship. This warranty does not
apply to any defect caused by negligence, misuse, accident, alteration, improper
maintenance, or an “act of God.” This warranty is nontransferable from the
original owner.
If, within three years from the date of purchase, any part of the StairMaster Stratus systems cycle ergometer should fail to operate properly (except any
accessories or the battery), contact our Customer Service
Department to report the problem. International customers should contact their
local distributor. When calling, please be prepared to provide our customer
service representative with the following information:
•
•
•
•
•
Your name, shipping address, and telephone number;
The model number of the inoperable unit;
The serial number of the inoperable unit (located on the frame);
The date(s) of purchase for the inoperable unit(s);
Your billing address.
This information will ensure that you are the only one ordering parts under
your warranty protection. If warranty replacement parts are shipped to you, you
may be required to return the inoperable part. To facilitate this process, the
following policy has been established:
• Please call our Customer Service Department to receive a return goods
authorization prior to shipment.
• StairMaster Health & Fitness Products™ will incur all freight (i.e.,
shipping and handling) charges for warranty parts ordered for a product
that is less than 45 days old. The parts will be shipped to you via an
overnight courier.
• The customer is responsible for freight charges on warranty parts for
products that are more than 45 days old. Customers will not be
responsible for the return shipment of the inoperable parts (see below).
• Some inoperable warranty parts must be promptly returned to our
Customer Service Department. We will pay the shipping cost for the
inoperable warranty parts. Detailed instructions are included with each
warranty replacement part shipment.
StairMaster Health & Fitness Products™ neither makes, assumes, nor
authorizes any representative or other person to make or assume for us, any
other warranties whatsoever, whether expressed or implied, in connection with
the sale, service, or shipment of our products. We reserve the right to make
changes and improvements in our products without incurring any obligation to
similarly alter products previously purchased. In order to maintain your product
warranty and to ensure the safe and efficient operation of your StairMaster
Stratus systems cycle ergometer, only authorized replacement parts can be used.
This warranty is void if any parts other than those provided by StairMaster
Health & Fitness Products™ are used.
* Note: Aerosol products cannot be transported via air.
Page iv
PREFACE
The StairMaster® Stratus systems cycle ergometer is a safe and effective way
to develop aerobic fitness while conditioning the major muscles of the lower
body. In order to get the best results, and to keep your machine in peak operating
condition, you should carefully read and follow the guidelines presented in this
manual.
WHAT IS IN THIS MANUAL?
This manual includes sections on safety, installation, operating instructions,
preventive maintenance, and detailed information on troubleshooting and repair
procedures. An appendix at the end of the manual provides important phone
numbers and drawings.
WHAT IS THE STAIRMASTER STRATUS CYCLE
ERGOMETER?
The Stratus systems cycle ergometers have 14 levels of intensity for the
MANUAL program and 20 levels of intensity for the other programs. The Stratus
uses a variable resistance system to maintain constant power within any given
intensity level. The resistance decreases as you pedal faster and increases as
you pedal slower. The variable resistance system ensures you will do the same
amount of work regardless of how fast or slow you pedal.
WHAT IS THE BATTERY CHARGER USED FOR?
Plug in the battery charger only to recharge a weak battery. Exercising on the
Stratus cycle while the battery charger is connected will not damage the
machine, but will affect the power output (watts) statistics.
Page v
CONTENTS
SAFETY GUIDELINES ....................................................................................... 1
INTRODUCTION ................................................................................................ 3
INSTALLATION INSTRUCTIONS ..................................................................... 5
BASIC OPERATING INSTRUCTIONS ............................................................. 6
Adjustments .......................................................................................... 6
The ATTRACT Mode .............................................................................. 7
Basic Instructions For First-Time Users ................................................ 7
GENERAL EXERCISE GUIDELINES ................................................................. 9
Setting a Goal ....................................................................................... 9
Flexibility Training ................................................................................. 9
Exercise Principles ................................................................................ 10
CONTACT HEART RATE (OPTIONAL) ............................................................. 11
POLAR® HEART RATE ....................................................................................... 12
CONSOLE ........................................................................................................... 13
Text Bar ................................................................................................. 13
Display .................................................................................................. 13
Function Keypad .................................................................................... 14
Exercise Program Keypad ..................................................................... 16
Road Race ............................................................................................. 25
Custom Exercise Programs ................................................................... 26
Custom Scrolling Message ................................................................... 27
Editing the Scrolling Message .............................................................. 28
Set Maximum Workout Length ............................................................. 29
Changing to the Clinical Mode ............................................................. 29
Changing the Console Units and Prompt Language ............................. 29
Console Codes ...................................................................................... 30
MAINTENANCE INSTRUCTIONS ................................................................... 31
Helpful Hints ......................................................................................... 31
Tool List ................................................................................................. 31
Maintenance Records ........................................................................... 31
Page vi
CONTENTS
Initial Service ........................................................................................ 32
Preventive Maintenance ....................................................................... 32
TROUBLESHOOTING GUIDELINES ................................................................ 36
General Troubleshooting Guidelines ..................................................... 36
Systematic Electrical Troubleshooting .................................................. 36
Systematic Mechanical Troubleshooting.............................................. 38
Console Diagnostic Tests ...................................................................... 40
PARTS REMOVAL AND REPLACEMENT ....................................................... 44
Covers ................................................................................................... 44
Console ................................................................................................. 44
Handlebar Assembly ............................................................................. 46
Seat ....................................................................................................... 47
Seat Location Post (3300 CE only) ........................................................ 48
Seat Track (3900 RC only) ..................................................................... 49
Drive Chain ............................................................................................ 49
Intermediate Shaft Assembly ............................................................... 50
Pedals .................................................................................................... 51
Crank and Bottom Bracket Assembly ................................................... 51
GROUNDING INSTRUCTIONS ........................................................................ 54
NOTICE OF FCC COMPLIANCE ....................................................................... 55
APPENDICES
Important Phone Numbers .................................................................... 56
Battery Recycling Centers ..................................................................... 57
Figures 11 - 24 ...................................................................................... 58
Wiring Diagram ..................................................................................... 73
LIST OF TABLES
Table 1: Specifications .......................................................................... 4
Table 2: Fitness Rating Norms .............................................................. 18
Table 3: Character Codes ...................................................................... 28
Table 4: Console Codes ......................................................................... 30
Table 5: Preventive Maintenance Schedule ......................................... 35
Page vii
CONTENTS
LIST OF ILLUSTRATIONS
Figure 1: Major Parts, 3300 CE ............................................................. 3
Figure 2: Major Parts, 3900 RC ............................................................. 4
Figure 3: End Caps ................................................................................ 5
Figure 4: Stratus Systems Console ....................................................... 13
Figure 5: Fat Burner ............................................................................... 19
Figure 6: Fat Burner Plus ....................................................................... 20
Figure 7: Rolling Hills ............................................................................ 21
Figure 8: Aerobic Training ..................................................................... 22
Figure 9: Cross Country ......................................................................... 23
Figure 10: Speed Training ..................................................................... 24
Figure 11: Cover Fasteners ................................................................... 59
Figure 12: Cover Fastener Location, 3300 CE ....................................... 60
Figure 13: Cover Fastener Location, 3900 RC ....................................... 61
Figure 14: Right Side View, 3300 CE ..................................................... 62
Figure 15: Left Side View, 3300 CE ....................................................... 63
Figure 16: Right Side View, 3900 RC .................................................... 64
Figure 17: Left Side View, 3900 RC ....................................................... 65
Figure 18: Seat Adjustment Pin Assembly, 3300 CE ............................. 66
Figure 19: Seat Assembly, 3900 RC ...................................................... 67
Figure 20: Drive Chain Tension ............................................................. 68
Figure 21: Intermediate Shaft Assembly .............................................. 69
Figure 22: J Bolt Assembly ................................................................... 70
Figure 23: Crank Assembly ................................................................... 71
Figure 24: Alternator/Flywheel Assembly ............................................ 72
Wiring Diagram 1: Wiring Schematic ................................................... 73
Page viii
SAFETY GUIDELINES
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:
IMPORTANT SAFETY INSTRUCTIONS
!
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is involved.
The following definitions apply to the words “Danger” and “Warning”
found throughout this manual:
DANGER - Used to call attention to IMMEDIATE hazards which, if not
avoided, will result in immediate, serious personal injury or loss of life.
WARNING - Used to call attention to POTENTIAL hazards that could
result in personal injury or loss of life.
READ ALL INSTRUCTIONS BEFORE USING THE MACHINE.
!
DANGER
To reduce the risk of electrical shock, always unplug
the external power supply from the AC wall outlet
before cleaning, maintaining, or repairing.
!
WARNING
To reduce the risk of burns, electric shock, or injury
to persons:
1.
The external power supply should always be unplugged from the AC wall
outlet before removing or installing parts. Never make adjustments or
repairs while an exercise program is in progress.
2.
Close supervision is necessary whenever the machine is used by or near
children, invalids, or disabled persons.
3.
Keep your hands away from all moving parts and keep your feet on the
pedals while exercising. Do not operate the machine with the side covers
removed.
Page 1
SAFETY GUIDELINES
4.
Use this machine only for its intended use as described in this Manual. Do
not use parts, attachments, or accessories other than those provided by
StairMaster Health & Fitness Products™.
5.
Do not use the external power supply if it has a damaged cord or plug, if it
is not working properly, if it has been dropped or damaged, or dropped
into water. Contact our Customer Service Department to arrange for the
return of damaged parts.
6.
Connect the external power supply to a properly grounded AC wall outlet;
refer to the “Grounding Instructions” section. Keep all cords away from
heated surfaces.
7.
To disconnect the external power supply, remove the plug from the AC
wall outlet.
8.
Never drop or insert any object into any opening on the machine.
9.
Do not operate where aerosol (spray) products are being used.
10. Always wear insulated gloves when handling batteries.
11. Do not crush, incinerate, or dismantle the battery. The electrolyte
contains sulfuric acid which can cause serious damage to eyes
and skin. Should this occur, flush profusely with water and seek
medical attention.
12. Do not use the machine outdoors.
The safety level given by the design of this equipment can only be maintained
when the equipment is regularly examined for damage and wear. Inoperable
components shall be replaced immediately or the equipment shall be put out of
use until it is repaired. Failure to follow all guidelines may compromise the
effectiveness of the exercise experience, expose yourself (and possibly others) to
injury, and reduce the longevity of the machine. Follow all training instructions
listed in the manual and/or on the machine. Physical injury may result from
incorrect or excessive training.
SAVE THESE INSTRUCTIONS
Page 2
INTRODUCTION
Before leaving the StairMaster manufacturing facility in Tulsa, Oklahoma, your
StairMaster® Stratus cycle ergometer was thoroughly inspected and tested to
ensure proper operation. The major parts of the StairMaster Stratus 3300 CE and
3900 RC are shown in Figures 1 and 2.
Figure 1: Major Parts, 3300 CE
Page 3
INTRODUCTION
Figure 2: Major Parts, 3900 RC
Throughout this manual, all references to the left or right side and to the front or
back are made as if you were on the machine, ready to exercise. For example, the
drive chain is located on the right side of the machine. The dimensions of the
machine are listed in Table 1.
Table 1. Dimensions of the Stratus Systems Cycle Ergometer
3300 CE
Length
Width
Height
Weight
Page 4
50 inches (127 cm)
22 inches (56 cm)
57 inches (145 cm)
125 pounds (57 kg)
3900 RC
64 inches (163 cm)
21 inches (53 cm)
42 inches (107 cm)
157 pounds (71 kg)
INSTALLATION INSTRUCTIONS
Assemble your machine before use. Machines shipped outside the United States
need to be uncrated before they can be assembled; refer to the “Uncrating
Instructions” included with your machine for the details.
1.
Remove all shipping material and the battery charger from the
console.
2.
Make sure the machine is level before you use it for the first time. The
four rubber end caps (see Figure 3) are designed to compensate for
slightly uneven floors. Each face of the caps is a different thickness.
Twist the caps to stabilize the machine.
Figure 3: End Caps
3.
Pedal the cycle to turn on the console. The console should produce an
audible sound and display a simulated EKG signal in the display area.
If it does not, contact our Customer Service Department. Refer to the
Appendix for the appropriate phone number.
Page 5
BASIC OPERATING INSTRUCTIONS
ADJUSTMENTS
You should check two adjustments before using your StairMaster® Stratus
systems cycle ergometer: the seat height and the pedal footstrap length.
Seat Height Adjustment on the Stratus 3300 CE Cycle Ergometer
Sit on the seat. Put both feet onto the pedals and into the footstraps. Pedal
slowly and then stop when one leg is extended and your foot is as close to the
floor as possible. The knee of the extended leg should be slightly bent when the
sole of your foot is parallel to the floor. If you need to adjust the seat height, get
off the bike and stand to one side. The seat adjustment knob is located on the
frame tube just below the front part of the seat. Hold onto the seat with one
hand and pull out on the seat adjustment knob with your other hand. You may
need to lift up on the seat to disengage the seat pin. Lower or raise the seat as
necessary.
!
WARNING
TO ELIMINATE THE RISK OF INJURY, DO NOT ADJUST THE SEAT HEIGHT
WHILE ON THE STRATUS 3300 CE CYCLE ERGOMETER. MAKE SURE THAT
THE SEAT ADJUSTMENT PIN COMPLETELY ENGAGES THE HOLE IN THE SEAT
POST BEFORE REMOUNTING THE BIKE.
Seat Adjustment on the Stratus 3900 RC Cycle Ergometer
Sit on the seat. Put both feet onto the pedals and into the footstraps. Pedal
slowly and then stop when one leg is extended. The knee of the extended leg
should be slightly bent. The seat adjustment lever is in front of the seat base.
Remain seated and keep your feet on the pedals. Pull up on the lever and slide
forward or backward as necessary. Release the lever and make sure the seat is
locked in place by trying to move the seat forward and backward.
Page 6
BASIC OPERATING INSTRUCTIONS
Footstrap Adjustment
To ensure your feet are properly secured to the pedals, you need to check the
position of the footstraps. Position your foot so that the ball of your foot is over
the pedal spindle. The pedal footstraps should be tight enough to secure your
feet to the pedals but not so tight so as to cut off the circulation. If you need to
adjust the footstrap length, get off the bike and stand to one side. There are two
adjusting holes on the inside footstrap mount and four holes on the outside
footstrap mount. Most shoes can be accommodated by adjusting the outside
mounting holes. To make the necessary adjustments, grasp the pedal with one
hand and the outside end of the footstrap with your other hand. Carefully pull the
outside end of the footstrap off the tab on the pedal. Insert the proper hole of the
footstrap onto the pedal tab. If you need to make additional adjustments, repeat
the process with the inside mounting holes of the footstrap.
THE ATTRACT MODE
All workouts on the StairMaster® Stratus cycle ergometer start from the ATTRACT mode. The console displays an EKG signal or scrolls a message in the text
bar when it is in the ATTRACT mode. You must pedal to get the console into the
ATTRACT mode.
You can customize the ATTRACT mode by programming your own
scrolling message. Refer to the “Customizing the Text Bar Scrolling Message”
section for instructions.
BASIC INSTRUCTIONS FOR FIRST-TIME USERS
1.
Warm up with light calisthenics and easy stretching exercises for at
least five minutes before beginning your exercise program.
!
WARNING
IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN,
EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF
BREATH, STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU
SHOULD CONSULT YOUR MEDICAL DOCTOR IMMEDIATELY.
Page 7
BASIC OPERATING INSTRUCTIONS
2.
Position yourself comfortably on the bike and begin pedaling.
3.
Select the MANUAL exercise program so you can control the pace of
your first workout and get used to the exercise motion.
Console Set-Up
1.
Press [MANUAL] and then press [ENTER].
2.
The console will prompt you to enter your body weight. Enter your
weight in pounds (or kilograms if the console is set up for
metric units). Correct entry errors by pressing [CLEAR] before you
press [ENTER].
3.
The console will prompt you to enter the workout time in one minute
increments between five and 60 minutes. Press [1], [0], [ENTER] to
exercise for ten minutes.
Begin Exercising
1.
Pedal at a comfortable pace. Although the resistance decreases as
you pedal faster, the intensity (watts) stays the same.
2.
Press [+ ARROW] and [- ARROW] to adjust your intensity level.
3.
Select an intensity level that allows you to stay at a comfortable pace.
Harder is not always better. Exercise at a level that is consistent with
your fitness level.
4.
The intensity (watts) remains constant provided you pedal at least 50
RPM. A message will prompt you to "Pedal Faster" if you pedal slower
than 50 RPM.
5.
Cool down after you get off the machine by walking or stretching for
at least five minutes.
Page 8
GENERAL EXERCISE GUIDELINES
SETTING A GOAL
The first step to a successful exercise program is to set realistic goals and
objectives. Are you wanting an exercise program that is geared to build muscle,
maintain muscle tone, or lose weight? In order to ensure that you fully receive all
the benefits of a sound exercise program, you need to first identify the existence
(if any) of risk factors that may influence the design of your exercise program.
Based upon a comprehensive analysis of your personal exercise needs and
interests, you should then develop (or have developed for you by a competent or
trained professional) an individualized program of exercise that is enjoyable,
easy, and yet challenging. Your greatest health benefit will come from a lifestyle
change that encourages a lifetime of physical activity.
One way to guarantee success in reaching your goal is to eat correctly. A
well-rounded diet provides the proteins, carbohydrates, fats, vitamins, minerals,
and water necessary for good health. If you are unsure of your dietary needs,
seek the advise of your physician, an exercise professional, or visit your local
bookstore for more information on nutrition.
FLEXIBILITY TRAINING*
Achieving and maintaining an adequate range of motion should always be
objectives of a comprehensive exercise program. The warm-up phase of your
exercise session should include some type of light warm-up activity to increase
both your heart rate and your body temperature, which is then followed by
flexibility exercises that are specifically designed to stretch the musculature
around your body’s major skeletal joints. Attempting to stretch a cold muscle can
be dangerous to the soft tissues surrounding the muscle. No matter how
controlled the movement, forcing a muscle through a full range of motion (and
beyond) without appropriately warming up is both unsafe and counterproductive.
A general exercise program for achieving and maintaining flexibility should
adhere to the following guidelines:
•Frequency
•Intensity
•Duration
- daily
- to a position of mild discomfort
- 10-30 seconds for each stretch
Page 9
GENERAL EXERCISE GUIDELINES
•Repetitions
•Type
- 2-6 for each stretch
- static, with a major emphasis on the low back and
hamstrings area because of the high prevalence
of low-back pain syndrome in our society.
EXERCISE PRINCIPLES*
The American College of Sports Medicine has developed a position paper
concerning exercise programs for healthy adults and the need for guidelines. The
following recommendations concern the quantity and quality of (exercise)
training for developing and maintaining cardiorespiratory fitness in a healthy
adult:
•Frequency
•Intensity
•Duration
•Mode of Activity
•Rate of Progression
-3 to 5 days per week
-50% - 85% of maximum oxygen
uptake (VO2 max)
-20 to 60 minutes of continuous
aerobic activity
-Any activity that uses the large
muscle groups, that can be
maintained continuously, and is
rhythmical and aerobic in nature.
-Initial Conditioning - 4 to 6 weeks; lowend intensity (40% - 60% VO2 max); low-end
duration (15 to 20 minutes).
-Improvement Stage - 6 weeks to 6 months;
moderate intensity; moderate duration.
-Maintenance Stage - 6 months plus;
moderate to high intensity; moderate to
high duration.
*Note: Some of the material contained in this section is adapted from The
StairMaster® Fitness Handbook 2nd Ed., James A Peterson, and Cedric X. Bryant
(editors), Sagamore Publishing, 1995.
Page 10
CONTACT HEART RATE
The StairMaster® Stratus Systems cycle ergometer features an optional digitized
contact heart rate monitoring system. Through the use of stainless steel sensors
built into the upper handles and sophisticated software, heart rate can be
checked at any time during a workout.
The heart generates a rhythmic, electronic signal each time it beats (the
electrocardiogram or EKG signal). The sensors detect this electrical signal
through the hands when the sensors are gripped during a workout. The signal is
converted into a heart rate, which is displayed on the console.
The contact heart rate system is very accurate (within 3% of the
medical standard), but its ability to detect a heart rate signal is influenced by
several factors. Movement of the muscles of the upper body produces an
electrical signal that will interfere with the detection of the heart rate signal by
the sensors. Movement of the hands while they are in contact with the sensors
also produces interference. Calluses and hand lotion act as an insulating layer to
reduce the signal strength. Also, the EKG signal generated by some individuals is
not strong enough to be detected by the sensors. Typically, these individuals
account for 5 - 7% of the population. Most people (between 93 – 95%) will not
have a problem with the system provided interference from movement is
minimal.
Lightly grip the sensors with each hand. The heart rate display is
shown automatically in the upper window the first time the sensors are touched.
A valid signal is shown by a pulsating heart icon and the number of beats per
minute next to the word “Pulse”. The heart icon will stop beating and two dashes
replace the numbers when the sensors are released or an invalid signal is
received.
Page 11
POLAR® HEART RATE
The StairMaster® Stratus cycle ergometer features Polar® heart rate
monitoring. The system consists of the receiver, located on the stepper, and
a transmitter belt (purchased separately), worn across your chest. The transmitter belt senses the heart beat and sends a signal to the receiver. Your heart rate,
in beats per minute, is shown on the console text bar.
The transmitter belt attaches an identification number to your heart rate
signal. Once the receiver locks on to your signal, it will ignore all other signals
without your identification number. Now, two people can exercise
side-by-side without interfering with each other's heart rate signal.
Before you put the transmitter belt on, wet the two contact patches (the
grooved rectangles on the reverse side of the belt). Secure the transmitter belt as
high under the pectoral muscles (chest) as is comfortable. The transmitter belt
should fit snugly and comfortably and allow normal breathing.
When the console detects a heart rate signal, heart rate is shown in the
display automatically. The word "PULSE", your heart rate in beats per minute, and
a pulsing heart icon are displayed in the text bar.
If you display a statistic other than heart rate during your workout, you
can return to heart rate by pressing the white [0] key. Heart rate is part of the
workout stats scrolling display. Average heart rate is shown at the end of your
workout. If you wear a transmitter strap during the Fit Test, the average heart
rate at the end of each stage is automatically used when estimating maximum
aerobic capacity.
Page 12
STRATUS SYSTEMS CONSOLE
The StairMaster® Stratus systems console is divided into four sections: the text
bar, the display, the function keypad and the exercise program keypad (see
Figure 4).
Figure 4: Stratus Systems Console
TEXT BAR
Information regarding workout statistics and data entry is displayed or scrolled
across the text bar. A countdown timer is located directly above the words
"Interval Time". The timer shows the number of seconds remaining in the current
interval.
DISPLAY
A profile of all exercise programs (except MANUAL and FIT TEST) appears in the
display when you press its key. The taller the column, the higher the intensity
(watts) for that interval. The flashing column shows your current interval. The
flashing column moves from left to right across the display as you complete each
interval.
Page 13
STRATUS SYSTEMS CONSOLE
Function keypad
The function keypad is located on the right side of the console. Nine of the keys
on the keypad have two pieces of information on them—a number and a
workout statistic. Before the exercise program begins, the numbers are used to
enter data in response to the console prompts. During or immediately after the
exercise program, the function keypad keys are used to recall workout statistics
which are then displayed on the text bar.
Time. Displays the elapsed time of your workout, in minutes and
seconds.
Speed. Displays the equivalent speed, in miles per hour (or
kilometers per hour if your console is set to metric units), you
would be traveling on a bicycle outdoors while riding at the same
relative intensity.
Distance. Provides a cumulative total of the equivalent distance,
in miles (or kilometers if your console is set to metric units), you
would have traveled while riding a bicycle outdoors at the same
relative intensity.
Watts. Displays the intensity in watts (746 watts = 1 horsepower). For
all programs, except the constant resistance ROAD RACE, the watts
remain constant in any given level as long as you pedal at least 50
RPM. During a workout, this key displays the power output at that
moment. Average power is shown during the workout summary.
Intensity Level. Shows the current level between 1 (the easiest) and
20 (the hardest). Shows the number of lights in the MANUAL program
between 1 and 14.
METs. Gives you the relative energy cost of exercise. MET stands for
multiples of the resting metabolic rate. While you are sitting quietly,
your body consumes oxygen at the rate of about 3.5 milliliters per
kilogram of body mass per minute. When you exercise, your body
needs more oxygen in order to function. For example, exercising at 10
METs requires ten times the resting rate of oxygen consumption, or
Page 14
STRATUS SYSTEMS CONSOLE
about 35 milliliters per kilogram per minute. During a workout, this key
shows the current MET level. During the workout summary, the
average MET level is displayed.
Calories. Provides a running total of the number of Calories burned
during a workout.
Enter. Confirms workout selections and stores the information used
by the console to calculate workout statistics.
Clear. Erases information from the console memory if pressed
before [ENTER].
[+] and [-] ARROWS. Increases or decreases the intensity level.
Workout Stats. If pressed during your workout, all workout statistics
continuously scroll across the text bar. Press any key to stop scrolling
at that statistic.
If [WORKOUT STATS] is pressed immediately after your
workout, the workout summary statistics will scroll once across the
text bar. Press any key to stop scrolling at that statistic.
If [WORKOUT STATS] is pressed while the console is in the
ATTRACT mode, the final totals from the last workout will scroll across
the text bar. This summary is stored in the console memory until the
next workout is started.
Yes and No. Respond to console prompts.
Start/Stop. If pressed while the console is in the ATTRACT mode, the
console will display the "Select A Program" prompt. If it is pressed at
any other time, the console will pause for 10 seconds.
Page 15
STRATUS SYSTEMS CONSOLE
EXERCISE PROGRAM KEYPAD
The purple exercise keypad is located below the display and to the left of the
function keypad. While the console is in the ATTRACT mode, press one of the
exercise program keys to preview the desired workout.
The sequence of prompts for the preset exercise programs is slightly
different than the sequence described earlier for the MANUAL program. After
you press one of the exercise program keys, the exercise program profile is
scrolled across the display.
After the profile is scrolled, the prompts are:
•
•
•
•
“PRESS ENTER KEY TO SELECT”
“ENTER BODY WEIGHT” -- type in your body weight in
pounds (or kilograms if your console is set to metric units).
“ENTER LEVEL 1 - 20” -- select your intensity level with
level 1 being the easiest and level 20 the hardest.
“ENTER TIME 5 - 60” -- select the workout duration in one
minute increments from five to 60.
The Quick Start Option
You can begin a manually-paced workout without pressing any keys just by
pedaling for 15 seconds. This program will last for 15 minutes.
You can quickly start a preset workout by first pressing one of the
purple exercise program keys and then pressing [ENTER] twice. You do not have
to enter any other information. The length of the workout is set automatically
and varies with the program. Quick starting MANUAL gives you a 15 minute
workout. The preset workouts last five minutes for every thirty intervals. So, a 60
interval program will last 10 minutes. The workout stats available are time,
speed, distance, watts, level, calories, RPM, and pulse (if wearing a transmitter).
The Fit Test does not have a quick start option.
Page 16
STRATUS SYSTEMS CONSOLE
Fit Test
The Fit Test is a program developed by the YMCA to estimate your maximum
aerobic capacity based on your heart rate response to submaximal exercise. Start
the Fit Test by pressing [FIT TEST], [ENTER]. You will be prompted to enter your
weight, age, and gender after a short message is scrolled across the text bar.
The Fit Test is a series of three minute stages of increasing intensity.
Maintain a steady pedal rate of 50 - 70 RPM throughout the entire test. The first
stage is a warm-up at 50 watts. At the end of the three minute (180 seconds)
warm-up, you will need to enter your heart rate. If you are wearing a heart rate
transmitter, your heart rate is entered automatically.
NOTE: Keep pedaling until the end of the Fit Test. The results will be
invalid if you do not maintain a steady pedal rate for the entire test.
The console will prompt you to find your pulse; use the artery below
your thumb in your wrist or the artery in the side of your neck. Start counting the
beats when the console prompts you--the first beat you feel is zero and then one
and so on. Enter the number of beats you counted in ten seconds.
The intensity of the remaining stages is based on your heart rate
response to the warm-up. The intensity of each successive stage will increase
until you have entered two consecutive heart rates between 19 and 25 counts
(115 - 150 beats per minute). The test typically lasts from nine to 15 minutes.
At the end of the Fit Test, your results scroll across the text bar. Prior to
a three minute cool-down, your estimated maximum aerobic capacity is shown in
METs. Next, your results are compared to normative values for others of your age
and gender (see Table 2). Your results are stored in the console until the next
person starts an exercise program. Press [WORKOUT STATS] to review your
results.
Page 17
STRATUS SYSTEMS CONSOLE
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20.0+
18.6+
17.4+
16.0+
14.3+
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14.0-16.8
13.7-16.6
13.1-16.0
12.0-14.0
10.6-12.6
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10.0-13.7
9.7-13.4
9.1-12.8
8.0-11.7
6.6-10.3
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17.1+
16.8+
16.3+
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12.8+v
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8.3-9.7
8.0-9.4
7.4-8.8
6.3-7.7
5.1-6.3
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Superior
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16.3-19.7
14.8-18.3
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<8.0
<7.7
<7.1
<6.0
<4.8
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12.6-16.0
11.4-14.6
10.3-13.4
9.1-12.3
7.7-11.1
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11.1-12.3
10.0-11.1
8.8-10.0
7.4-8.8
6.3-7.4
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<10.8
<9.7
<8.6
<7.1
<6.0
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Above Average
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Average
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Fair
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Men
20-29
30-39
40-49
50-59
60-69
Women
20-29
30-39
40-49
50-59
60-69
Low
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Gender/Age
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Table 2. Fitness Rating Norms for Stratus Systems
Cycle Ergometer Aerobic Fitness Test (METs)
Preset Exercise Programs
There are seven preset exercise programs. The exercise intensity (watts) during
the programs varies automatically over 14 increments within each of the 20
different levels. Varying the intensity level of an exercise program does not
change the profile shown on the display. Change the intensity level of your
workout by pressing [+ ARROW] or [- ARROW]. For each level, the average energy
cost of all programs is about the same.
Page 18
STRATUS SYSTEMS CONSOLE
The Fat Burner program (Figure 5) is a 60 interval workout designed for
people just starting a weight control program. The Fat Burner Plus program
(Figure 6) is similar but has 90 intervals. It is meant for the longer workouts you
will need as your fitness level increases.
Figure 5a: Fat Burner, Screen 1
Figure 5b: Fat Burner, Screen 2
Page 19
STRATUS SYSTEMS CONSOLE
Figure 6a: Fat Burner Plus, Screen 1
Figure 6b: Fat Burner Plus, Screen 2
Figure 6c: Fat Burner Plus, Screen 3
Page 20
STRATUS SYSTEMS CONSOLE
Rolling Hills (Figure 7) is a 30 interval workout with gradual
speed changes. It is geared for those who are just starting to exercise or
for those who need an easy day of recovery exercise.
Figure 7: Rolling Hills
Page 21
STRATUS SYSTEMS CONSOLE
Aerobic Training (Figure 8) is a 60 interval workout with slightly more
varied speed changes. It is ideal for those long, slow workouts to increase your
aerobic capacity.
Figure 8a: Aerobic Training, Screen 1
Figure 8b: Aerobic Training, Screen 2
Page 22
STRATUS SYSTEMS CONSOLE
Cross Country and Speed Training (Figures 9 and 10) are 90 interval
workouts with lots of speed changes to get your legs moving. Think of the terrain
you would find on a hike cross country.
Figure 9a: Cross Country, Screen 1
Figure 9b: Cross Country, Screen 2
Figure 9c: Cross Country, Screen 3
Page 23
STRATUS SYSTEMS CONSOLE
Figure 10a: Speed Training, Screen 1
Figure 10b: Speed Training, Screen 2
Figure 10c: Speed Training, Screen 3
Page 24
STRATUS SYSTEMS CONSOLE
ROAD RACE
1.
The Road Race is a unique program that places the user in a race
against a computer pacer.
2.
The Road Race uses a resistance system that increases the
resistance as you pedal faster, just like a real bicycle. The faster you
pedal, the heavier the resistance, and the faster you will travel.
3.
Start the Road Race program by pressing [ROAD RACE] and then
[ENTER]. Input your weight, and the total race distance in miles (or
Kilometers, if your console is set to metric units).
4.
Enter the level. You can change the pacer's speed at anytime during
the race. Use the [+ ARROW] or [- ARROW] to change the speed.
5.
The console will be count down to the start of the race. Start
pedaling when the word “GO !” appears in the text bar.
6.
Three lights will appear at the bottom of the display. The two outside
dots are you, and the inside dot is the pacer. Your progress, and the
pacer’s, is shown by lit LEDs.
7.
Each lap of the display area is 0.25 miles (0.25 kilometers)
8.
When the cyclist or the pacer enters the last lap, the entire track lights
up. As the finish line is approached, each LED corresponding to the
current position is turned off.
9.
The race ends when you cross the finish line. The race results are
shown on the text bar during the cool down period. The results are
stored until the next workout is started. Press [WORKOUT STATS] to
review your results.
Page 25
STRATUS SYSTEMS CONSOLE
CUSTOM EXERCISE PROGRAMS
The console has enough memory space for nine custom exercise programs. Only
the exercise profile is saved. You must enter your body weight, the intensity
level, and the workout time when you use the custom program. Custom programs
have a quick start option, but the time is limited to 15 minutes.
Programming Your Workout
1.
The console must be in the ATTRACT mode. Press [+ ARROW],
[1], [6], [5], [0], [ENTER]. Press the exercise program keypad
button that you want to assign to your custom program.
2.
If you select an exercise program keypad button that is already
programmed, the profile will appear; it can be modified or
completely rewritten. If the exercise program keypad button was
not previously programmed, you will see a single row of dots
along the bottom of the display.
3.
The flashing dot or column indicates which interval can be
modified. Press the [+ ARROW] or [- ARROW] to make the column
taller or shorter. Press [ENTER] to move one column to the right
and [CLEAR] to move one column to the left.
4.
When all of the intervals are correctly programmed, press [YES]
to save the profile. Press [START/STOP] to abort the programming
process without saving the profile.
Using a Custom Program
1.
Press [- ARROW] and the exercise program keypad button you
assigned to the custom program.
2.
Enter your body weight, the intensity level and the workout time
in response to the prompts.
Page 26
STRATUS SYSTEMS CONSOLE
CUSTOM SCROLLING MESSAGE
The message that scrolls across the text bar during the ATTRACT mode can be
replaced with a message of your choice. The console accepts messages up to
128 characters in length, including spaces. To program your message:
1.
Encode your message using the character codes listed in Table 3.
2.
While the console is in the ATTRACT mode, press [+ ARROW], [7],
[6], [0], [7], [ENTER].
3.
Enter the two-digit code for each letter of your message. The
letter will appear in the text bar as you press the second digit of
each code. Do not press [ENTER] between the code numbers.
4.
For example, to program the message “EXERCISE IS FUN”,
press [+ ARROW], [7], [6], [0], [7], [ENTER]. Then press [1], [5],
[3], [4], [1], [5], [2], [8], [1], [3], [1], [9], [2], [9], [1], [5], [1], [0], [1],
[9], [2], [9], [1], [0], [1], [6], [3], [1], [2], [4], [ENTER]. At that point,
your message will begin scrolling. The console is again in
the ATTRACT mode.
5.
If you make a mistake while entering the codes, press [CLEAR] to
erase the last character entered.
Page 27
STRATUS SYSTEMS CONSOLE
Table 3. Character Codes for the Scrolling Message
Character
Code
Character
Code
Character
Code
0
1
2
3
4
5
6
7
8
9
SPACE
A
B
C
D
E
F
G
H
I
J
K
L
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
Ä
Ü
Ö
ß
Å
Á
Ó
É
Ñ
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Í
À
Î
È
Â
Ç
Ê
¿
+
$
.
,
%
?
´
!
#
:
;
)
(
/
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
EDITING THE SCROLLING MESSAGE
1.
While the console is in the ATTRACT mode, press [+ ARROW], [7],
[6], [0], [7], [ENTER] to display the first character of the message
onto the text bar.
2.
Press [+ ARROW] or [- ARROW] to scroll through the message.
3.
Press [CLEAR] to delete the last character displayed on the text bar.
Press [ENTER] to end the editing process.
4.
To edit multiple characters at one time, press [9], [9], [ENTER].
This will erase all of the characters to the right of the last
character displayed on the text bar.
Page 28
STRATUS SYSTEMS CONSOLE
5.
To erase the entire message, press [+ ARROW], [1], [0], [5], [ENTER]
while in the ATTRACT mode.
6.
The edited message will scroll across the text bar. If you have
erased the entire message, the text bar area will be blank during
the ATTRACT mode.
7.
Press [+ ARROW], [2], [1], [2], [3], [ENTER] to display the default
scrolling message on the text bar.
8.
Press [+ ARROW], [2], [1], [2], [1], [ENTER] to display your custom
scrolling message on the text bar.
SETTING THE MAXIMUM WORKOUT LENGTH
Change the time limit by pressing [+ ARROW], [9], [7], [4], [0], [5], [ENTER], while
in the ATTRACT mode. Next, type in a number less than 60, but greater than 5,
and press [ENTER].
CHANGING TO THE CLINICAL MODE
Certain facilities may want to use the clinical mode which allows the user to
pedal at speeds less than 50 RPMs without the "PEDAL FASTER" prompt being
displayed. Turn on the clinical mode by pressing [+ ARROW], [9], [7], [6], [6],
[ENTER], [1], [ENTER] while in the ATTRACT mode. The battery will not be
charged at pedal speeds lower than 50 RPMs. To ensure trouble-free operation,
you must connect the battery charger at all times while the clinical mode is
turned on.
*** THE BATTERY CHARGER MUST BE CONNECTED AT ALL TIMES
WHILE THE CLINICAL MODE IS TURNED ON! ***
Turn off the clinical mode by pressing [+ ARROW], [9], [7], [6], [6],
[ENTER], [0], [ENTER].
CHANGING THE CONSOLE UNITS AND PROMPT LANGUAGE
The console is preset to English language prompts and English units. While the
Page 29
STRATUS SYSTEMS CONSOLE
console is in the ATTRACT mode, set the console for foreign language prompts or
metric units by pressing the [+ ARROW], [9], [7], [6], [0], [ENTER] and then [1],
[ENTER]. Press [+ ARROW], [9], [7], [6], [0], [ENTER] and then [0] to change back to
English units.
CONSOLE CODES
You must press [+ ARROW] before pressing the code's number keys, and then
press [ENTER].
Table 4. Console Codes
Code
105
Clears the custom programmed scrolling message
107
0
1
2
3
4
Activates the Diagnostic mode
Display test
Speaker test
Keypad test
N/A
Software revision test
1650
Programs a custom workout
2121
Turns on the custom scrolling message
2123
Turns off the custom scrolling message
7424
Changes the language of the console prompts
7607
99
7703
7704
7705
9760
9766
Page 30
Function
Turns on the custom message option
Text bar scrolling message editing function
Displays machine usage information
0
1
Allows you to turn the console speaker on or off
Turns the speaker on
Turns the speaker off
0
1
Allows you to turn the Heart Rate feature on or off
Turns the Heart Rate feature on
Turns the Heart Rate feature off
0
1
Allows you to change the units displayed by the console
Changes the console to English units
Changes the console to metric units
0
1
Allows you to turn the Clinical Mode on or off
Turns the Clinical Mode off
Turns the Clinical Mode on
97405
Changes the maximum workout time
52475
Reset time limit to 60 minutes
MAINTENANCE INSTRUCTIONS
HELPFUL HINTS
If you keep your StairMaster® Stratus systems cycle ergometer properly serviced
and in good condition, it will operate more efficiently and last longer. It is
strongly recommended that you adhere to the maintenance service guidelines
presented in this Owner’s Manual. Read all maintenance instructions thoroughly
before beginning work. In some instances, the use of an assistant is recommended to perform the necessary task efficiently.
All references to the right or the left side and to the front or the back of
the Stratus systems cycle ergometer are made as if you were sitting on the
machine ready to exercise. For example, the drive chain is on the right side of the
bike. Major component names and locations are shown in Figures 14 through 17.
TOOL LIST
The following tools are needed to perform service and maintenance on the
Stratus systems cycle ergometer:
•
•
•
•
•
•
•
•
•
shop goggles or other eye protection
snap ring pliers, internal snap rings
snap ring pliers, external snap rings
combination wrenches (sizes 7/16" to 3/4")
adjustable wrench
2-mm cone wrench
allen wrenches (T-handled and L-bend)
socket set or nut driver set (sizes 1/4" to 3/4")
freewheel removal tool
•
•
•
•
•
•
•
standard screwdriver
locking pliers
phillips screwdriver
adjustable pliers
alligator clips
15-mm cone wrench
volt-ohm meter
Maintenance Records
The console on the Stratus systems cycle ergometer will keep track of the
following usage data on the machine:
•
•
•
•
the number of hours the machine has been turned on
the number of hours the machine has been in use
the total number of miles cycled
the number of exercise programs completed
Page 31
MAINTENANCE INSTRUCTIONS
•
the number of exercise programs completed with a heart rate monitor
While the console is in the ATTRACT mode, the machine usage data can
be displayed by pressing [+ ARROW], [7], [7], [0], [3], and [ENTER]. The console
displays the information in the sequence listed above.
NOTE: The console may display several hours of use when your machine
first arrives due to testing at the manufacturing facility.
INITIAL SERVICE
Upon receiving your new Stratus systems cycle ergometer, use a soft, clean
towel to wipe off the dust that may have accumulated during shipping. Your new
machine will require minor assembly. Refer to the “Installation Instructions”
section of this manual for details.
PREVENTIVE MAINTENANCE
The procedures for performing recommended preventive maintenance on the
Stratus systems cycle ergometer are summarized in Table 5.
Cleaning
1.
DO NOT USE GLASS CLEANER OR ANY OTHER HOUSEHOLD
CLEANERS ON THE CONSOLE. Clean the console daily with a waterdampened cloth and wipe dry after cleaning.
2.
Clean the exterior covers, the pedals, and the seat on a weekly
basis using either soap and water or a diluted, non-mineral based
household cleaner such as Fantastic®.
!
WARNING
TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE THE PEDAL
AREA IS FREE OF GREASE OR OIL. WIPE ANY EXCESS OIL OFF
THE MACHINE SURFACES.
Page 32
MAINTENANCE INSTRUCTIONS
Weekly Inspection
1.
Inspect the painted surfaces of the exposed frame for any rust,
bubbling, or chips during the weekly cleaning. The salt in perspiration
will damage unpainted surfaces. Repair the damaged area with a
touch-up paint kit provided by StairMaster® Sports/Medical Products,
Inc. (part number 22181).
2.
Inspect the pedal footstraps at both the inside and outside
attachment sites. Replace the footstraps if they are torn or ripped.
3.
3300 CE only: Inspect the seat post and the seat adjustment pin. The
seat post should slide up and down freely in the plastic collar with the
adjustment pin pulled out. Clean the seat post of any accumulated
grime with a clean rag. The seat adjustment pin should completely
engage the holes in the seat post. If the seat adjustment pin spring
action is sticky, apply a few drops of 30W motor oil, or the equivalent
lubricant, to the pin shaft.
Monthly Inspection
1.
Inspect the crank bearings for either excessive play or tightness.
Either condition will reduce the life of the bearings. Ensure the
bearing clamps are tight. Refer to the “Part Removal and
Replacement” section of this manual for the proper maintenance
and adjustment procedures.
2.
Lubricate the drive chain with a spray-on chain lubricant such as
Tri-Flow™. There is a lubrication hole on the right side cover at the nine
o’clock position in reference to the crank (see Figure 12 or 13). You
must use the plastic nozzle extension if you lubricate the chain
through this hole. Insert the nozzle extension into the hole and spray
the chain while turning the pedal crank counterclockwise. Three
revolutions of the crank will ensure lubrication of the entire chain—
make sure that you do not over-lubricate the chain.
Page 33
MAINTENANCE INSTRUCTIONS
Quarterly Maintenance
1.
Clean and thoroughly lubricate the drive chain and adjust the chain
tension every three months. Follow the chain removal and tensioning
procedures in the “Parts Removal and Replacement” section. Use a
degreaser to clean the accumulated grime from the chain. Lubricate
the chain with a spray-on chain lubricant such as Tri-Flow™ before
installing the cover.
!
WARNING
TO AVOID POSSIBLE BEARING FAILURE, DO NOT LUBRICATE THE SEALED
BEARINGS ON THE INTERMEDIATE SHAFT, OR THE CRANK. THEY ARE
LUBRICATED AT THE MANUFACTURING PLANT.
Page 34
MAINTENANCE INSTRUCTIONS
Table 5. Preventive Maintenance Schedule
PART
RECOM M ENDED
ACTION
FREQUENCY
CLEANER
LUBRICANT
Console
Wipe clean
Daily
Water
N/A
Covers
Clean and inspect
Daily
Soap and water,
diluted household
cleaner
N/A
Seat
Clean
Each week,or Soap and water,
afterevery 70 diluted household
hours ofuse
cleaner
N/A
Pedals and
footstraps
Clean and inspect
Each week,or Soap and water,
afterevery 70 diluted household
hours ofuse
cleaner
N/A
Seatpost
Clean and inspect
Each week,or
afterevery 70
hours ofuse
Clean,dry rag
N/A
Seatpost
locatorpin
Inspectand lubricate
Each week,or
afterevery 70
hours ofuse
N/A
30W motoroil
orequivalent
Crank
bearings
Inspect
Each month,or
300 hours
N/A
N/A
Drive chain
Lubricate
Each month,or
300 hours
N/A
TriFlow™ or
equivalent
Clean,lubricate,and
adjust
Each month,or
300 hours
Degreaser
TriFlow™ or
equivalent
Page 35
TROUBLESHOOTING
GENERAL TROUBLESHOOTING GUIDELINES
This section outlines several tests to systematically identify and isolate problems
with the electrical system and the drive train. This troubleshooting section is
organized into three basic problem sections: Electrical System, Console
Diagnostics, and the Drive Train. Perform the tests in exactly the same order as
written. Refer to the “Parts Removal and Replacement” section of this manual
for any disassembly and assembly instructions. To order a replacement part, or
to get help with the troubleshooting process, contact the Customer Service
Department of StairMaster Health and Fitness Products™ at (800) 331-3578.
International customers should contact their local distributor or call
(425) 823-1825.
SYSTEMATIC ELECTRICAL TROUBLESHOOTING
The electrical system of your Stratus systems cycle ergometer has five major
components: the power control board, the alternator, the load resistor, the main
cable assembly, and the console. In order to identify the component that is
causing the problem, you must systematically test the entire system. You will
need a Volt-Ohm meter (multimeter) and alligator clips to conduct portions of the
following procedures. The console, battery, and power control board are not
serviceable by the owner. If any of these parts are inoperable, they must be
replaced. Attempted repairs to the console, battery, or the power control board
will void the warranty.
1.
Remove the neck covers (3300 CE only) and side covers.
2.
Unplug the battery from the power control board and locate pin 2 and
pin 3 in the end of the cable (see the wiring diagram).
3.
Use a voltmeter to verify that the voltage between pin 2
(Negative) and pin 3 (Positive) is a minimum of 6.0 VDC. Install the
battery charger for at least 24 hours if the voltage measured is below
6.0 VDC.
4.
Plug the battery cable back into the power control board,
Page 36
TROUBLESHOOTING
5.
Measure VDC between test points 7 and 12 of the power control
board for a minimum of 6.0 VDC.
6.
Test pins 1 and 7 of the main cable at the console connection for a
minimum of 6.0 VDC.
7.
Reconnect the main cable to the console.
8.
Verify that the inductive switch is adjusted to within 1/32" (0.8 cm) of
the speed sensor disk on the front of the alternator.
9.
Unplug the inductive switch cable from the power control board and
test pins 1 and 2 for AC voltage while pedaling. VAC should increase
with RPM.
10.
Plug the inductive switch back in. Use a voltmeter to verify that the AC
voltage at pins 10 and 12 of the power control board increases when
RPM's increase (pin 10 is positive, pin 12 is negative).
11.
Unplug the alternator wiring connector from the power control board.
12.
Connect alligator clips between the B+ terminal and the FLD terminal
of the alternator.
13.
Pedal the cycle at a high RPM rate for 10-15 seconds or until you feel
the resistance level change making it harder to pedal.
14.
Unplug the diode from the FLD terminal of the alternator.
15.
Use a voltmeter, set to Ohms to test the diode. A good diode will show
a high resistance reading in one direction and a low resistance
reading when the voltmeter leads are reversed.
16.
Reconnect the diode to the FLD terminal of the alternator.
17.
Reconnect the alternator wiring connector to the power control board.
18.
Unplug the load resistor from the power control board and locate pin
1 and pin 2 at the end of the cable.
Page 37
TROUBLESHOOTING
19.
Use a voltmeter, set to Ohms to test the load resistor for a correct
reading of 1/2 Ohm between pins 1 and 2.
20.
Plug the load resistor back into the power control board.
21.
Check the main cable assembly for continuity and cross check
each wire in the cable to check for shorted wires (see the wiring
diagram ). Call StairMaster® Customer Service at (800) 331-3578
for assistance. International customers should contact their local
distributors.
SYSTEMATIC MECHANICAL TROUBLESHOOTING
These steps should be performed in exactly the order written. Refer to the "Parts
Removal and Replacement" section of this manual for any disassembly and
assembly instructions.
1.
Remove the neck covers (3300 CE only) and the side covers.
2.
Adjust the Poly-V belt so that the compressed distance of the valve
spring is 1-11/16" (4.3 cm) (see Figure 22). Retest the machine if
Poly-V belt adjustment was necessary.
3.
Verify the drive chain alignment and tension between the freewheel
of the intermediate shaft assembly and the pedal chain ring (see
Figure 20).
4.
Remove the drive chain and inspect the chain for frozen links. Replace
the chain if any frozen links are found and tension the chain according
to the "Drive Chain" section of this manual.
5.
Verify that the jam nut and bearing retainers on the crank assembly
are tight.
6.
Spin the crank assembly with the drive chain removed and listen for
any clicking or grinding noises. The crank should spin freely 4 or 5
revolutions. Resume troubleshooting at step 7 if no noises are heard.
Page 38
TROUBLESHOOTING
7.
Verify that the jam nut on the flywheel and the alternator/flywheel
assembly brackets are tight.
8.
Adjust the inductive switch to 1/32" from the speed sensor disk.
9.
Loosen the nyloc nut of the J-bolt assembly (see Figure 22) and the
nut and bolt that mount the alternator/flywheel brackets to the frame
(see Figure 24). Now pivot the alternator/flywheel assembly down so
the Poly-V belt is slack without allowing the flywheel to touch the
Poly-V pulley.
10.
Spin the alternator/flywheel assembly and listen for clicking and/or
grinding noises.
11.
Inspect the Poly-V pulley for excess wear and spin the pulley to check
the intermediate bearings.
12.
Disassemble the intermediate shaft assembly and inspect the
intermediate shaft and wave washer for wear.
13.
Inspect the Poly-V belt for wear.
14.
Verify that the freewheel, on the Poly-V pulley, spins freely in one
direction and engages in the other.
15.
Contact our Customer Service Department or your local distributor for
assistance. Refer to the Appendix for the appropriate phone number.
Page 39
CONSOLE DIAGNOSTIC TESTS
The following tests must be performed while the console is in the DIAGNOSTIC
mode. To activate the DIAGNOSTIC mode, press the [+ ARROW], [1], [0], [7],
[ENTER]. If the console fails any test, the console should be replaced or exchanged.
Display Test
Use this test if the console display or the text bar exhibits blank spots during use.
This test checks for inoperable light emitting diodes (LEDs) in the console display
and the text bar. If any LED will not light, replace the console.
1.
Press [0] to start the test.
2.
All LEDs in the console display and text bar should flash.
3.
Press [CLEAR] to end the test.
Speaker Test
Use this test to make sure the console speaker is fully operational. The speaker
will ascend and then descend through the musical scale.
1.
Press [1] to start the test.
2.
Press [ENTER] to pause the test. Press [CLEAR] to end the test.
Keypad Test
Perform this test if you are having trouble entering data into the console. If you
cannot enter the DIAGNOSTIC mode code due to an inoperable keypad, replace
the console.
1.
Press [2] to start the test.
2.
The display LEDs will light up in an L-shaped formation, representing
the keypad matrix. Pressing a button on either the exercise program
keypad or the function keypad will light an LED within the outline on
the display that corresponds to that button’s position on the console.
Page 40
CONSOLE DIAGNOSTIC TESTS
3.
Firmly press each button. If the LED corresponding to the button you
pushed does not light up, the keypad is bad and the console must
be replaced.
4.
Pressing the [CLEAR] button will light that LED and then end the
keypad test 10 seconds later.
Tach Test
This test makes sure the console is sensing the correct RPM's. If you want to
verify the console RPM reading, count the crank revolutions while pedaling
during the tach test and compare your count to the RPM displayed in the text bar.
1.
Press [3] to start the test.
2.
The text bar will display the pedal RPM continuously if the inductive
sensor is working properly. Refer to the appropriate troubleshooting
section if the RPM feedback is either wrong or erratic.
3.
Press [CLEAR] to end the test.
Software Revision Level Test
This test allows you to check the version number of the software installed in the
console.
1.
Press [4] to start the test.
2.
The software version number will scroll across the text bar. The
console will automatically return to the ATTRACT mode.
3.
Contact the Customer Service Department for the most current
software revision updates.
Page 41
CONSOLE DIAGNOSTIC TESTS
Contact Heart Rate Test
The contact heart rate system is made up of the console and the contact heart
rate handles. You can test each component by performing the following steps:
1.
While the console is in the ATTRACT mode (noted by a simulated EKG
signal in the console display), or at the “SELECT A WORKOUT”
prompt, press [+INCREASE], [1], [0], [8], [ENTER].
2.
After approximately ten seconds a flashing ♥ should be displayed in
the console text bar. Your heart rate, in beats per minute, will show
next to the heart icon. If the heart icon does not show, or if your heart
rate is not displayed in the text bar, you have a problem with either
the console or the contact heart rate handles.
3.
If possible, replace or exchange your console with a console (from
the same type of machine) you know is working and retest the
machine.
4.
If possible, replace or exchange your contact heart rate handles with
handles (from the same type of machine) that you know is working
and retest the machine.
5.
If you do not have spare parts contact the Customer Service
Department at 800-331-3578.
Polar® Heart Rate Test
The Polar heart rate system is made up of the console, the heart rate receiver,
and the chest strap (available separately). You can test each component by
performing the following steps:
1.
You will need to put a chest strap on in order to test the Polar heart
rate. Before you put the chest strap on, wet the two contact patches.
Secure the chest strap as high under your pectoral muscles (chest) as
is comfortable. The chest strap should fit snugly, comfortably, and
allow normal breathing.
Page 42
CONSOLE DIAGNOSTIC TESTS
2.
While the console is in the ATTRACT mode (noted by a simulated EKG
signal in the console display), or at the “SELECT A WORKOUT”
prompt, press [+INCREASE], [1], [0], [8], [ENTER].
3.
A flashing ♥ should be displayed in the console text bar. Your heart
rate, in beats per minute, will show next to the heart icon. If the heart
icon does not show, or if your heart rate is not displayed in the text
bar then you have a problem with either the console, chest strap, or
heart rate receiver.
4.
Test your chest strap with a machine that you know is working, or
with a heart rate watch that you know is working.
5.
If possible, replace or exchange your console with a console (from
the same type of machine) that you know is working and retest the
machine.
6.
Visually check that the heart rate receiver is positioned correctly in
the neck cover. The heart rate receiver jack should point down. Ensure
that the heart rate receiver is connected to the console, and that the
connection is not loose. If possible, swap the heart rate receiver with
one from another machine.
7.
If the problem still exists, contact the Customer Service Department at
800-331-3578.
Page 43
PARTS REMOVAL AND REPLACEMENT
COVERS
3300 CE
The Stratus 3300 CE cycle ergometer is protected by four plastic covers: two
large side covers and two smaller neck covers. Refer to Figure 12 for the fastener
locations.
1.
The neck covers are held in place with six reusable fasteners. Slide
either end of the fastener removal tool under the edge of the head pin
and pull the pin out about halfway (see Figure 11). The pin should not
be pulled out of the base. The neck covers must be removed before
the side covers are removed.
2.
Disconnect the battery charger from the connector located just inside
the bottom front corner of the side cover.
3.
Remove the four reusable fasteners from the side panels.
4.
Slide the square rubber grommet, on the seat tube, up the frame and
away from the covers.
5.
Move the crank to about the eleven o’clock position on the right side
to get the right side cover over the crank. Once the right cover is off
the frame, move the cranks to the one o’clock position on the left side
and remove the left cover.
6.
To reinstall the cover fasteners, insert the fastener base through the
cover and into the frame. When the base is in place, push the head
pin in all the way to secure the fastener (see Figure 11). Connect the
battery charger to the power connector once the side covers are
attached.
Page 44
PARTS REMOVAL AND REPLACEMENT
3900 RC
The Stratus 3900 RC cycle ergometer is protected by two plastic side covers.
Refer to Figure 13 for the fastener locations.
1.
The side covers are held in place with six reusable fasteners. Slide
either end of the fastener removal tool under the edge of the head pin
and pull the pin out about halfway (see Figure 11). The pin should not
be pulled out of the fastener base.
2.
Slide the neck grommet up the frame and away from the covers.
3.
Move the crank to about the eleven o'clock position on the right side
to get the right side cover over the crank. Once the right cover is off
the frame, move the cranks to the one o'clock position on the left side
and remove the left cover.
4.
To reinstall the cover fasteners, reinsert the fastener base through the
cover and into the frame. When the base is in place, push the head
pin in all the way to secure the fastener.
Console
1.
Unscrew the console mounting knobs (2-3300 CE, 4-3900 RC) from
the back of the console, and disconnect the main cable connector
from the console.
2.
Reverse the steps to reinstall the console.
Page 45
PARTS REMOVAL AND REPLACEMENT
HANDLEBAR ASSEMBLY
3300 CE
1.
Remove the console and neck covers.
2.
Loosen and remove the four screws and flat washers from the frame
tube (see Figure 14).
3.
Hold onto the handlebar with both hands and remove the handlebar
assembly from the frame tube. You may have to twist the handlebar
assembly as you pull up on the handlebar.
4.
Reinstall in the reverse order.
3900 RC
1.
Remove the console.
2.
Loosen and remove the four nyloc nuts from the mounting flange (see
Figure 17).
3.
Remove the mounting bolts and flat washers from the frame.
4.
Hold onto the handlebar with both hands and lift the handlebar off
the frame.
5.
Reinstall in reverse order.
Page 46
PARTS REMOVAL AND REPLACEMENT
SEAT
3300 CE
1.
Loosen and remove the four mounting nuts and lock washers located
underneath the seat (see Figure 18).
2.
Remove the seat. Reverse the steps to reinstall.
3900 RC
The seat pads can be removed while the seat is in the seat track. Loosen and
remove the four mounting bolts from each seat pad and lift the pad free. To
remove the seat from the seat track:
1.
Loosen and remove the nyloc nut and flat washer from the rear of the
seat track. Remove the bolt (see Figure 17).
2.
Remove the seat track cover.
3.
Lift the seat adjustment handle and slide the seat to the rear and off
the track.
4.
To reinstall the seat, line up the front guide wheels with the seat
track. Carefully slide the seat forward while holding up on the seat
adjustment handle until all six wheels are in the seat track.
5.
Verify proper operation of the seat adjustment handle before
installing the seat track cover.
6.
Install the bolt through the seat track and track cover. Install and
securely tighten the flat washer and the nyloc nut.
7.
The seat track play can be adjusted by loosening the nut on both
center wheels while using a standard screwdriver to turn the bolt.
Ideally, the seat should slide easily without excessive side play.
Tighten the nuts after the wheels are adjusted (see Figure 19).
Page 47
PARTS REMOVAL AND REPLACEMENT
SEAT LOCATION POST (3300 CE ONLY)
1.
Pull the seat adjustment knob out and raise the seat.
2.
Insert a phillips screwdriver into one of the holes in the seat post that
are visible above the seat tube cap (see Figure 18). Gently lower the
seat so that the seat is held up by the screwdriver.
3.
Hold the seat adjustment shaft with a pair of locking pliers and
remove the seat adjustment knob from the shaft by turning the knob
counterclockwise.
4.
Remove the screwdriver from the hole in the seat post and lower
the seat slightly so the seat adjustment shaft engages a hole in the
seat post.
!
WARNING
TO REDUCE THE RISK OF EYE INJURY, WEAR EYE
PROTECTION WHEN REMOVING SNAP RINGS.
5.
Remove the internal snap ring that is now visible inside the seat
knob housing.
6.
Lift the seat slightly and pull out the seat adjustment shaft. Remove
both washers and the spring from inside the seat knob housing.
7.
Insert a phillips screwdriver into one of the holes in the seat post that
are visible above the seat tube cap and remove the internal snap
ring located in front of the seat adjustment bushing inside the seat
knob housing.
8.
Remove the two screws securing the seat tube cap to the frame.
9.
Remove the screwdriver from the seat post. Raise the seat tube cap
up and away from the frame.
Page 48
PARTS REMOVAL AND REPLACEMENT
10.
Push the seat post forward so the seat adjustment bushing is moved
slightly forward in the bushing housing.
11.
Insert a standard screwdriver between the front of the seat post and
the mainframe to pry the seat adjustment bushing into the bushing
housing and out of the way of the nylon seat post guides.
12.
Remove the grommets from the holes in the seat tube. Pull the seat
post up and out of the frame.
13.
Reverse the steps to reinstall the seat post in the frame.
SEAT TRACK (3900 RC ONLY)
1.
Remove the right side cover.
2.
Remove the seat assembly.
3.
Loosen and remove the three nyloc nuts, bolts and flat washers that
fasten the seat track to the frame (see Figure 17).
4.
Reverse the steps to reinstall the seat track.
DRIVE CHAIN
1.
Remove both neck covers (3300 CE only) and the right side cover.
2.
Locate the master link (see Figure 20). Remove the master link from
the drive chain using a standard screwdriver to push the retaining
plate off the pins.
3.
Remove the chain from the chain ring and freewheel.
4.
Reverse the steps to install the chain. Ensure that the closed end of
the master link retaining plate is facing the direction of chain travel.
Page 49
PARTS REMOVAL AND REPLACEMENT
5.
Check the tension in the drive chain for a total of 1" (2 cm) of
deflection at the midpoint of the lower chain section (see Figure 20).
6.
To adjust the chain tension, loosen the nuts at the top and the bottom
of the intermediate shaft bracket. Pivot the brackets as needed to get
the proper chain tension. Tighten the nuts and recheck the chain
tension. Readjust the chain if necessary.
7.
Reinstall the covers.
INTERMEDIATE SHAFT ASSEMBLY
1.
Remove both neck covers (3300 CE only) and the side covers.
2.
Remove the drive chain.
3.
Loosen, but do not remove, the nuts at the top and bottom of the
intermediate shaft bracket (see Figure 21).
4.
Loosen the J-bolt nut so the Poly-V belt is slack.
5.
Support the alternator/flywheel assembly and remove the two
screws from the threaded spacer. Carefully lower the flywheel onto
the Poly-V pulley.
6.
Support the intermediate shaft bracket and remove the nut and bolt
from the top of the intermediate shaft bracket. Lean the intermediate
shaft bracket out of the way.
7.
Loosen and remove the nut from the left side of the intermediate
shaft. Pull the intermediate shaft out of the intermediate shaft
bracket.
8.
Remove the Poly-V pulley and Poly-V belt from the intermediate shaft
bracket.
9.
Inspect the intermediate shaft bearings (they are inside the Poly-V
pulley) for smoothness of operation. Replace the bearings if
necessary.
Page 50
PARTS REMOVAL AND REPLACEMENT
10.
Inspect the freewheel for smoothness of operation in the counter
clockwise direction and for positive engagement in the clockwise
direction. Use a freewheel tool to remove the freewheel from the
Poly-V pulley, if replacement is necessary.
11.
Reverse the steps to reinstall the parts. Additionally, ensure that:
•
•
•
•
The short side of the J-bolt hook faces to the rear of the frame.
The wider portion of the threaded spacer faces to the right.
The drive chain is adjusted according to the procedure outlined
in the “Drive Chain” section of this manual.
The Poly-V belt is adjusted so the distance between the edges of
the top and bottom spring retainers on the J-bolt is 1-11/16"
(4.3 cm) (see Figure 22).
PEDALS
1.
Use a 15-mm pedal wrench or a 5/8" open end wrench to loosen and
remove the pedals from the crank.
2.
The pedal on the left side of the crank is marked with an "L" on the
pedal spindle, and has reverse threads. Turn the wrench on the left
pedal clockwise to loosen it. Turn the wrench on the right pedal
clockwise to tighten it.
3.
Apply a small amount of multi-purpose grease to the threads of the
pedal spindle before reinstalling the pedals on the crank.
CRANK AND BOTTOM BRACKET ASSEMBLY
1.
Remove both neck covers (3300 CE only) and the side covers.
2.
Remove the drive chain.
3.
Remove the left pedal.
Page 51
PARTS REMOVAL AND REPLACEMENT
4.
Loosen and remove the bottom bracket jam nut located on the left
side of the crank (see Figure 23). This nut has reverse threads; loosen
it by turning it clockwise.
5.
Remove the round, metal crank shield from the left side of the crank.
6.
Remove the bearing clamps by loosening the allen bolts from the left
side clamp.
7.
The left bearing nut assembly can be removed from the crank with a
15-mm cone wrench. This nut has reverse threads; loosen and
remove it by turning it clockwise.
8.
Slide the crank out of the frame to the right.
9.
The right bearing nut assembly can be removed from the crank with a
32-mm cone wrench. The right bearing nut assembly also holds the
chain ring in place on the crank. If the chain ring is damaged, replace
it now.
10.
Inspect the bearings for smoothness of operation. Replace the
bearings if necessary.
11.
Ensure that the right bearing nut assembly is tight against the
chain ring before reinstalling the crank into the frame. The outside
edge of the bearing nut assembly should be flush with the bottom
bracket when the crank is installed.
12.
Install the left bearing nut assembly onto the crank and tighten it so
the outside edge of the bearing nut assembly is flush with the bottom
bracket (see Figure 23). Do not overtighten the nut; the crank should
spin freely.
13.
Install both bearing clamps and tighten the allen bolts. Do not
overtighten the allen bolts; the crank should spin freely.
Page 52
PARTS REMOVAL AND REPLACEMENT
14.
Install the round, metal crank shield, the jam nut and the pedal onto
the left side of the crank. Remember, the jam nut and the pedal have
reverse threads (tighten them in the counterclockwise direction).
15.
Adjust the side play in the crank by tightening or loosening the left
side bearing nut with a 32-mm cone wrench. The crank should spin
freely without binding. When the crank is properly adjusted, hold the
left side bearing nut with the cone wrench and tighten the jam nut
securely. Recheck the crank adjustment after tightening the jam nut.
16.
Install the drive chain, side covers and neck covers (3300 CE).
Page 53
GROUNDING INSTRUCTIONS
The StairMaster® Stratus systems cycle ergometer must be grounded. If it should
malfunction or break down, grounding provides the path of least resistance for
the electric current, thereby reducing the risk of electric shock. This machine is
equipped with a cord having an equipment-grounding conductor and a grounding
plug. The plug must be plugged into an appropriate outlet that is properly
installed and grounded in accordance with all local codes and ordinances.
!
DANGER
IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONNECTOR CAN
RESULT IN THE RISK OF ELECTRIC SHOCK. CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE
MACHINE IS PROPERLY GROUNDED. DO NOT MODIFY THE PLUG PROVIDED
WITH THIS MACHINE. IF IT WILL NOT FIT THE AVAILABLE OUTLET, HAVE A
PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN.
The Stratus systems cycle ergometer is designed for use on a nominal
120-volt circuit, and has a grounding plug that looks like the plug illustrated in
sketch A below.* A temporary adapter that looks like the adapter illustrated in
sketches B and C may be used to connect this plug to a two-pole receptacle as
shown in sketch B if a properly grounded outlet is not available. The temporary
adapter should be used only until a properly grounded outlet (sketch A) can be
installed by a qualified electrician. The green colored lug extending from the
adapter must be connected to a permanent ground such as a properly grounded
outlet box cover. Whenever an adapter is used, it must be held in place by a
metal screw.
* This may vary for International power supplies.
Grounding Systems
Page 54
NOTICE OF FCC COMPLIANCE
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC rules. These limits are designed to
provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio frequency
energy and, if not installed and used in accordance with the instructions, may
cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If this
equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following
measures:
•
•
•
•
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.
!
WARNING
CHANGES OR MODIFICATIONS TO EQUIPMENT NOT
EXPRESSLY APPROVED BY STAIRMASTER® SPORTS/MEDICAL
PRODUCTS, INC. COULD VOID THE USER'S AUTHORITY TO
OPERATE THIS EQUIPMENT.
Canadian Doc Class B Compliance
This digital apparatus does not exceed the Class B limits for radio emissions from
digital apparatus set out in the radio interference regulations of the Canadian
Department of Communications.
La présent appareil numérique ne dépasse pas les limites etablies pour les bruits
radioélectriques applicables aux appareils numériques de la Class B prescrites
dans les règlement sur le brouillage radioélectrique édicté par le Ministère des
Communications du Canada.
Page 55
IMPORTANT PHONE NUMBERS
If you need assistance, please have both the serial number of your machine
and the date of purchase available when you contact the appropriate
StairMaster Health and Fitness Products™ office listed below.
OFFICES IN THE UNITED STATES
CORPORATE HEADQUARTERS
12421 Willows Road NE, Suite 100
Kirkland, WA 98034
(800) 635-2936 or (425) 823-1825
FAX: (425) 814-0601
Web Site: www.stairmaster.com
CUSTOMER SERVICE
12421 Willows Road NE, Suite 100
Kirkland, WA 98034
(800) 331-3578
FAX: (425) 814-0601
INTERNATIONAL OFFICES AND DISTRIBUTORS
For technical assistance and a list of distributors in your area, please call or fax
one of the following numbers.
INTERNATIONAL DIVISION
(425) 823-1825
FAX: (425) 820-7505
EUROPE: HEADQUARTERS
41-91-827-3801
FAX: 41-91-827-3802
E-Mail: stairmasterch@swissonline.ch
GERMANY: HEADQUARTERS
49-2204/610-27
FAX: 49-2204/628-90
E-Mail: stairmaster.de@t-online.de
U.K.: HEADQUARTERS
44-1908/221-323
FAX: 44-1908/223-162
E-Mail: stairmasteruk@msn.com
Page 56
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(407) 857-9234
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(404) 446-8663
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(303) 763-5833
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(818) 333-3060
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(510) 887-8080
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Colorado
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(410) 768-5586
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(617) 932-6570
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California, Southern
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(616) 531-1120
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(612) 631-2150
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PHONE NUMBER
(205) 591-0606
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(816) 231-1414
(816) 231-0685
(603) 886-5900
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California, Northern
ADDRESS
906 40th St.
Birmingham, AL 35222
3470 Depot Rd.
Hayward, CA 94545
1250 Bixby Dr.
City of Industry, CA 91745
12860 W. Cedar Dr.
Suite 106A
Lakewood, CO 80228
11310 Satellite Blvd.
Orlando, FL 32821
1721-C Oakbrook Dr. NE
Norcross, GA 30093
5303 Ninth Ave
Countryside, IL 60525
899 Airport Rd. Ste E
Glen Burnie, MD 21061
13 Wheeling Ave.
Woburn, MA 01801
2760 Auburn Rd.
Auburn Hills, MI 48326
2882 Remico St. SW
Grandville, MI 49418
1900 Oakcrest Ave. Ste 5
Roseville, MN 55113
5328 Winner Rd.
Kansas City, MO 64127
17 Clinton Dr.
Hollis, NH 03049
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STATE
Alabama
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After installing a new battery, you will need to properly dispose of (recycle) your
old lead-acid battery. Most federal and state regulations require lead-acid
batteries be recycled. Do not throw away old batteries. Lead is a heavy metal
and is toxic to living organisms. Contact the nearest Yuasa-Exide, Inc. recycling
center from the list below to get information on the proper disposal of your old
lead-acid battery.
Page 57
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West Virginia
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Washington
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(513) 851-3838
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(216) 241-6231
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(216) 241-6231
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(215) 921-4480
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(315) 437-1788
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(215) 443-0912
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(412) 788-1613
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(901) 365-6944
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(214) 869-1855
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(210) 661-5497
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Ohio, Central
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(713) 690-8700
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(425) 575-3090
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PHONE NUMBER
(201) 641-5900
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New York
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ADDRESS
131 Industrial Ave.
Hasbrouck Hgts., NJ 07604
26 Corporate Circle
E. Syracuse, NY 13057
Rickenbacker ANG
Bldg. 1073
Columbus, OH 43217
2635 Hamilton Ave.
Cleveland, OH 44114
540 Northland Blvd.
Cincinnati, OH 45240
3000 Montrose Ave.
Laureldale, PA 19605
320 Constance Dr.
Warminster, PA 18974
920 Vista Park Rd.
Pittsburgh, PA 15205
3356 Democrat Rd.
Memphis, TN 38118
11420 Ferrell Dr. Ste 300
Dallas, TX 75234
4738 Cotton Belt
San Antonio, TX 78219
4301 S. Pinemont Ste 114
Houston, TX 77041
660 Industry Dr.
Tukwila, WA 98188
P.O. Box 1666
Rte. 2, Box 1
Bluefield, WV 24701
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STATE
New Jersey
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BATTERY RECYCLING CENTERS
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(304) 327-3594
FIGURES
Figure 11: Cover Fasteners
Page 59
FIGURES
Figure 12: Cover Fastener Locations, 3300 CE
Page 60
FIGURES
Figure 13: Cover Fastener Location, 3900 RC
Page 61
FIGURES
Figure 14: Right Side View, 3300 CE
Page 62
FIGURES
Figure 15: Left Side View, 3300 CE
Page 63
FIGURES
Figure 16: Right Side View, 3900 RC
Page 64
FIGURES
Figure 17: Left Side View, 3900 RC
Page 65
FIGURES
Figure 18: Seat Adjustment Pin Assembly, 3300 CE
Page 66
FIGURES
Figure 19: Seat Assembly, 3900 RC
Page 67
FIGURES
Figure 20: Drive Chain Tension
Page 68
FIGURES
Figure 21: Intermediate Shaft Assembly
Page 69
FIGURES
Figure 22: J-Bolt Assembly
Page 70
FIGURES
Figure 23: Crank Assembly
Page 71
FIGURES
Figure 24: Alternator/Flywheel Assembly
FLYWHEEL NO LONGER AVAILABLE
Page 72
WIRING DIAGRAM
Wiring Diagram
WIRING SCHEMATIC
BATTERY CHARGER
CONSOLE
FUSE
POWER CONTROL BOARD
ALTERNATOR
LOAD
RESISTOR
INDUCTIVE
SWITCH
BATTERY
BATTERY CHARGER
PIN 1 – VDC + (WHT)
PIN 2 – GROUND (BLK)
PIN 3 – N/C
BATTERY
PIN 1 – N/C
PIN 2 – GROUND (BLK)
PIN 3 – VDC (WHT)
CONSOLE
INDUCTIVE SWITCH
PIN 1 – VSUPPLY (BLK)
PIN 2 – ALTERNATOR SHUTDOWN (BRN)
PIN 3 – B+ OUT (RED)
PIN 4 – RESISTOR CONTROL (ORG)
PIN 5 – VCC (YEL)
PIN 6 – TACH (GRN)
PIN 7 – GROUND (BLU) - PIN 10 of Pwr.Con.Brd.
PIN 8 – AUXILLARY (VIO)
PIN 9 - SHUT DOWN (GRY)
5VAC at PINS 1 AND 2 WHILE STEPPING.
ALTERNATOR
PIN 1 – B+ (WHT)
PIN 2 – GROUND (BLK)
PIN 3 – FIELD (BRN)
PIN 4 – N/C
LOAD RESISTOR
FUSE
5 Amp 250V
Replace fuse with same type
½ Ohm 240 Watt
½ Ohm measured at PINS 1 AND 2 of load resistor
connector.
Page 73
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