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CROSSROBICS 1650 LE OWNER`S MANUAL

1. 71 APPENDICES Important Phone Numbers sn opos dente E Balb aude cb teenie rs 72 ROUTES Tal 13 Wiring Diagram os eme 98 LIST OF TABLES Table 1 Dimensions and Specifications for the StairM aster FreeClimber Exercise Systems 4 Table 2 Fitness Rating Norms VO Present 28 Table 3 Recommended Preventive Maintenance Schedule 38 LIST OF ILLUSTRATIONS FOUT LE Mea OF PSUS asc oo Ro ir tore etn Ha m eto 3 CONTENTS Figure 2 Exercise Starting Position 9 Figure 3 Exercise Motion pipe qp te 10 Figure 4 Transmitter on touc Time 16 Figure 5 Crossrobics 1650 LE Console c eie 17 Figure 6 StairM aster Fitness 27 Figure 7 Parts Needing Periodic Lubrication eee 73 Figure B LOR SiGe ee d 74 Figure 9 Right Side View 15 Figure 10 Reduction Belt Tension visser 16 Figure 11 Handle Assembly oc o centre tado 71 Figure 12 Console Assembly 78 Figure 13 Cover Fastener Locations ssiri 79 Figure 14 Cover Fasteners o tecti rint eb 80 Figure 15 Top View of Cover Seams nn 81 Figure 16 Weight Stack Belt Assembly 82 Figure 17 Weight Stack Belt Path 83
2. 20188 Drive chain 2 4 N Weight Drive chain 2 stack Pedal arm damper stra 23770 d return spring o Floating Lower idler pulley 9 spring assembly assembly OF Lower spring A stop assembly Page 75 FIGURES Figure 10 Reduction Belt Tension Alternator AS Cy 2 Alternator poly v belt ke 25 8 inch poly v pulley Drive reduction A 25 belt 23326 80 tooth sprocket Page 76 FIGURES Figure 11 Handle Assembly Top View with Seat and Seat Tray Removed 21478 03 x Right side cover RON D Frame tube J nut NEU 22029 Bolt Hat washer 22097 22030 Left handle Right handle eua FIGURES Figure 12 Console Assembly Console Screw 22246 5 A se Flat washer 22030 Lock washer 23729 Page 78 1 gt 23792 Grommet 21149 Console mounting knob 24677 FIGURES Figure 13 Cover Fastener Location Inside weight stack cover 23742 2 Fasteners on seat tray Seat 23342 Seat tray 23823 Left side 21480 22100088089 2 Fasteners Front panel 22514 1 2 Fasteners 4 F
3. Page 98
4. 7 The bearings can now be slid off the shaft Inspect the bearings for excess play or roughness Replace the bearings if necessary Install the shaft in the reverse order of the removal procedures 8 Adjust the alternator Poly V and HTD belts see the Alternator Poly V Belt and HTD Belt sections for tensioning instructions Adjust the HTD belt first then the alternator Poly V belt 9 Reattach the side covers MAIN CABLE 1 Remove the left side cover the outside weight stack cover and the console 2 Note and mark by color the location of each wire attached to the alternator see Wiring Diagram 1 3 Detach the wires from the alternator Disconnect the power connector 4 Disconnect the main cable from the console 5 Remove the main cable from the wire saddles see Figure 30 6 Tie a length of string about five feet long to the console connection of the old cable and to the lower end of the new main cable 7 Pull the old cable out of the frame arch and feed the new cable through the upper hole in the frame Be careful to retain the rubber grommets 8 When the wire ends of the new cable reach the lower hole untie the string and pull the cable through Be sure to seat the rubber grom mets into the holes in the frame to prevent damage to the cable 9 Insert the main cable into the wire saddles Page 61 PARTS REMOVAL AND REPLACE 10 Crimp a wiring lug onto each bared wire end and attach the wires
5. 5 Although all equipment manufactured by StairM aster Health amp Fitness Products Inc has been thoroughly inspected at the manufac turing facility prior to shipment proper installation and regular maintenance are required to ensure safety The owner has sole responsibility for maintaining the machine Page 7 BASIC OPERATING INSTRUCTIO YOUR FIRST WORKOUT ON THE STAIRMASTER CROSSROBICS 1650 LE CONDITIONING SYSTEM Basic Instructions for First Time Users 1 Warm up with light calisthenics and easy stretching exercises for at least five minutes before beginning your workout IF AT ANY TIM E DURING YOUR WORKOUT YOU FEEL CHEST PAIN EXPERIENCE SEVERE MUSCULAR DISCOM FORT FEEL FAINT OR ARE SHORT OF BREATH STOP EXERCISING IM M EDIATELY IF THE CONDITION PERSISTS YOU SHOULD CONSULT YOUR M EDICAL DOCTOR IM M EDIATELY 2 Face the machine so that you can see both the console and the weight stack Next step over and straddle both pedal arms 3 Reach over with your right hand and place the weight stack pin in the number three plate 4 Select the M ANUAL exercise program so you can control the pace of your first workout and get used to the exercise motion Press M ANUAL and then press ENTER The console will return to the start screen if you do not press ENTER within 60 seconds 5 The console will prompt you to enter your body weight Enter your Weight in pounds or kilograms if the console is set up for me
6. MAX TIME Press ENTER The console will then display the current time limit Use the keypad to enter the desired time then press ENTER For no time limit press 0 The console will display TIME LIMIT OFF Page 29 CROSSROBICS 1650 LE CONSOLE 2 Change the units to either Metric or USA units by pressing LEVEL 3 1 ENTER The console will display the current units either USA UNITS or METRIC UNITS Use the SELECT key to change option and then press ENTER Choose the desired heart rate input preference by pressing LEVEL 3 2 The console will then display HR INPUTS Press ENTER The console will then display the current hear rate input selection Press the SELECT key to scroll through the other options Press ENTER after the desired option Change the language by pressing LEVEL 3 4 The console will display LANGUAGE Press ENTER The console will then display the current language Press the SELECT key to scroll through the other options Press ENTER to change the option Adjust the contrast on the LCD screen by pressing LEVEL 3 5 The console will display CONTRAST ADJ Press ENTER The console will then display the current contrast number Press the LEVEL and LEVEL v keys to increase or decrease the contrast The changed value will remain on exit Reset the console to factory defaults by pressing LEVEL 3 9 The con
7. Follow the onscreen prompt to continue your work out after a rest period To stop completely either press STOP or stop the exercise movement and step off the machine Cool Down 17 When you are finished with your workout the machine will slow down and the message GOAL ATTAINED will be displayed You can Page 11 BASIC OPERATING INSTRUCTIONS cool down on the machine by continuing to step The console timer will continue to count up from the selected time and the intensity level will default to level 3 If there is a time limit set on the console the timer will last only until the maximum time has been met For example if the time limit was set for 30 minutes and you worked out for 25 minutes the cool down period would last for 5 minutes or until you stepped off the machine If no time limit has been set the console will continue to run the cool down until the STOP key is pressed 17 You can also cool down by getting off the machine walking or stretching for at least five minutes Keep your feet on the pedals and let both pedal arms return all the way up Support your weight on the handles and swing your right foot off to the right and then your left foot off to the left Step over the pedal arms with your right foot NOTE SOME INDIVIDUALS MAY NEED ASSISTANCE GETTING OFF THE MACHINE PROVIDE ASSISTANCE BY HOLDING THE PEDALS DOWN UNTIL THEY ARE OFF THE MACHINE Page 12 HEART RATE MONITORING HEART RATE
8. SELECT N A SELECT MAINT HOURS 6 The machine may show a few hours of use due to testing at the manufacturing facility Page 33 MAINTENANCE INSTRUCTIONS PREVENTIVE MAINTENANCE A schedule of the recommended preventive maintenance is shown in Table 3 This schedule assumes moderate to heavy usage in a commercial health club environment Refer to the appropriate Parts Removal and Replacement section of this manual for all disassembly and assembly instructions Initial Service Upon receiving your new machine use a soft clean towel to wipe off the dust that may have accumulated during shipping Your machine may require minor assembly Refer to the Installation Instructions section of this manual for details Cleaning 1 DO NOT USE GLASS CLEANER OR ANY OTHER HOUSEHOLD CLEANERS ON THE CONSOLE Use a water dampened cloth when you clean the electronic parts and wipe them dry after cleaning 2 Clean the covers daily using soap and water 3 Clean the pedals weekly with a solution of either vinegar and water or ammonia and water TO REDUCE THE POSSIBILITY OF SLIPPING BE SURE THE PEDAL AREA 5 FREE OF GREASE OR OIL WIPE ANY EXCESS OIL OFF THE MACHINE SURFACES 4 Thoroughly clean the entire machine including the interior at least once a week Weekly Inspection 1 Inspect the exposed frame for any rust bubbling or paint chips during the weekly cleaning The salt in perspiration can dam
9. 4 The console will display CROSSROBIC or other machine type Display the machine run time since last cleared by pressing LEVEL 4 6 The console will display M AINT HOURS XXXX Page 31 CROSSROBICS 1650 LE CONSOLE Quick Scan Programming You can quickly access any of the custom menus by pressing LEVEL 4 ENTER The console will then display MACHINE STATUS Scroll through the following options SELECT RUN HOURS XXXX 0 SELECT WORKOUTS XXXX 1 SELECT DISTANCE XXXX 2 SELECT CONS 90211 3 SELECT CROSSROBIC 4 SELECT N A SELECT MAINT HOURS 6 Resetting the Maintenance Hour Counter For ease of maintenance records the console has a maintenance timer that will clock the number of hours workouts and time between last servicing After each maintenance period reset the counter 7 1 Reset Service 1 Reset the maintenance hour counter by pressing LEVEL 7 1 The console will display RESET SERVICE Press ENTER The console will display DONE Press CLEAR to return to the starting screen Configuration Code The Crossrobic console supports other StairM aster exercise systems It is important to verify that the machine configuration code matches the type of machine you have 8 0 Change M achine 1 Change the machine type by pressing LEVEL 8 0 The console will display CHANGE MACHINE Press ENTER The conso
10. Figure 18 Guide Rod Assembly rte 84 Figure 19 Weight Stack Assembly cede e 85 Figure 20 Pedal Arm Spring Assembly etes 86 Figure 21 M aster LINK us rm qe bh oe Bero PR 87 Figure 22 Drive Chain Assembly etin trie ctae 88 Figure 23 Drive Shaft Assembly sean d ood oed 89 Figure 24 Lower Reduction Shaft Assembly 90 Figure 25 Pivot ASSembly 3 91 Figure 26 Floating Pulley Assembly 92 Figure 27 Upper Spring Stop Assembly sss 93 Figure 28 Chain Tensioning Idler Sprocket Assembly 94 Figure 29 Left Pedal Arm Assembly 95 Figure 30 M ain Cable Routing eiit rnt t 96 Figure 31 Alternator and Resistor M ounting 97 Wiring Diagram 1 Main Cable lt 98 Page x SAFETY GUIDELINES VEN 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
11. Resetting the power may clear the following microprocessor errors EEPROM ERROR and PROGRAM ERROR If resetting the power doesn t work the console may need to be replaced Page 44 CONSOLE DIAGNOSTICS The Telemetry Polar Heart Rate Test The telemetry heart rate system is made up of the console the heart rate re ceiver and the chest strap available separately You can test each compo nent by performing the following steps 1 You will need to put a chest strap on in order to test the telemetry heart rate Before you put on the chest strap 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 A flashing should be displayed on the console 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 on the console then you have a problem with either the console chest strap or heart rate receiver Verify that the console software has been set up to receive telemetry see the heart rate monitoring section of this manual Note that holding the contact heart rate sensors if enabled can inhibit the telemetry heart rate input from working Test your chest strap with a machine that you know is working or with a heart rate watch that you know is working If possible replace or exchange your consol
12. Soap amp Water Weight stack Inspect Weekly or N A N A connectors of use Pedal arm Inspect clean amp Weekly or N A Oil damp return after 70 hours ened rag Springs of use Alternator Check tension amp Weekly or and drive after 70 hours belts of use Pedal arm Clean amp Weekly or Degreaser 30W motor chains and ubricate after 70 hours oil drive chain of use Remove clean amp Avery 3 months Degreaser 30W motor hours of use Guide rods Clean amp Weekly or Window Silicone ubricate after 70 hours cleaner Spray of use Bottom stop Wipe clean amp Every 3 months N A Heavy multi spring grease or after 900 purpose hours of use grease Note Use of a silicone spray on parts not so specified will result in diminished performance and a shorter life span for that part N A Not Applicable Page 38 TROUBLESHOOTING This section outlines several tests to systematically identify and isolate the cause of problems in the electrical system and the drive train The first step is to identify the problem This troubleshooting section is organized into three problem sections Electrical Troubleshooting Console Diagnostics and mechanical Troubleshooting Once you have identified the problem perform the tests in exactly the same order as written Refer to the appropriate Parts Removal and Replacement section of this manual for all disassembly and assembly instructions Contact our Customer Service Departme
13. and electrical specifications for a fully assembled machine are listed in Table 1 Table 1 Specifications of the Crossrobics 1650 Conditioning System Physical Length 64 5 inches 164 cm W idth 41 0 inches 104 cm Height 72 0 inches 183 cm W eight 425 pounds 193 kg Power Supply Characteristics Input Voltage 110 120 VAC 50 60 Hz Output Voltage with load console connected 9 to 15 VDC Output Voltage no load 14 to 17 VDC Output Current Capacity 2 5 amps Input Power Consumption 55 watts Optional power supplies intended for use outside the United States are available for 220 240 VAC 50 60 Hz power requirements Page 4 INSTALLATION INSTRUCTIONS The StairM aster Crossrobics 1650 LE exercise system must be placed on a solid level surface near an AC wall outlet A minimum ceiling height of 6 5 feet 1 98 meters and a doorway width of 34 inches 86 cm is required Upon delivery the shipping representative of StairM aster Health amp Fitness Products Inc will place your new StairM aster Crossrobics 1650 LE conditioning system wherever you designate in your facility The machine requires minor assembly M achines shipped outside the United States may require additional assembly refer to the International Installation Instruction Sheet for details To install the machine perform the following steps Once the machine is in the desired location remove the shipping casters and place the rubber end
14. BELT WILL CAUSE EXCESSIVE NOISE AND BELT WEAR 1 Remove the seat and seat tray Page 48 1 Loosen the adjustment bolt that mounts the alternator to the slotted alternator brace Rotate the alternator downward Remove the Poly V belt Install the new belt and center it on the pulleys Pivot the alternator up or down as necessary to allow 1 4 0 6 cm of belt deflection using a fingertip in either direction see Figure 10 Tighten the alternator adjustment bolt Verify 1 4 0 6 cm of play in the belt Reattach the seat tray and seat CHAIN TENSIONING IDLER SPROCKET ASSEMBLY Remove the left side and right rear covers Remove the drive chain Remove the idler sprocket Apply downward pressure on the spring assembly cap and remove the snap ring from the top of the assembly shaft see Figure 28 TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS THE PARTS IN THIS ASSEM BLY ARE UNDER CONSIDERABLE PRESSURE M AKE SURE THAT YOUR FINGERS ARE OUT OF THE WAY WHEN REM OVING THE SNAP RING Remove the spring cap washer and the spring from the shaft Replace worn parts Page 49 PARTS REMOVAL AND REPLACEMENT 6 The guide bolt on the idler sprocket bracket should be loosely secured 7 Support the bottom of the assembly shaft with your fingers and reattach the snap ring Reverse these procedures to complete the reassembly CONSOLE 1 Loosen and remove the four mountin
15. DISPLAY WINDOW Time The selected workout time is displayed in 3 D the upper left section of the display window Once TEE the time is entered the timer will count down in min utes and seconds until the workout is finished or stopped If 0 is entered in the MANUAL or CON STANT HEART RATE program the timer will count up Calories The real time amount of calories burned is continually updated and displayed in the upper right section of the display window Interval Timer The interval timer is displayed below the Time The interval timer counts down time left within each interval Heart Rate Current heart rate is displayed below the Calories next to the heart icon Workout Option Profile A profile of the selected exercise program ap pears in the lower section of the display window during a workout The taller the column the higher the intensity watts for that interval The flashing col umn shows your current interval The flashing column moves from left to right across the display as you complete each interval Page 17 CROSSROBICS 1650 LE CONSOL NUMERIC KEYPAD The numeric keypad is located on the right side of the con sole Before the exercise program begins the numbers are used to enter data in response to the console prompts Enter Confirms workout selections and stores the informa tion used by the console to calculate workout statistics Clear Erases information from the con
16. Page v PREFACE The Crossrobics Conditioning Matrix Table Type of Training d trengt Emphasis Speed level Resistance PT M edium Taran Plates TE Energy Anaerobic System Aerobic Aerobic Page vi Endurance Slowest Aerobic SAFETY GUIDELINES mn 1 INTRODUCTION isis tiii ru fuia cogi 3 INSTALLATION INSTRUCTIONS mens 5 BASIC OPERATING INSTRUCTIONS mms 7 General Guidelines for Safe 7 Your Fist WOPKOUE ci conii t d bte n dete eina 8 HEART RATE MONITORING mens 13 Heart Rate WUE cosa ice netu es th ttes et fin tede 13 Locked Non locked Options 13 Error MESSIES cies 14 TELEMETRY HEART RATE URN Cn 15 Using the Transmitter 15 Maintaining the Transmitter Ruta 16 CROSSROBICS 1650 LE CONSOLE sens 17 17 N meric a 18 Entertainment Keypad a na 18 Intensity Level 18 BOD P 18 Workout Statistics aee roa aret punti 19 Exercise Program Keypad cos siste nes Phe auc pia 20 The Quick Start PEOGFAITI rts etra acts dee tdt etn oo tede 20 The Manual Program 20 The Fat Burner Promise nent tiu tenes 21 The Aerobic Training Program ad iecore ei teca tres cda ins 21 The Spee
17. THE WEIGHT STACK MAY CAUSE THE WEIGHT STACK TO FALL Page 69 GROUNDING INSTRUCTIONS The machine must be grounded if you are using the external power supply or the battery charger Grounding provides the path of least resistance for the electric current thereby reducing the risk of electric shock The power supply or battery charger must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances IM PROPER CONNECTION OF THE EQUIPM ENT GROUNDIN G CONNECTOR CAN RESULT IN THE RISK OF ELECTRIC SHOCK CHECK WITH A QUALIFIED ELECTRI CIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE M A CHINE IS PROPERLY GROUN DED DO NOT M ODIFY THE PLUG PROVIDED WITH TRIS M ACHINE IF IT WILL NOT FIT THE AVAILABLE OUTLET HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN The grounding plug on the power supply and the battery charger is Shown in sketch A below A temporary adapter shown in sketches B and C may be used to connect the plug to a two pole receptacle if a properly grounded outlet is not available The adapter should be used only until a prop erly grounded outlet sketch A can be installed by a qualified electrician The tab extending from the adapter must be connected to a permanent ground such as the metal screw on the outlet cover This may vary for International power supplies _ 3 prong grounded outlet box Adapter 2 pr
18. 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 machine only authorized replacement pari can be used This warranty is void if any parts other than those provided by StairM aster Health amp Fitness Products Inc are used Note Aerosol products cannot be transported via air Page iv PREFACE The StairMaster Crossrobics 1650 LE conditioning system is a highly effective tool for developing and improving lower extremity strength and aerobic fitness 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 The first part of this manual includes sections on safety installation operating instructions and preventive maintenance The second part contains detailed information on problem troubleshooting and repair procedures An appendix at the end of the manual provides additional information for the owner WHAT IS THE STAIRMASTER CROSSROBICS 1650 LE CONDITIONING SYSTEM The Crossrobics 1650 LE conditioning system is a non weight bearing weight loading exercise sys
19. picked up by the console 1 Press LEVEL 6 6 ENTER The console will display TAR TACH ACT The target tach speed of 2 000 RPM s will be shown in the upper left corner of the display window The actual tach picked up by the console will be shown in the upper right corner of the display window 2 Start stepping on the pedals The number in the right hand corner of the console should increase to 2 000 RPM s 200 If the tach signal picked up by the console is less then 1 900 RPM s then there is a problem in the AC tach circuit either with the console software alternator check the AC tach wire the field wire the diode and the terminal posts or the main cable Error Reporting The console will display various error messages in the display window The total amount of errors will be displayed in the upper right numeric window Note that only the highest priority reported error will be displayed Errors are handled in two ways One as a non fatal WARNING which will display the text message but continue system operation until the user presses the CLEAR key The second way is as a fatal ERROR which will stop the exercise and return the system to an idle intensity state The console will display the error text and not let the user restart the programs unless power has been turned off and then back on The following microprocessor errors require a console replacement ALU ERROR TIM ER ERROR and STATIC RAM ERROR
20. that a steady state has been achieved the heart rate should be measured after two minutes of exercise at a given workload and again after the third minute of exercise at that workload These two heart rates should then be compared If a difference of more than five beats per minute between the two is found the subject should continue to exercise at one minute intervals at the same workload until two successive heart rates differ by less than five beats per minute It is also important that the submaximal heart rates obtained be between 115 and 150 beats per minute because it is within this heart rate range that a linear relationship tends to exist between heart rate and oxygen uptake or workload for most adults W hen the heart rate is less than 115 many external factors e g talking laughing apprehension etc can greatly influence heart rate Once the heart rate reaches a level between 115 and Page 23 CROSSROBICS 1650 LE CONSO 150 external factors no longer influence heart rate and a linear relationship exists As the heart rate rises above 150 the heart rate oxygen uptake rela tionship becomes curvilinear The third assumption involves maximal heart rate Maximal heart rate is the greatest heart rate that can be measured when an individual is exercis ing to the point of volitional fatigue i e exhaustion during a graded exercise test Several equations have been developed to estimate the average maximal heart rate for hu
21. to be removed 1 2 Remove the seat and the seat tray Remove the left side cover Remove the five fasteners on the middle seam located on the right side of the machine The right rear cover can then be removed by pivoting its top portion toward the rear of the machine Remove the fastener located on the right front cover Remove the right front cover Note The bottom front cover which is located on the vertical post between the pedal arms should be left in place Reinstall the right side covers in the reverse order that you removed Page 52 them To install the middle seam fasteners see Figure 13 reach inside from the front right below the pedal arms and support the seam while installing the bottom three fasteners Next reach in from the left side to support the covers while installing the top two fasteners Install the left side cover then the seat tray and seat The front face of the right front cover goes in front of the right pedal arm stop see Figure 15 Weight Stack Covers 1 Remove the fasteners securing the weight stack covers to the frame remove the top middle fastener last and take off the covers The fasteners are located around the perimeter of the covers 11 on each side For some maintenance it may be necessary to expose the outside of the weight stack the inside weight stack cover will rarely need to be removed Reinstalling the weight stack covers requires that you perform the Same proced
22. until you find either Both HR Off or Telemetry Only Press the ENTER key to select the desired option Page 13 HEART RATE MONITORING TELEMETRY ONLY locks out contact heart rate signals and will only detect telemetry signals Set your console to this default BOTH HR OFF turns off the ability to detect any signal at all Used in rare situations where there is excessive interference with the heart rate signals This option turns off disables the Constant HR program and the Fitness Test program Error Messages Text line messages are only seen in the Constant Heart Rate and Fitness Test programs due to the design of the program that necessitates a valid heart rate signal at all times during the program CHECK HR BELT The heart rate signal has been missing for the last 30 seconds in telemetry signal detection HR BELT NEEDED No telemetry belt signal been sensed during the initial setup time HR MODE DISABLED No heart rate signal is allowed due to the set up option that was chosen Heart rate monitoring is not possible Page 14 TELEMETRY HEART RATE TELEMETRY HEART RATE The StairM aster Crossrobics 1650 LE features telemetry 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 monitoring function is activated as soon as you strap on the chest belt and step within
23. ATING PULLEY ASSEMBLY BELT IDLER PULLEY 1 Remove the weight selector pin lift the first three plates to create Slack in the weight stack belt and remove the belt from the top two idler pulleys Set the plates back down onto the stack 2 Loosen the nut and remove the bolt securing the idler pulley to the assembly see Figure 26 3 Reinstall the idler pulley in the reverse order of the removal procedures FLOATING PULLEY ASSEMBLY IDLER SPROCKET 1 Remove the floating pulley assembly 2 Loosen and remove the nut and bolt securing the sprockets to the assembly see Figure 26 3 Replace the sprocket and tighten the nut and bolt 4 Reinstall the floating pulley assembly HAND GRIPS 1 Slide the old grip off the handle Do not use a knife as you may damage the handle 2 Apply water onto the handle and slide on the new grip Page 58 HANDLE ASSEMBLY 1 Lift the seat off of the machine 2 Remove the two fasteners on the seat tray Lift the seat tray off the machine 3 Loosen and remove the nyloc nuts see Figure 11 Remove both handles from the frame 4 Reinstall the handles in the reverse order HTD BELT 1 Remove the seat seat tray and the left side cover 2 Remove the alternator Poly V belt 3 Use an allen wrench to loosen the pivot assembly mounting bolts Rotate the assembly downward 4 Remove the HTD belt 5 Install the new belt and adjust to proper tension Pivot the bracket up or down as ne
24. CROSSROBICS 1650 LE OWNER S MANUAL StairMaster THE RESULTS YOU WANT Printed in the United States 2001 StairM aster Health amp Fitness Products Inc 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 StairMaster P N 22872 A 2001 StairM aster Health amp Fitness Products Inc StairM aster Crossrobics and the Crossrobics logo are registered trademarks or trademarks of StairM aster Health amp Fitness Products Inc in the United States and or other countries All other trademarks are trademarks of their respective companies StairM aster is a Rutledge Capital Company Page iii WARRANTY This is to certify that the StairM aster Crossrobics 1650 LE conditioning system is warranted for a period of three years by StairM aster Health amp _ Fitness Products Inc 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 date of purchase any part of the StairM aster Crossrobics 1650 LE conditioning system should fail to operate properly contact our Customer Service Department to report the problem Refer to the Appendix for the phone number of the office neares
25. E THIS EQUIPM ENT 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 Ca nadian Department of Communications La pr sent appareil num rique ne d passe pas les limites etablies pour les bruits radio lectriques applicables aux appareils num riques de la Class B prescrites dans les r glement sur le brouillage radio lectrique dict par le Minist re des Communications du Canada Page 71 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 StairM aster Health amp Fitness Products Inc office listed below OFFICES IN THE UNITED STATES CORPORATE HEADQUARTERS CUSTOMER SERVICE 12421 Willows Road NE Suite 100 12421 Willows Road NE Suite 100 Kirkland WA 98034 Kirkland WA 98034 800 635 2936 or 425 823 1825 800 331 3578 FAX 425 823 9490 FAX 425 814 0601 www stairmaster com E mail customerservice stairmaster com 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 ASIA PACIFIC HEADQUARTERS 425 823 1825 Telephone Fax 81 45 590 5686 FAX 425 820 7505 E mail stairintl aol com E M ail intlservice stairmaster com EUROPE H
26. EADQUARTERS 41 91 827 3801 FAX 41 91 827 8902 E Mail stairmasterch swissonline ch GERMANY HEADQUARTERS 49 2204 610 27 FAX 49 2204 628 90 E M ail stairmaster deQ t online de U K HEADQUARTERS 44 1908 267 345 FAX 44 1908 267 346 E mail stairmasteruk msn com Page 72 FIGURES Figure 7 Parts Needing Periodic Lubrication EN Pedal arm x A chains Pedal orm return spring spring stop ossembly Page 73 FIGURES Figure 7 Parts Needing Periodic Lubrication T Pedal arm chains RY Drive chain Pedal arm return spring Lower spring stop assembly miu 73 FIGURES Figure 8 Left Side View Console mounting arm Pedal arm assembly oo 65 9 Drive shaft assembly Load resistor Alternator Alternator poly v belt Pivot shaft assembly L Drive reduction belt Rubber end cap E 21166 Page 74 E Lower reduction shaft assembly FIGURES Figure 9 Right Side View Weight 5 xa e Weight stack guide rods Upper spring stop assembly NI Shock mount
27. INPUT The 1650 LE console uses telemetry e g Polar heart rate signal detection Ensure that your console is set up for telemetry signal detection only There is a short lock out period at the beginning of each workout session during which the console first detects a signal and then validates the signal type e Telemetry heart rate after the initial belt signal is detected the console will enter a validation phase in which four good heart beat signals within four seconds are required before locking on telemetry heart rate signals for the duration of the workout session During the validation phase the console will not recognize contact heart rate signals Locked Non locked Option When the not locked option is selected the heart rate source signal is not fixed during the exercise if the signal is lost either input will be valid If the locked option is selected then the heart rate source signal is locked on the first detected signal during the workout To set a heart rate signal input or to turn off the heart rate option all together perform the following steps 1 the console keypad press LEVEL 3 2 At this point the screen will display HR INPUTS Press ENTER to select this option 2 There are 4 options to handle heart rate input signals Only 2 of those options are appropriate for the 1650 LE Both HR Off and Telemetry Only Press the SELECT key to scroll past the other options
28. Inspect the shaft and bushings for signs of wear and corrosion Clean corrosion off the pedal arm shaft with fine steel wool and replace any worn bushings before reassembling DO NOT SAND THE PEDAL ARM SHAFT Replace all parts ensuring proper tension of the alternator and drive reduction belts Lubricate the drive and pedal chains Page 47 PARTS REMOVAL AND REPLAC ALTERNATOR 1 Unscrew the DC power cable from the connector located inside the lower corner of the right rear cover 2 Remove the left side cover di Note the origin and color of each wire at the alternator terminals see Wiring Diagram 1 Remove the wires 4 Remove the alternator Poly V belt 5 Remove the nut at the frame pivot and the bolt at the brace see Figure 31 6 Remove the alternator T To install the new alternator reverse these procedures The alternator Poly V belt is tensioned properly when the center of either side of the belt can be deflected 1 4 0 6 cm from its center line with fingertip pressure see Figure 10 8 Connect the DC power cable before you install the side cover If the console does not power up check your wiring against the Wiring Diagram 1 9 If the console powers up reattach the side cover ALTERNATOR POLY V BELT THE BELTS M UST BE TENSIONED SO THAT THE CENTER OF EITHER SIDE CAN BE DEFLECTED 1 4 0 6 CM FROM ITS CENTER LINE WITH FINGERTIP PRESSURE A TIGHT BELT MAY CAUSE SLOW AND SLUGGISH OPERATION A LOOSE
29. J URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS Remove the sprocket and other small parts from the left side of the hub assembly see Figure 23 6 Slide the drive shaft to the right out of the drive hub assembly 7 Inspect the shaft and the bearings for excess wear or pitting The bearings should spin freely Replace worn parts if necessary Page 56 PARTS REMOVAL AND 8 Two sprockets located on the right side of the shaft 30 tooth drive sprocket and the smaller clutch sprocket To remove the clutch sprocket slide it off the left side of the shaft 9 Remove the 30 tooth sprocket by removing the snap ring from the right end of the shaft Unscrew the allen head set screws located on the inside flange of the drive sprocket TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS 10 To reinstall the drive shaft carefully reverse the disassembling procedures Install the drive shaft from the right side TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS FLOATING PULLEY ASSEM BLY 1 Remove the right and left side covers 2 Detach the weight stack belt at the frame junction 3 Remove the drive chain 4 Remove the floating pulley assembly see Figure 26 5 Reverse the removal procedures to install Make sure that the drive chain and weight stack belt are routed properly 6 Reattach the side covers Page 57 FLO
30. L ARM CHAIN 1 2 Remove the left side cover and the right rear cover if necessary While an assistant supports the pedal arm detach the pedal arm Spring from the frame Lift the pedal arm chain off the clutch sprocket Lower the pedal arm to the floor Remove both master link retaining plates using a standard screw driver See Figure 21 Use the flat of the screwdriver to push the retaining plate off the pins To reinstall the chain reverse the procedures Lubricate the chain before reattaching the cover s Page 63 PARTS REMOVAL AND REPLACE PEDAL ARM RETURN SPRING 1 Remove the left and right rear as needed side cover 2 While an assistant supports the pedal arm detach the pedal arm spring from the frame see Figure 10 3 Lift the pedal arm chain off the clutch sprocket Lower the pedal arm to the floor 4 Remove the other end of the spring from the double pitch master link 5 Ensure that the pedal arm chain passes over the clutch sprocket Support the pedal arms and reconnect the end of the spring to the spring hanger 6 Reattach the side covers PIVOT ASSEMBLY 1 Remove the right rear and left side covers 2 Loosen the alternator reduction and the drive reduction belts 3 Remove the two lower snap rings pivot adjustment shaft and two 4 upper bolts see Figures 8 and 25 vens TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS Spin th
31. USING THE MACHINE DANGER reduce the risk of electrical shock always unplug the external power supply from the AC wall outlet before cleaning maintaining or repairing A nac reduce the risk of burns electric shock or injury to persons 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 Close supervision is necessary whenever the machine is used by or near children invalids or disabled persons 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 4 9 11 SAFETY GUIDELINES Use this machine only for its intended use as described in this M anual Do not use parts attachments or accessories other than those provided by StairM aster Health amp Fitness Products Inc Do not use the external power supply if it has a damaged cord or plug or if it is not working properly if it has been dropped or damaged or dropped into water Contact our Customer Service Department at 1 800 331 3578 to arrange for the return of damaged parts 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 To disconnect the external power supply remove the plug from t
32. Y CAREFUL WHEN LUBRICATING THE CHAINS BE PARTICULARLY AWARE OF ALL BELTS AND PULLEYS WHICH ARE EXPOSED WHEN THE SIDE COVERS ARE REM OVED Remove the chains every three months to thoroughly clean and lubricate them Use a mild degreaser and a stiff brush to remove dirt and corrosion from the chains Wipe the weight stack guide rods weekly do not remove the weight stack covers with a rag dampened with window cleaner in order to clean off the old lubricant and prevent buildup To lubricate the guide rods spray silicon lubricant onto a clean rag and wipe the guide rods In order to keep the pedal arm return springs free of corrosion wipe the springs with an oil dampened rag once each week Page 36 Have an assistant work the pedal arms to raise the floating pulley assembly Remove the lower spring from the lower spring stop assembly located on the bottom frame rail every three months Wipe off the old grease and apply a new coat of heavy multi purpose grease before replacing the spring in its holder The grease will keep the spring from squeaking and rattling in its housing NEVER LUBRICATE THE SEALED BEARINGS ON THE IDLER PULLEYS OR IDLER SPROCKETS THEY ARE PERM ANENTLY LUBRICATED AND MAY FAILIF YOU ADD LUBRICATION Page 37 MAINTENANCE INSTRUCTIONS Table 3 Preventive Maintenance Schedule PART RECOM M ENDED FREQUENCY CLEANER LUBRICANT ACTION Plastic Side Clean Daily Soap amp Water N A Cover ext only
33. ack pin through the hole in the fourth plate and through a hole in the selector rod to create slack in the weight stack belt Use two wrenches to loosen the four nuts on the weight stack belt connector plates at the weight stack end see Figure 16 Pull the belt from the frame junction to remove the belt from its track see Figure 17 Loosen the four bolts on the connector plate at the frame junction of the belt Remove the old belt Insert 1 2 5 cm of the new belt in between the plate and the frame at the frame junction Tighten the bolts securely and evenly the plates should be parallel Thread the belt over the floating pulley assembly idler pulley and under the next idler pulley The belt goes between the retaining pins and the pulley see Figure 17 Push the belt through the belt guard tube Thread the belt under the next idler pulley and between the retaining pin Insert 1 2 5 cm of the new belt in between the weight stack connector plates Tighten the nuts securely but make sure the gap between the plates is parallel Page 67 dee PARTS REMOVAL AND REPLACEMENT 10 Lower the weight stack Ensure that the belt is properly seated in all five idler pulleys with the proper twist between the top and bottom idler pulleys 11 The belt should be taut with the spring of the lower spring stop Slightly compressed 3 4 2 cm and the top three weight plates resting on the top of the fourth weight p
34. age the unpainted Surfaces Repair the damaged area with a touch up kit Page 34 TO REDUCE THE RISK OF INJ URY DO NOT EXERCISE ON THIS MACHINE WHILE THE SIDE COVERS ARE REM OVED DO NOT DEPRESS OR RAISE THE PEDALS WHILE ANYONE S HANDS ARE INSIDE THE MACHINE DO NOT WEAR LOOSE CLOTHING OR NECKTIES WHILE WORKING ON THIS MACHINE Inspect the weight stack belt for undue wear and or fraying The 3 4 2 cm weight stack belt is made of Kevlar fibers and can withstand rather severe fraying Replace the belt if it wears to two thirds of its original width i e 1 2 or 1 cm The frame end junction of the belt is located on the bottom frame rail see Figure15 Plug in the machine and inspect this end of the belt by repeatedly pushing down on the left pedal arm raising the floating pulley assembly until it contacts the upper stop Allow the Weight stack to fall and inspect the rest of the belt through the slot in the weight stack covers Unplug the machine Inspect the weight stack belt connector plates at both ends of the belt see Figure 14 The plates should be evenly tensioned with a parallel gap between them Inspect the belt at the connections Visible serrations on the weight stack belt above the connector plates indicate belt slippage that should be corrected immediately Inspect the alternator reduction and the drive reduction belts for wear and proper tension You should be able to deflect the belt approximately 1 4 0 6 cm in ei
35. ainst the work rate and the pro gram advances to the next 3 minute stage The program continues for 2 to 4 stages until 2 steady state heart rates between 110 to 150 beats min are ob tained in 2 consecutive stages The line generated from the plotted points is then extended to the age predicted maximal heart rate A corresponding maxi mal work rate and VO can then be calculated At the end of the 3 minute of each stage if the heart rates at the end of the 2 and 3 minute are not within 5 beats min of each other then that work rate is maintained for an additional minute At the end of the 4 minute the heart rate is compared to the heart rate at the end of the 3 minute If the heart rates are within 5 beats min then the heart rate during the 4 minute is plotted against the work rate If the heart rate at the end of the 3 and 4 minute are not within 5 beats min then the work rate is maintained for one more additional minute If the heart rate at the end of the 4 and 5 minutes are within 5 beats min then the heart rate at the end of the 5 minute is plot ted against the work rate If the heart rate at the end of the 4 and 57 minutes are not within 5 beats min then the test failed Once 2 consecutive heart rate measurements are obtained in the 110 to 150 beats min range then the test ends successfully and the results are displayed The estimated maximum aerobic capacity is shown in ml kg min and METs Next the results are compared t
36. asteners Right rear cover 22337 11 Fasteners aes 5 Fasteners Right front W Outside weight stack cover cover 21483 23902 5 Fasteners Note there are a total of 43 fasteners 22086 Page 79 FIGURES Figure 14 Cover Fasteners Cover fastener 22086 Ji Side Frame cx HN Fastener removal tool Fastener removal tool 23853 80 FIGURES Figure 15 Top View of the Cover Seams Page 81 FIGURES Bolt 22026 Lock washer 22027 Bolt 22162 Page 82 FIGURES Figure 17 Weight Stack Belt Path Retaining pin Idler pulley 60 degree Twist Page 83 FIGURES Figure 18 Guide Rod Assembly Screw 23083 Fat washer 22038 Guide rod spacer 23708 Nut 22035 _ Guide rod 23364 i Rubber bumper 23069 Gromet 3 146 is 1 SIDE VIEW SEE SIDE VIEW Page 84 FIGURES Figure 19 Weight Stack Assembl
37. caps onto the frame TO PREVENT TIPPING THE MACHINE AND TO REDUCE THE CHANCES OF INCURRING A FOOT INJ URY REM OVE ALL SHIPPING CASTERS AND PLACE THE RUBBER END CAPS ONTO THE FRAME BEFORE OPERATING THIS EQUIPM ENT 2 Connect the DC power cable to the machine at the connector located inside the right rear cover of the machine 3 Place the power supply on the floor near an AC wall outlet 4 Check to be sure that the input AC power rating marked on the power supply matches the available power If it does not obtain the matching power supply from StairM aster Health amp Fitness Products Inc before proceeding any further 5 Connect the AC power cord to the AC wall outlet Refer to the Grounding Instructions section if the AC wall outlet does not accept a three prong plug Page 5 TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO PREVENT SEVERE DAM AGE TO THE MACHINE USE ONLY THE POWER SUPPLY APPROVED FOR USE WITH THIS EQUIPMENT IN ADDITION YOUR MACHINE MUST BE PROPERLY GROUNDED 6 Watch the console The console should display a software revision code and then show SELECT WORKOUT If the console does not unplug the power supply and then plug it back in If the console still does not power up correctly contact our Customer Service Department Refer to the Appendix for the appropriate phone number 10 The display SELECT WORKOUT tells you the machine is ready to use A selection of different len
38. cessary to allow 1 4 0 6 cm of play see Figure 10 6 Tighten the mounting bolts Install and adjust the alternator Poly V belt 7 Reattach the left side cover seat tray and seat HTD SPROCKET 1 2 Remove the lower reduction shaft assembly from the frame see Figure 24 Punch out the roll pin and remove the sprocket from the shaft Page 59 4 6 PARTS REM OVAL AND REPLACE 3 When reinstalling the sprocket use a new roll pin Reinstall the shaft Adjust the HTD and the alternator Poly V belts see the Alternator Poly V Belt and HTD Belt sections for tensioning instructions Adjust the HTD belt first then the alternatorPoly V belt Reattach the side covers LOAD RESISTOR 1 Remove the left side cover and locate the load resistor see Figure 8 Label the load resistor wires and remove them from the terminals on the ends of the resistor see Wiring Diagram 1 Remove the resistor mounting screws see Figure 31 Reinstall the resistor to the frame and reconnect the wires LOWER REDUCTION SHAFT AND BEARINGS Remove the right rear and left side covers Loosen and remove the alternator reduction and the drive reduction belts Remove the drive chain Remove the nut on the right side of the shaft see Figure 24 Unscrew the allen head set screws on the outside flange of the 16 tooth sprocket Remove the sprocket and the key Slide the shaft out to the left Page 60
39. d Intervals Program br ttt ts 21 The Constant Heart Rate Program occ 22 The Fitness Test Programs sine einen 23 Understanding Submaximal Exercise 23 Pretest Screening 25 The StairM aster Submaximal Fit Test 25 Page vii CONTENTS CONSO CARS dei latices sleet enteric te idee 29 Custom CodeS sc acer nent tubo en nnd 29 Quick Scan Programming Cabs tcd ne ete ted red 30 achine Status cse coo dede nime rei atraer re 31 Quick Scan Programming etre 32 Configuration Code 32 MAINTENANCE economie 33 hiinc ai 33 TOOL EISE aententia Ree 33 Maintenance ReCOLOSd 33 Preventive Maintenance 34 TROUBLESHOOTING icis pidan cuori oio i DERE 39 Troubleshooting the Electrical System 39 Console Diagnostic Tests eder rete i 42 M echariical Troubleshooting 46 PARTS REMOVAL AND REPLACEM ENT sms 48 PIE Deere vM Cr e 48 Alternator Poly V Belt coss ettet tuit rr aree 48 Chain Tensioning Idler Sprocket Assembly 49 dc M 50 Console M ounting AM 50 CONTE caecum depen ago mea ee du duds 51 Drive NI DR ES 54 Drive Chain Damper iude 55 Drive Cha
40. e Provides a cumulative total of the equivalent horizontal distance in miles or kilometers you would have traveled if you used the same amount of energy Calories Hour Provides a running total of the number of calories burned during a workout Rate Displays the current pedal strokes per minute Reps One rep is counted each time one pedal arm is pushed down toward the floor The length of an average person s pedal stroke is used to calculate the number of reps Level Shows the current intensity level between 1 the easiest and 20 the hardest Watts Displays the exercise intensity in watts 746 watts 1 horsepower METs Gives you the relative energy cost of exercise MET stands for mul tiples 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 func tion For example exercising at 10 M ETs requires ten times the resting rate of oxygen consumption or about 35 milliliters per kilogram per minute During a Workout this key shows the current M ET level During the workout summary the average M ET level is displayed Target Heart Rate Available only during the Constant Heart Rate program Shows the selected target heart rate At the completion of a workout the statistic averages are calculated based on the accumulation of data during the
41. e fastener removal tool under the edge of the pin head and pull the pin out about halfway The pin should not be removed You may now pull the cover away from the frame DO NOT use the fastener removal tool or any other sharp tool to pry out the fastener base because you may damage the covers 2 To reinstall the fastener insert the base of the fastener through the cover and into the frame When the base is in place push the pin in all the way to secure the fastener Seat Tray 1 Lift off the seat 2 Remove the two fasteners on top of the seat tray 3 Reinstall the seat tray with both fasteners and then set the seat into the four mounting holes Page 51 PARTS REMOVAL AND REPLAC Left Side Cover 1 2 6 Remove the seat and the seat tray Remove the five fasteners along the back seam Remove the three fasteners on the left front the two between the pedal arms and the seat and the one on the lower left side Remove the fastener located on the right front cover Pull the left side cover off To reinstall the left side cover line up the holes in the cover with the holes in the frame and insert the fasteners Reinstall the seat and the seat tray Right Side Covers There are two right side covers one in the rear and one in the front As a general rule the right rear cover is removed only if more extensive mainte nance is required Under very special circumstances only will the right front cover have
42. e shaft and inspect the bearings for excess play or roughness The shaft should turn freely Replace the pivot assembly if necessary Page 64 7 To reassemble the pivot pulley shaft and bearings reverse these procedures Adjust the HTD and the alternator Poly V belts see the Alternator Poly V Belt and HTD Belt sections for tensioning instructions Adjust the HTD belt first then the alternatorPoly V belt Reattach the right rear and left side covers SELECTOR ROD 1 Remove the outside weight stack cover 2 Remove the weight selector pin lift the first three plates to create Slack in the weight stack belt and remove the belt from the top two idler pulleys Set the plates back down onto the stack 3 Punch out the roll pin in the third weight plate and remove the selector rod from the weight stack see Figure 19 4 Punch out the roll pin securing the weight stack belt connector plates to the selector rod 5 Install the new selector rod by reversing the steps SHOCK MOUNT 1 Remove the side cover s 2 Have an assistant depress and hold the pedal arm down 3 Loosen the locking set screw and unscrew the shock mount see Figure 9 4 Screw in the new shock mount Tighten the set screw so that it just comes into contact with the shock mount screw 5 Release the pedal arm Page 65 PARTS REMOVAL AND REPLACE 6 The ends of the pedals should be even Adjust the pedal arm height by rotating the s
43. e should be replaced Alternator Test 11 Check for loose wiring connections on the alternator diode and load resistor 12 Perform the Positive Output to Field test on the alternator Diode Test Disconnect the power cord from the electrical outlet Remove the black wire from the B terminal on the alternator Remove the brown wire from the field terminal on the alternator Place a short wire with alligator clips on the terminal and the field FLD terminal of the alternator Step on the machine for approximately 10 to 15 seconds If full resistance is achieved during this time your alternator has correct current flow If no resistance is achieved replace the alternator 13 Remove the brown wire and diode from the field terminal of the alternator and set your voltmeter to the Ohms setting 14 Place one lead from the voltmeter on each end of the diode and then reverse the leads A diode that is good will show a high reading in one direction and a low reading when the leads are reversed Replace the diode if the readings recorded are both high or both low Resistor Test 15 Remove one wire from the load resistor and place one lead from the voltmeter on each of the threaded posts on the load resistor Replace the load resistor if the voltmeter does not read 0 5 Ohms 10 Page 41 CONSOLE DIAGNOSTICS The following tests are performed while the console is in the SELECT WORKOUT mode If the console fails a
44. e with a machine that you know is working and retest the machine Excess false heart rate detection the telemetry receiver located in the console is susceptible to mechanical vibration as well as external electrical interference Hitting the console or the frame may momen tarily cause errant heart beat detection this is normal If excessive false heart beats appear only during workouts check that the console cable is not curled up behind the console Pull as much of the cable down and away from the console as possible False heart beats while the machine is idle are most likely due to external interference Try plugging the machine into a different outlet or moving it to a new location Page 45 MECHANICAL TROUBLESHOOTI If you hear a grinding or clicking noise or experience excessive vibration during exercise a problem exists in the drive train of your machine Isolate the problem area by performing the following steps in the order listed below Refer to the appropriate Parts Removal and Replacement section of this manual for all disassembly and assembly instructions 1 Ensure the weight stack guide rods are properly lubricated Refer to the general maintenance section for instructions Remove the seat seat tray left side cover and right rear cover Remove the alternator Poly V belt and inspect the belt for cracks and or fraying Replace the belt if it is worn Spin the alternator pulley The pulley should spin fr
45. eely four to five revolutions without any clicking or grinding noises Replace the alternator if any noises are heard Remove the HTD belt and inspect the belt for cracks and or fraying Replace the belt if it is worn see Figure 8 Spin the 8 inch Poly V pulley on the pivot adjustment assembly see Figure 8 The pulley should spin freely without any clicking or grinding Replace the pivot adjustment assembly if any noises are heard Rotate the HTD pulley of the lower reduction shaft assembly by hand see Figures 8 and 24 The pulley should rotate freely without any clicking or grinding Remove the drive chain then disassemble and inspect the lower reduction shaft assembly if any noises are heard see Figure 24 Remove the step chains and inspect the chains for frozen links Flex each link up and down each link should move freely Replace a chain if any frozen links are found Do not reinstall the chains Rotate the clutch sprockets see Figure 17 Each sprocket should lock in one direction and rotate freely in the reverse direction Inspect the Page 46 10 11 12 SERRE d 52 MECHANICAL TROUBLESHOOTING drive shaft for wear when replacing a failed clutch sprocket Inspect the full length of the weight stack belt for fraying and verify that the belt is routed correctly over all of the weight stack belt idler pulleys see Figure 17 Check the pedal arm shaft and pedal arm bushings by removing both pedal arms
46. g knobs and lock washers from the back of the console see Figure 12 2 Disconnect the main cable connector from the back of the console 3 To install reconnect the main cable connector into the receptacle on the console Insert the cable into the wire saddles on the mounting arm 4 To install the console align the holes in the mounting plate with the holes in back of the console Insert and tighten the four lock washers and mounting knobs CONSOLE MOUNTING ARM Remove the console Loosen and remove the bolts lock washers and flat washers see Figure 12 To install the mounting arm first align the holes in the frame with the holes in the console mounting arm flange Insert each bolt with a lock washer and a flat washer and tighten the bolts securely Reinstall the console Page 50 COVERS DO NOT OPERATE THE MACHINE WHILE THE SIDE COVERS ARE REM OVED DO NOT DEPRESS OR RAISE THE PEDALS WHILE ANYONE S HANDS ARE INSIDE THE MACHINE DO NOT WEAR LOOSE CLOTHING OR NECKTIES W HILE WORKING ON THIS MACHINE WITH THE SIDE COVERS REM OVED GEARS SPROCKETS CHAINS AND BELTS OPERATE AT HIGH SPEEDS AND HAVE THE POTENTIAL TO INFLICT SERIOUS BODILY URY Cover Fasteners There are three types of covers side covers a seat tray and weight stack covers All covers are held in place with reusable plastic fasteners see Figure 13 for their location To remove the fasteners see Figure 14 1 Slide either end of th
47. ge 15 TELEMETRY HEART RATE e Adjust the belt higher or lower on your chest Remoisten the electrodes e Test your chest strap with a machine that you know is working or With a heart rate watch that you know is working f possible replace or exchange your console with a console from the same type of machine that you know is working and retest the machine e Verify that the console software has been set up properly for heart rate detection see pg 13 Elastic Strap ipe c Figure 4 Transmitter Belt Maintaining the Transmitter Belt Clean the chest belt regularly with mild soap and water then dry thoroughly residual sweat and moisture keep the transmitter active and drain the battery in the transmitter Do not use abrasives or chemicals such as steel wool or alcohol for cleaning as they can damage the electrodes permanently You can order replacement belts from StairM aster Polar Electro Inc or your local fitness store StairM aster 800 331 3578 P N 64000 Polar Electro Inc 800 227 1314 Page 16 The StairM aster Crossrobics 1650 LE console is divided into seven sections the display window the workout options the numeric keypad the entertain ment keypad the workout statistics the stop key and the intensity level keys see Figure 5 Display Window Entertainment N umeric Keypad Keypad Workout Statistics sto Intensity Level Figure 5 Crossrobics 1650 LE Console
48. gnal has been sensed during the initial setup time HOLD HR SENSORS In contact heart rate signal situations this message will come every 30 seconds to prompt the user to hold the sensors MODE DISABLED No heart rate signal is allowed due to the set up option that was chosen Heart rate monitoring is not possible Page 22 THE FITNESS TEST PROGRAM Understanding Submaximal Exercise Testing Before using the StairM aster Crossrobics 1650 LE for submaximal exercise testing it should be noted that all submaximal fitness tests make several assumptions e That a steady state heart rate is obtained for each exercise workload e That a linear relationship exists between heart rate oxygen uptake and workload e the maximal heart rate for a given age is uniform e That the mechanical efficiency of the physical activity performed i e oxygen uptake at a given workload is the same for everyone It should be kept in mind that any one or all of the above mentioned assumptions may not be met during a submaximal exercise test If for any reason one of the assumptions is not met then errors in predicting VO occur will 2 max Unfortunately it is often quite difficult to meet all of the requirements for the four listed assumptions For example exercising at a given workload for only a few minutes can involve an insufficient amount of time for many indi viduals to achieve a true steady state To ensure
49. gth DC cables brackets for multiple power supplies and other accessories are available from StairM aster Health amp Fitness Products Inc Refer to the Appendix for the phone number of the office nearest you Page 6 BASIC OPERATING INSTRUCTIONS GENERAL GUIDELINES FOR SAFE OPERATION THESE GUIDELINES ARE DIRECTED TO YOU AS THE OWNER OF THE MACHINE YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAM E GUIDELINES YOU SHOULD M AKE THIS M ANUALAVAILABLE TO ALL USERS 1 Obtain a complete physical examination from your medical doctor and enlist a health fitness professional s aid in developing an exercise program suitable for your current health status 2 When working out for the first time use the MANUAL workout option with low weight and a low intensity until you feel comfortable and capable of exercising at a higher intensity or with heavier weight 3 The speed and the duration of your workout should always be consistent with how you feel Never permit external influences to override your personal judgment about what constitutes a safe exercise intensity for you at a particular moment in time 4 Overweight or severely deconditioned individuals should be particu larly cautious when using the machine for the first time Even though such individuals may not have histories of serious physical problems they may perceive the exercise to be far less intense than it really is resulting in the possibility of overexertion or injury
50. he AC wall outlet Never drop or insert any object into any opening on the machine Do not operate where aerosol spray products are being used 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 manufacturing facility in Tulsa Oklahoma your StairM aster Crossrobics 1650 LE conditioning system was thoroughly inspected and tested for proper operation The major parts of the machine are shown in Figure 1 F Weight stack in here Weight stack torget x one dec Pedal arm End cop 1 Figure 1 Major Parts Page 3 INTRODUCTION 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 weight stack is on the right side of the machine The dimensions
51. hock mount clockwise to lower the pedal arm or counterclockwise to raise the pedal arm 7 Tighten the set screw Reattach the side cover UPPER SPRING STOP ASSEMBLY 1 Remove the left side cover 2 Use a combination wrench and an allen wrench to loosen and remove the shoulder bolt see Figure 27 from the threaded shaft 3 Examine the shoulder bolt and bronze bushing for excessive radial play Punch out the old bushing and replace if necessary Tighten the shoulder bolt all the way to the shoulder no other adjustment is necessary 4 Reattach the left side cover WEIGHT PLATE 1 Remove the outside weight stack cover 2 Remove the selector rod 3 Remove one of the two guide rods TO REDUCE THE RISK OF PERSONAL INJ URY NEVER PULL MORE THAN ONE GUIDE ROD OUT OF THE WEIGHT STACK AT ANY GIVEN TIM E REM OVIN G BOTH GUIDE RODS FROM THE WEIGHT STACK M AY CAUSE THE WEIGHT STACK TO FALL 4 Pivot the weight plate out of the stack and put the new weight plate in place Replace the guide rod which was previously removed Page 66 6 PARTS REM OVAL AND REPLACEM ENT Remove the other guide rod and take out the plate Pivot the new plate into place and reinstall the guide rod Reinstall the weight stack cover WEIGHT STACK BELT 1 Remove the left and right side covers and the outside weight stack cover Lift the top three weight plates four to five inches above the fourth weight plate Insert the weight st
52. htly barely in contact with the drive chain 5 Reattach the left side and right rear covers DRIVE CHAIN IDLER SPROCKET 1 Remove the left and right side covers 2 Remove the drive chain Inspect the idler sprocket It should spin freely and the teeth should be uniform Any damaged sprocket should be replaced 4 Remove the snap ring securing the damaged sprocket to its shaft 5 Pull off the damaged sprocket and replace it with a new sprocket TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS 6 Reinstall the drive chain and reattach the side covers Page 55 MENT PARTS REMOVAL AND REPLACE DRIVE HUB ASSEMBLY 1 Remove the drive shaft assembly 2 The hub assembly is held in place by eight one inch 2 5 cm bolts four bolts on each side Loosen and remove the bolts and slide the housing out of the frame see Figure 23 3 Replace the hub assembly if the bearings are worn 4 Reinstall the housing and the drive shaft assembly 5 Reattach the side covers DRIVE SHAFT ASSEMBLY 1 Remove the left side and right rear covers 2 Have an assistant support the pedal arms while you detach both pedal arm springs from the frame pin Lift the pedal arm chains off the sprockets and lower the pedal arms to the ground 3 Remove the drive chain 4 Remove the snap ring from the left end of the drive shaft vens TO REDUCE THE RISK OF EYE IN
53. in Idler S DIDCKOE securo mitra he b tite da 55 Drive Hub Assembly uie ctn ne irren tuper oret 56 Drive Shart ASSemDIl oae apti Dodo ou Spes 56 Floating Pulley 57 Floating Pulley Assembly Belt Idler 58 Floating Pulley Assembly Idler 5 58 Page viii rca ee aceon adn qd 58 Handle 5 59 Belus ccn cto sta Dep dc mra condi eet 59 HTD S ROCKO nios noe td 59 60 Lower Reduction Shaft and 5 60 Main Cable Pon 61 nA 62 Pedal AFM 63 Pedal 63 Pedal Arm Return SING cen Det 64 Pivot Er ew m 64 iJ nM mM 65 Shock M cessione male Ros yo praed b pup 65 Upper Spring Stop ASSemMDlIy pa tta Poet teet attulit 66 recs etie a atenta conca coe Na Md HR BENE 66 2 c evite Bes 67 Weight Stack Belt Idler Pulley beret e ta ore o Fon bet 68 Weight Stack Guide ROD une ie eie otras tonat aie 69 GROUNDING INSTRUCTIONS sn rennen nennen 70 NOTICE 25 555
54. late If the belt is tensioned properly skip step 12 12 If necessary adjust the portion of the belt between the connector plates at the weight stack and trim off the excess belt 13 Reattach the covers WEIGHT STACK BELT IDLER PULLEY 1 Remove the covers the outside weight stack cover and the left and right side covers as needed 2 Lift the top three weight plates 4 5 10 12 5 cm above the fourth weight plate Insert the weight stack pin through the hole in the fourth plate and through the selector rod hole to create slack in the weight stack belt 3 After you have identified the damaged idler pulley remove the snap ring securing it to its shaft and slide the pulley off wee TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS 4 Install the new pulley Page 68 6 Remove the weight stack pin and carefully lower the top three plates of the weight stack Ensure the weight stack belt is seated properly in the pulleys see Figure 17 Reattach the covers WEIGHT STACK GUIDE ROD 1 2 Remove the outside weight stack cover Loosen the nuts and remove the bolts at the top of the guide rods see Figure 18 Pull one guide rod only out of the weight stack and replace it before pulling out the other guide rod TO REDUCE THE RISK OF PERSONAL INJ URY NEVER PULL MORE THAN ONE GUIDE ROD OUT OF THE WEIGHT STACK AT ANY GIVEN TIME REM OVING BOTH GUIDE RODS FROM
55. le will then display the current machine type Use the SELECT key to toggle between options Press ENTER for the desired option Page 32 MAINTENANCE INSTRUCTIONS HELPFUL HINTS Read all maintenance instructions thoroughly before beginning work In some cases an assistant is required to perform the necessary tasks All references to the right or left side and to the front or back are made as if you were on the machine ready to exercise Major component names and locations are shown in Figure 7 TOOL LIST The following tools are needed to perform service and maintenance Torx screwdriver e phillips screwdriver combination wrenches sizes 7 16 3 4 wonder bar included w unit combination pliers locking pliers volt ohm meter multimeter wire stripper crimper tool allen wrench set sizes 5 64 1 4 external snap ring pliers shop goggles or other eye protection torque wrench socket set or nut driver set sizes 1 4 3 4 in 1 16 increments MAINTENANCE RECORDS For ease of maintenance the Crossrobic console will keep track of hours number of workouts time between last servicing etc You can quickly access any of the custom menus by pressing LEVEL J 4 ENTER The console will then display M ACHINE STATUS Scroll through the following options SELECT RUN HOURS XXXX 0 SELECT WORKOUTS XXXX 1 SELECT DISTANCE XXXX 2 SELECT CONS 90211 3 SELECT CROSSROBIC 4
56. mans Maximal heart rate 220 minus age low estimate Maximal heart rate 210 minus 0 5 x age high estimate e Maximal heart rate 226 minus age estimate for older individuals M aximal heart rate can however vary greatly among different individuals of the same age One standard deviation is 12 bpm which means that two thirds of the population varies an average of plus or minus 12 heart beats from the average given by a prediction equation If an individual s age predicted maximal heart rate is higher than that person s true maximal heart rate then his her estimated VO will be an overestimation of the correct or actual value 2 max The final assumption addresses the issue of mechanical efficiency Oxygen uptake at any given work rate can vary by approximately 15 between different individuals Therefore individuals vary in the amount of oxygen they require to perform a certain exercise workload Some individuals are more efficient at performing a given task than others As a result the aver age oxygen consumption associated with a given workload may vary signifi cantly from one person to another Thus VO predicted by submaximal exer cise tests tends to be overestimated for those who are mechanically efficient and underestimated for those who are inefficient The point to remember is that submaximal exercise testing though not as precise as maximal exercise testing is not without advantages For example the re
57. mercial entertainment systems is working You must have the loop back cable assembly PN 040051 001 to perform this test 1 Insert the loop back cable assembly into the RS 232 port on the back of the console Press LEVEL 6 2 The console will display SERIAL TESTS Press ENTER to access the C S A FE test Press ENTER a second time The console will run a diagnostic test and then display either PASS or FAIL Replace the console if it fails this test Alternator Test Use this test to verify the alternator field routines of the console You will need to briefly exercise on the machine for this test 1 2 Press LEVEL 6 3 to start the test For Field on press LEVEL Step on the machine for approximately 10 to 15 seconds If full resistance is achieved during this time your console has correct current flow If no resistance is achieved either the console or the alternator is bad See the electrical troubleshooting portion of this manual to isolate and test the alternator Replace the console if the alternator is good For Field off press LEVEL V Step on the machine for approximately 10 to 15 seconds You should not get resistance with the field turned off Press CLEAR to end the test Page 43 CONSOLE DIAGNOSTICS Tach Test If you do not have resistance perform the tach test The tach test will tell you the tach signal in revolutions per minute RPM s
58. nt to order a replacement part or to get help with the troubleshooting process See the Appendix for the appropriate phone number Troubleshooting The Electrical System The electrical power system has four major components the power supply the power cables the alternator and the console In order to identify the compo nent that is causing the problem you must systematically test the system You will need a volt ohm meter multimeter to conduct portions of the following procedures The console and power supply are not user serviceable If either of these parts are inoperable they must be replaced Opening the console or power supply will void the warranty TO REDUCE THE RISK OF ELECTRICAL SHOCK W HEN WORKING WITH AC VOLTAGE A QUALIFIED ELECTRICAL TECHNICIAN SHOULD PERFORM ALL ELECTRICAL TESTS THAT INVOLVE CHECKING AC POWER 1 Use a voltmeter set on VAC to verify that the AC wall outlet has 100 to 120 VAC or 220 to 240 VAC if applicable If you do not have a voltmeter plug in an alternate AC powered device e g a lamp If the device does not work when plugged into the electrical outlet consult an electrician for further assistance and then retest the electrical outlet Page 39 ELECTRICAL TROUBLESHOOTING 2 Plug the power supply into the wall outlet The green Light Emitting Diode LED on the power supply should be on If the LED does not light up replace the power supply Disconnect the DC cable from the lef
59. nut 22023 Nylon flat washer Nyloc nut 22114 22092 Flat washer d i Screw 23081 22046 Page 94 _ FIGURES Figure 29 Left Pedal Arm Assembly Pedal arm bushing 20365 22 Pedal arm Nyloc nut 22032 Rt 23335 Flat washer 22128 dui 23327 Snap ring 20213 Screw 23318 7 95 FIGURES Figure 30 Main Cable Routing Diagram Main cable 7 27830 mo Wire saddle YN 23792 Power Harness s 14112 Ne pQ X Grommet 21149 s ie B Page 96 FIGURES Figure 31 Alternator and Resistor Mounting Nyloc nut 22036 Hat washer 22038 Resistor mounting screw 22133 Load resistor 24874 3 Alternator brace Nylon flat washer 22114 Bolt 22116 Shoulder washer Screw 22181 22165 Alternator Lock washer 20205 22070 Flat washer Nyloc nut 22030 22029 Page 97 WIRING DIAGRAM Wiring Diagram 1 Main Cable Assembly Connections Power harness 14112 Grounding screw 22134 Toothed washer Mounting screw 22109 24208 Nut 22110 Load resistor 24874 Main cable 1 27830 Black Wie Diode assembly Power Harness N Alternator Brown 20205
60. ny test the console should be replaced or exchanged To return to the SELECT WORKOUT mode press either CLEAR or STOP while in the DIAGNOSTIC mode Please note that there may be additional verbiage on the display other than is listed in this manual The Crossrobics console is used on other StairM aster equipment DIAGNOSTIC CODES 6 0 Test display 6 1 Test keyboard 6 2 Test serial port 6 3 Test alternator 6 4 N A 6 1 5 N A 6 6 Test Tach 6 7 6 9 N A Display Test During the display test the console screen alternates between all LCD segments turned on and the sample program profile screen at a 2 second rate 1 Press LEVEL 6 0 ENTER The console will display DISPLAY TEST 2 All LCD segments will turn on for 2 seconds and then a sample program profile will be displayed for 2 seconds Press CLEAR to end the test Keypad Test Perform this test if you are having trouble entering data into the console During the test pressing any key displays that key name on the message line Press CLEAR to exit 1 Press LEVEL 6 1 ENTER to start the test Page 42 2 CONSOLE DIAGNOSTICS Firmly press each button except CLEAR The name of the key will be shown in the display window Press CLEAR to end the test Serial Port Test This test verifies that the RS 232 port used for linking to external C S A F E systems com
61. o normative values for others of the same age range and gender see Table 2 Results are stored in the con sole until the next person starts an exercise program Page 26 pus DE A CROSSROBICS 1650 LE CONSOLE Figure 6 StairMaster Fitness Protocol First Work Level 4 METs E UM P If HR 100 If 100 lt HR lt 120 If HR 120 v Second Work Level Second Work Level Second Work Level 7 METs 6 METs 5 METs EL 3115 Third Work Level Third Work Level 9 METs 8 METs PN 4 I HRs gt 115 gt NL Y _ v v Fourth Work Level Fourth Work Level 11 METs 10 METs Test fails if 2 stages of atleast 115 bpm are not Y obtained Test Complete gt Display Results lt Page 27 CROSSROBICS 1650 LE CONSOLE Table 2 Fitness Rating Norms VO High Good Average nad Fair gt 51 gt 50 gt 48 gt 45 gt 43 High 51 47 50 45 48 42 45 39 42 35 Good 4 43 45 41 42 38 38 35 35 32 WOMEN Average 42 40 41 37 38 35 35 32 32 29 Fair gt 44 gt 41 gt 40 gt 35 gt 35 Page 28 44 38 41 37 39 34 35 31 35 39 38 35 37 34 34 31 31 28 29 26 35 32 34 31 31 28 28 26 26 24 CROSSROBICS 1650 LE CONSOLE CONSOLE CODES There are
62. ong outlet box f D A Grounded 4 outlet 11 Tab for grounding screw Grounding pin T wv Metal screw NA Grounding System Page 70 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 instruc tions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installa tion 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 fol lowing measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help CHANGES OR ODIFICATIONS TO EQUIPM ENT NOT EXPRESSLY APPROVED BY STAIRM ASTER HEALTH amp FITNESS PRODUCTS INC COULD VOID THE USER S AUTHORITY TO OPERAT
63. pen dently using the level keys For example if you decrease the intensity level during a rest interval then subsequent rest intervals will be the same How ever the EXERCISE interval remains at the same intensity level you started with To change the intensity level of the EXERCISE interval you must change Page 21 CROSSROBICS 1650 LE CONSOLE the intensity level during an EXERCISE interval The intensity level shown dur ing an EXERCISE interval is indicative of your current speed However the cur rent speed during a REST interval is equal to a scaled percentage of the dis played intensity level Note that the program profile does not change at any time during the workout session Rest Interval Exercise Interval The Constant Heart Rate Program The Constant Heart Rate program maintains a chosen target heart rate by automatically varying the climbing speed during each workout The default target heart rate is equal to 70 of your maximum heart rate which is calcu lated by the following equation 220 Age x 70 Choose a different target heart rate between 80 and 180 beats per minute at any time during the work out by using the numeric keypad to enter the new target heart rate followed by the ENTER key The following messages may be shown during a workout e CHECK HR BELT The heart rate signal has been missing for the last 30 seconds in telemetry signal detection BELT NEEDED No telemetry belt si
64. r any user information This program uses the standard default settings for derivation of calories burned The Manual Program After pressing the M ANUAL key enter user and workout information Begin exercising at the selected level If desired adjust the workout manually by using the intensity level arrow keys The profile in the display window is divided into 15 equal intervals within the workout time The profile is based Page 20 CROSSROBICS 1650 LE CONSOLE on the selected intensity level with 2 levels equating to one vertical bar The Fat Burner Program The Fat Burner program is a 60 interval workout designed forpeople just Starting a weight control program The relative intensity level is indicated on the profile and any changes in the intensity level will continue for the remainder of the program E 1 Aerobic Training Program The Aerobic Training program is a 60 interval workout designed to increase aerobic capacity The relative intensity level is indicated on the profile and any changes in the intensity level will not change the look of the remaining profile HER BM BE is Speed Intervals Program The Speed Intervals program is a workout with 8 rest intervals and 7 exercise intervals that alternate speed intensity level changes You can change the REST interval speed level and the EXERCISE interval speed level inde
65. r washer 23638 Lower reduction shaft 23636 Spacer 23854 Bearing 5555 8mm 80 Tooth sprocket 23842 Page 90 FIGURES Figure 25 Pivot Assembly Rear frame rail _ Pivot shaft assembly 24167 PF KA Bronze thrust washer 23728 Flat washer 22030 Lock washer 23729 Bolt 22246 H Thrust was her adjustment shaft 23641 Snap ring 20213 Page 91 FIGURES Figure 26 Floating Pulley Assembly 25 Tooth idler Nyloc nut 22029 sprocket 23875 Floating pulley bracket 23387 03 Bolt 22196 le Bearing adapter 2 23716 Flat washer 22030 Idler pulley 23337 Bearing adapter 23852 Page 92 FIGURES Figure 27 Upper Spring Stop Assembly Shoulder screw 23847 Nyloc nut 22032 Flat washer 22038 Bushing 23849 Valve spring 23758 Spring retainer 23760 Page 93 FIGURES Figure 28 Chain Tensioning Idler Sprocket Assembly 25 Tooth idler sprocket 23875 Nen Chain tensioning C idler bracket 23391 03 13 Snap ring 23354 Y I Flat washer 22046 CCE E Flat washer 22038 y Screw 22024 Spring 23707 E Nyloc
66. range of the receiver in the machine Two electrodes on the underside of the chest belt sense the heart rate signal and send it to the receiver The heart symbol on the console pulses to indicate that the console is receiving a valid signal A microprocessor in the console calculates the heart rate and displays it in beats per minute on the console Using the Transmitter Belt J N WARNING PACEM AKER USERS SHOULD NOT USE THE POLAR TRANSMITTER BEFORE CONSULTING THEIR DOCTOR Before you put the transmitter belt on wet the two electrode 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 transmit ter 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 auto matically Your heart rate in beats per minute and a pulsing heart icon are dis played on the console After the initial belt signal is detected the console will enter a valida tion phase in which four good heart beat signals lasting four seconds are required before locking on telemetry heart rate signals for the duration of the workout session During the validation phase the console will not recognize contact heart rate signals If you do not see a heart rate on the console try one of the following Move closer to the console e Tighten the elastic part of the chest belt Pa
67. sole memory if pressed before ENTER The Crossrobics comes equipped to facilitate the use of commercial entertainment systems Using any of these keys will send an output signal through the Communication Speci fication for Fitness Equipment C S A FE port to a connected C S A FE or compatible system If a system is not connected pressing these keys will have no effect Volume Up Down Increases or decreases the volume level of the audio source Mute Removes the audio sound from the headphones Channel Up Down Changes the channel of the commercial entertainment system INTENSITY LEVEL KEYS LEVEL The exercise intensity level may be changed at any time dur V A ing a workout Pressing the v key decreases the intensity and pressing the key increases the intensity STOP KEY Press the STOP key any time you want to pause the exercise program for up to one minute Press STOP a second time or 1 and the console will return to the SELECT WORKOUT Prompt Page 18 WORKOUT STATISTICS During the exercise program the Stats keys are used to track workout statis tics which are then shown in the display window Pressing the SELECT key turns off the scanning feature and shows the statistic of choice in the display window Continue to press the SELECT key until you reach the desired Statistic Pressing the SCAN key will prompt the console to cycle through the following statistics Distanc
68. sole will display SET DEFAULTS Press ENTER Then console will rest itself and then display DONE Quick Scan Programming You can quickly access any of the custom menus by pressing LEVEL 7 3 ENTER The console will then display CUSTOMIZE Scroll through the following options SELECT MAX TIME SELECT CHANGE UNITS SELECT INPUTS SELECT LANGUAGE gt Page 30 CROSSROBICS 1650 LE CONSOLE SELECT CONTRAST SELECT SPEED N A SELECT CLINICAL M ODE N A SELECT SET DEFAULTS C Machine Status Codes 1 4 0 display machine run time in hours display number of workouts 1 4 2 display distance traveled 4 3 display software rev 1 4 4 display machine type 1 41 5 N A 1 4 6 display machine run time in hours since last cleared used for maintenance Display the machine run time by pressing LEVEL 4 0 The console will display RUN HOURS XXXXX Display the number of workouts by pressing LEVEL 4 1 The console will display WORKOUTS XXXX Display the total distance covered up to date by pressing LEVEL 4 2 The console will then display DISTANCE XXXX Display the console software revision number by pressing LEVEL 4 3 The console will display CONS 92111 Display the machine type by pressing LEVEL 4
69. sults of such testing can provide a fairly accurate reflection of an individual s fitness status without the cost risk effort on the part of the subject and time involved in max testing If an individual is given repeated Page 24 submaximal exercise tests and that person s heart rate response to a fixed workload is found to decrease over time it is reasonably safe to conclude that the individual has made improvements in aerobic cardiorespiratory fitness irrespective of the accuracy of the VO prediction 2 max Pretest Screening Prior to any exercise test maximal or submaximal participants should complete a brief health medical questionnaire have their resting blood pressure and heart rate measured and provide an informed consent form The Physical Activity Readiness Questionnaire PAR Q is an example of a valid health medical questionnaire for screening individuals prior to submaximal exercise testing Canadian health and fitness practitioners have extensively and quite successfully used the PAR Q to determine whether individuals Should be given an exercise test A yes answer to any of the following seven questions taken from the PAR Q would disqualify a participant from taking part in an exercise test until appropriate medical clearance was obtained gt ND PHYSICAL ACTIVITY READINESS QUESTIONNAIRE PAR Q Has your doctor ever said you have a heart condition and recom mended only medically super
70. t side panel Set the voltmeter to VDC and test for 12 to 19 VDC in pins 1 and 2 Replace the power supply if the voltage reading is outside the specified range Remove the bottom cover and connect the DC cable to the power connector on the left side of the frame Locate the black and white wires on the backside of the power connector Follow the white power connector wire to the where it plugs into the main cable white wire and disconnect it from the main cable white wire Set your voltmeter to VDC Connect the positive lead of your voltmeter to the white wire from the power connector and touch the gray casing of the alternator with the negative lead of your voltmeter DC voltage measured should be 12 to 19 VDC Replace the power connector if the voltage is not the same value as in step 3 Connect the two white wires Remove the console knobs from the back of the console lift the console up and disconnect the 20 pin main cable from the console Test for 12 to 19 VDC in pins 1 and 10 in the main cable connector Replace the main cable if the voltage reading is not the same as in step 7 19 20 img 3 4 1 2 ELECTRICAL TROUBLESHOOTING 10 If all voltage readings have been within the specified range and the console will not power up the consol
71. t you When calling please to provide our customer service representative with the following information Your name shipping address and telephone number The model and serial number of the inoperable unit 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 Material Authorization RMA prior to shipment StairM aster Health amp Fitness Products Inc will incur all freight charges for warranty parts ordered for a product that is less than 45 days old The parts will be shipped to you via an courier You are responsible for freight charges on warranty parts for poe that are more than 45 days old You will not be responsible or the return shipment of the inoperable parts Some inoperable warranty parts must be promptly returned to our Customer Service Department We will pay the cost to return the inoperable parts Detailed instructions are included with each warranty replacement part shipment StairM aster Health amp Fitness Products Inc neither makes assumes nor authorizes any representative or other person to make or assume for us
72. tem Regular use produces increased aerobic capacity as well as stronger muscles and bones Traditional types of weight loading exercise such as weight lifting produce stronger muscles and bones but cannot be performed in the rhythmic continuous fashion needed to improve aerobic fitness Traditional weight bearing exercise such as jogging improves aerobic fitness but does little to enhance muscular strength This type of exercise also increases a user s risk of injury by placing high impact forces on their joints The difference between the Crossrobics 1650 LE conditioning system and other types of exercise is the patented Crossrobics loading system The Crossrobics loading system allows the user independent control of both speed level and resistance The exercise speed is controlled with the FASTER and SLOWER keys on the console The resistance is controlled by selecting the appropriate number of plates on the weight stack The training emphasis of any given workout depends on how the two variables speed level and resistance are combined see The Crossrobics Conditioning M atrix Table pg 6 A strength workout consists of lower exercise speeds and heavier resistance A power workout combines faster exercise speeds and heavy resistance Fast exercise speeds and lighter resistance improve leg speed An endurance program using slower speeds and lighter weights is ideal for the long duration workouts recommended by weight control experts
73. ther direction with your fingertip see Figure 8 Carefully turn the 8 inch Poly V pulley counterclockwise and check for smoothness of operation If noise or roughness of operation is present you must inspect the pivot shaft assembly Inspect the pedal arm return springs at both connection points Replace broken spring s 2 Reinstall the left side cover the seat tray and the seat Page 35 MAINTENANCE INSTRUCTIONS Lubrication There are five components that require periodic lubrication the weight stack guide rods the pedal arm chains the drive chain the pedal arm return springs and the lower spring stop assembly see Figure 7 These lubrication proce dures if performed as outlined will minimize chain wear and maximize parts life You will need to remove the seat seat tray and the left side cover to lubricate these components 1 Place a protective mat on the floor when you are oiling your machine A rubber floor mat is available from StairM aster Health amp Fitness Products Inc Lubricate the drive and pedal arm chains weekly using SAE 30W motor oil Rotate the 8 inch Poly V pulley counterclockwise while you drip oil onto the drive chain and pedal arm chain rollers especially on the section of the pedal arm chains which are in contact with the drive hub sprockets Let the oil soak in for a few minutes and then remove any excess oil with a dry rag TO REDUCE THE RISK OF SERIOUS BODILY INJ URY BE EXTREM EL
74. three groups of console codes which are differentiated according to function The first group of codes are customization codes and are used to set defaults such as units language heart rate input type etc The second group of codes are machine status codes and are used to track hours and other gen eral usage patterns for maintenance purposes The third group of codes are diagnostic codes and are used for troubleshooting The following key actions are valid in each group of console codes Pressing LEVEL A 15 ENTER displays what group of codes is being accessed Pressing SELECT or LEVEL A at that point allows you to view all possible selections Once in this mode pressing LEVEL v backs up through the selections pressing ENTER then selects that item If another test level is available at this point the SELECT ENTER process is repeated Pressing 15 or 2 ENTER selects that item directly Pressing CLEAR exits any of the special access modes Custom Codes 1 3 0 change workout time limit between 5 to 99 minutes 1 3 1 change units M PH or KMH 1 31 2 choose type of heart rate input and priority telemetry or contact 31 3 3 4 choose console language 31 5 change contrast on console l 3 6 N A 13 7 N A 3 8 N A 31 9 reset to factory defaults 1 Change the workout time by pressing LEVEL 3 0 The console will display
75. to the proper alternator terminals see Wiring Diagram 1 Attach the wires to the alternator case or adjusting bracket with a wire tie to protect them from being damaged by moving parts 11 Reconnect the power connector junction box 12 Attach the connector at the upper end of the main cable to the console and take a test run 13 If the machine operates properly these steps complete the replace ment procedure If the console does not power up check your wiring against Wiring Diagram 1 14 Reattach the side and weight stack covers PEDAL 1 Use an allen wrench and an open end wrench to remove the two bolts the nuts and the washers 2 Remove the pedal see Figure 29 3 To install the pedal slide the pedal over the end of the pedal arm 4 Reinstall the hardware being careful not to over tighten the bolts PEDAL ARM 1 Remove the side cover s 2 Support the pedal arm and remove the pedal arm spring 3 Remove the snap ring from the pedal arm mounting post see Figure 33 Page 62 TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS Slide or gently tap the pedal arm off the mounting post Remove the master link from the pedal arm chain connection Clean the pedal arm mounting post before reassembling DO NOT SAND THE SHAFT To reinstall the pedal arm reverse these procedures Adjust the shock mounts so that both pedals are lined up refer to the shock mount section PEDA
76. tric units Correct entry errors by pressing CLEAR before you press EN TER 6 The console will prompt you to enter the number of weight plates Enter 3 for three weight plates Correct entry errors by pressing CLEAR before you press ENTER 7 The console will prompt you to enter your intensity level Enter 3 for intensity level 3 Correct entry errors by pressing CLEAR before you press ENTER Page 8 _ BASIC OPERATING INSTRUCTIONS The console will prompt you to enter the workout time in one minute increments between 5 and 99 minutes Press 1 0 ENTER to exercise for ten minutes If you do not start exercising within 60 seconds the console will return to the start screen Grasp both handles with your palms facing inwards Support your weight with your arms and lean back on the seat Bend your legs and Swing your feet up onto the pedals see Figure 2 pace Bs 192 Figure 2 Exercise Starting Position Page 9 BASIC OPERATING INSTRUCTION NOTE SOME INDIVIDUALS MAY NEED ASSISTANCE TO GET THEIR FEET ONTO THE PEDALS WHOEVER IS GOING TO PROVIDE ASSISTANCE SHOULD STAND IN FRONT OF THE MACHINE AND PUSH BOTH PEDAL ARMS DOWN AS FAR AS NECESSARY THE EXERCISER THEN PLACES THEIR FEET ONTO THE PEDALS ONE FOOT ATA TIME Begin Exercising 10 At this point begin exercising The exercise movement pattern consists of an alternating rhythmic series of single leqged squat Fig
77. ure 3 Exercise Motion Page 10 11 12 13 14 15 BASIC OPERATING INSTRUCTIONS Exercise at an intensity that Keeps the weight stack arrow suspended in the target zone If the arrow goes too high slow your stepping rate If the arrow goes too low step faster Your legs move the pedal arms against the resistance of the weight stack at a speed set by the console Relax your upper body The primary purpose of the handgrips is to aid you getting on and off the machine You will get the most benefit from your workout if you move the pedals through the greatest range of motion Push each pedal down as Close to the floor as possible and let it passively return as close to your chest as possible Change your rate of pedal movement faster or slower as needed not the range of motion to keep up with changes in speed As you become comfortable with exercise motion press LEVEL A and LEVEL v to adjust your speed You may vary the emphasis of your workout by sliding up or down on the seat M oving your body down on the pad exaggerates the pedal range of motion working the hamstring and gluteal muscles M oving your body up on the pad shortens the stroke emphasizing the quadriceps muscles Rest Periods 16 You can stop and rest as many times as necessary for up to one minute for each rest period during all programs The console returns to the start screen if you rest longer than the allotted rest period
78. ures for removing these covers only in reverse Page 53 PARTS REMOVAL AND REPLACEMENT DRIVE CHAIN 1 Remove the left side and right rear covers 2 Place the open end of a 3 4 combination wrench under the idler spring bracket the spring assembly under the lower right idler sprocket Pry up on the bracket to slacken the chain While support ing the idler sprocket assembly slide the chain off the upper left idler sprocket Remove the chain from the remaining sprockets UPON INSTALLATION MAKE SURE THE CLOSED END OF THE MASTER LINK RETAINING PLATE IS FACING THE DRIVE DIRECTION OR THE MASTER LINK MAY COME OFF DURING OPERATION 3 When installing the chain perform the following steps see Figure 22 Install the chain on the top left sprocket Install the chain on the bottom left sprocket Thread the chain through the floating pulley sprockets Install the chain on the top right sprocket While prying up on the idler sprocket bracket install the chain on the bottom right sprocket 4 Lubricate the new chain and reattach the covers Page 54 PARTS REM OVAL AND REPLACEM ENT DRIVE CHAIN DAMPER STRAP 1 Remove the left side and right rear covers 2 The drive chain damper strap is located between the alternator and the pivot pulley assembly on the right side of the rear vertical frame rail see Figure 9 3 Loosen the nuts and remove the mounting bolts 4 Replace the strap and adjust the strap so it is slig
79. vised physical activity Do you have chest pain brought on by physical activity Have you developed chest pain within the past month Do you tend to lose consciousness or fall over as a result of dizziness Do you have a bone or joint problem that could be aggravated by the proposed physical activity Has a doctor ever recommended medication for your blood pressure or a heart condition Are you aware through your own experience or a doctor s advice of any other physical reason against your exercising without medical supervision The StairMaster Submaximal Fit Test The StairM aster branching protocol is a series of 3 minute stages of continuous exercise at increasing intensity The first stage is a warmup at approximately 4 M ETs The intensity of the remaining stages is based on the heart rate response to the warmup The test is designed to raise the steady Page 25 CROSSROBICS 1650 LE CONSO state heart rate of the subject to 110 to 150 beats min for two consecutive Stages It is important to remember that two consecutive heart rate measure ments must be obtained in the 110 to 150 beats min range to predict VO The test typically lasts from 9 to 15 minutes 2max In the StairM aster protocol each work rate is performed for 3 minutes with heart rates recorded during the final 4 seconds of the 2 and 37 minutes of each stage If the heart rates are within 5 beats min then the heart rate during the last minute is plotted ag
80. workout program and not including the cool down period Page 19 CROSSROBICS 1650 LE CONSOL EXERCISE PROGRAM KEYPAD The exercise keypad is located below the display window While the console is in the SELECT WORKOUT mode press one of the six exercise program keys to preview the desired workout The standard defaults are pressing ENTER without inputting data first will prompt the console to enter these values Weight 175 lbs Intensity Level 3 e Workout Time The default time in the programmed workouts and Quick Start is 20 minutes The M anual and Constant Heart Rate programs do not have a specified default time In these programs the console timer will count up to the maximum time of 99 minutes return to 0 and count back up if no time limit is set Age Constant Heart Rate program only 40 years Once you have selected a program the prompts are ENTER WEIGHT LBS type in your body weight in pounds or kilograms if your console is set to metric units ENTER PLATE 3 12 select the desired number of plates ENTER LEVEL 1 20 select your intensity level with level 1 being the easiest and level 20 the hardest ENTER TIME 5 99 select the workout duration in one minute increments from 5 to 99 Press 0 in the M ANUAL and CONSTANT HEART RATE program to workout for an unspecified amount of time The Quick Start Program Provides an immediate start without having to ente
81. y So Selector rod roll mo 23719 Pad 1624 DETAIL DETAILA Decal 24390 Selector rod 23368 0 Weight stack plug 23912 odio T 3 Plate assembly 23910 03 B Weight stack tape 23791 Weight plate 23870 03 aes Weight stack a roll pin 23094 NC Selector pin 22325 Decal insert 23911 Page 85 FIGURES Figure 20 Pedal Arm Spring Assembly Pedal arm LES chain 23319 Double pitch 40 Master master link 20329 Spring chain une AZT senneclor 20768 Pedal arm return spring 22391 Page 86 FIGURES Figure 21 Master Link DIRECTION OF CHAIN TRAV Page 87 LO ER ON 2 ow e e gt gU a m i ON m 2 500 7 8 Me gt gt a N 5 o LO 5 x m OA GN 5 pu 5 tu ES FT lt 9 oa SoS 2 CN N 88 FIGURES Figure 23 Drive Shaft Assembly Snap ring 23713 Set screw 22066 30 Tooth drive sprocket 23315 Lock washer 22027 Screw 22028 Page 89 FIGURES Figure 24 Lower Reduction Shaft Assembly Nyloc nut 22029 Key 20833 Set screw 22037 16 Tooth sprocket 23316 Space

CROSSROBICS 1650 LE OWNER`S MANUAL

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