Stairmaster StepMill SM5 Technical Manual Download Page 6

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Tools

# Units Tool

Suggested Manufacturer Minimum Specifications

Multi-meter

Various

Digital, Continuity,

Socket Set, SAE

Various

1/4" - 5/8"

Socket Set, Metric

Various

4mm - 21mm

Socket driver

Various

Open end wrenches, SAE

Various

1/4" - 3/4"

Open end wrenches, Metric

Various

4mm - 17mm

Hex Bit Socket Set, SAE

Various

5/64 - 3/8

Hex Bit Socket Set, Metric

Various

4mm - 14mm

Adjustable Wrench

Various

Torque Wrench

Various

Torque Wrench

Various

Screwdriver Set, Phillips

Various

Screwdriver Set, Flat

Various

Tape Measure

Various

Ball Pene Hammer

Various

10 oz

Rubber Mallet

Various

USB - Flash Drive

Various

1 GB

Motorcycle straps, adjustable

Various

Loctite 680

Various

1’ Jumper wire w/ alligator clips

Various

zip ties

Various

zip ties

Various

Last revised 10/5/15

Summary of Contents for StepMill SM5

Page 1: ...StairMaster StepMill Technical Manual Last revised 10 5 15 ...

Page 2: ...t up and operate this machine on a solid level horizontal surface Do not step off the machine until the Steps have fully stopped Do not operate this machine outdoors or in moist or wet locations Keep at least 19 7 0 5m on each side of the machine clear This is the recommended safe distance for access and passage around and emergency dismounts from the machine Keep third parties out of this space w...

Page 3: ...cement o Alternator Removal Replacement o Transmission Removal Replacement o Step Chain Removal Replacement o Upper Lower Sprocket Removal Replacement Consoles Electrical Troubleshooting o Power Trace o No Resistance o Choppy Resistance o Relay Board Tests o Other Key Points o Contact Heart Rate Test SM3 Light Commercial Residential StepMill Product Detail Last revised 10 5 15 ...

Page 4: ...that members are familiar with are also included Landmark Challenge feature available on the TSE 1 TS 1 Console Only Warm Bar Functions Contact Heart Rate sensors and automatic stop button Fitness Tests Multi stage Fit Test CPAT Fire Fit Test and WFI StepMill Test Drive System Electronically controlled alternator with chain drive precisely controls the stair speed Step Action Revolving staircase w...

Page 5: ...s Landmark Challenge Program where users climb well known landmarks from around the world Standard programs that members are familiar with are also included Landmark Challenge feature available on the TSE 1 TS 1 Console Only Drive System Electronically controlled alternator with chain drive precisely controls the stair speed Step Action Revolving staircase with eight steps 8 20cm high 9 23cm deep ...

Page 6: ...cket Set SAE Various 5 64 3 8 1 Hex Bit Socket Set Metric Various 4mm 14mm 1 Adjustable Wrench Various 1 Torque Wrench Various 1 Torque Wrench Various 1 Screwdriver Set Phillips Various 1 Screwdriver Set Flat Various 1 Tape Measure Various 1 Ball Pene Hammer Various 10 oz 1 Rubber Mallet Various 1 USB Flash Drive Various 1 GB 4 Motorcycle straps adjustable Various 1 Loctite 680 Various 1 1 Jumper ...

Page 7: ...mage the unpainted surfaces Repair the damaged area with a touch up paint kit from customer service Maintenance Schedule General Maintenance Daily Weekly Monthly Comments Check Safety Warning Labels X Spot Check Step Chains X Alternator Belt Tension X Tension to 40 54 lbs inch Lubrication Drive Chains X or every 300 hours 30W Motor Oil Bearing Plate X Multi Purpose Grease White Lithium Cleaning Cl...

Page 8: ...pper and lower sprockets are held to the chassis of the machine by pillow block bearings and connect the left side and right side step chains Pillow blocks can be adjusted on the frame to ensure alignment from upper to lower sprockets and for tensioning the step chains As the steps rotate bearings in the step shaft hardware ride down the rails on bearing plates These bearing plates need to be grea...

Page 9: ...ere is an idler arm and sprocket on the transmission to assist with keeping tension on the drive chain Ensure the idler arm moves with the chain and that the bolt that connects it to the transmission is not over tensioned Resistance System Resistance is applied to the steps of the machine by use of an alternator 12VDC power from the lower board is fed into the alternator to control the amount of r...

Page 10: ... Ensure the belt is not too tight or damage to the alternator bearings or transmission housing can occur The inner pulley of the transmission has a set screw so the poly V belt can be aligned with the alternator pulley Wiring connections to Alternator W5 White B Alt output voltage W3 Brown Field Alternator Control Current W6 Black Ground Alternator return W4 Blue Tach velocity signal to console Al...

Page 11: ... from the J3 location connect to the appropriate posts on the alternator When the machine is plugged in and on the Power and Relay LEDs should be lit Once the alternator senses motion i e a user is on the machine the Field LED will become lit The lower board mounts to a plate that also houses the 0 5 ohm resistor Lower Board Resistor Wires to Alternator Last revised 10 5 15 ...

Page 12: ...Major Components Power System Last revised 10 5 15 ...

Page 13: ...ransmission drive sprocket set screw is tight 8 Visually inspect both upper and lower sprocket assemblies including pillow block bearings for signs of unusual or excessive wear 9 Check side to side alignment of sprocket assemblies by measuring from the outside face of each sprocket to the outside edge of the corresponding bearing rail Measurement on sprockets should be 1 11 16 left justified 10 In...

Page 14: ... alternator and pivot assembly hardware 12 Replace side covers Transmission Replacement 1 Remove side covers 2 Remove drive chain master link and chain from transmission upper sprocket 3 Optional Remove a step shaft allowing top down access for transmission removal 4 Remove poly V belt from inner transmission and alternator pulleys 5 Remove the transmission brace from the transmission body leaving...

Page 15: ...procket Replacement 1 Prepare a clean work area 2 Remove side covers 3 Remove console 4 Tip machine forward so the console mast is resting on the ground 5 Remove drive chain master link and chain from transmission upper sprocket 6 With an assistant loosen and remove 9 16 nuts on upper sprocket pillow blocks until the pillow block bearing is removed from the chassis and the upper sprocket is no lon...

Page 16: ...D Readout Console PN 055 0034 Replacable overlay PN SM27780 001 SM27790 SM27779 Display Board PN SM40070 001 Process Board PN SM27130 Menu map available C40 Console Gray Faced Overlay Blue LCD Readout Console PN 055 0034 Replacable overlay PN SM25673 SM27790 SM27779 Display Board PN SM40070 001 Process Board PN SM27130 Menu map available Last revised 10 5 15 ...

Page 17: ...M5 SC5 D1 LCD Console Blue LCD Readout Console PN 050 0035 Replacable overlay PN 050 0287 USB port for software upload Menu map available TS 1 TSE 1 Console Touchscreen TS 1 PN 050 0129 TV Optional TSE 1 PN 050 0034 USB port for software upload Ipod connector for use with iDevice Menu map available Last revised 10 5 15 ...

Page 18: ...Console PN 050 0035 35 Replacable overlay PN 050 0287 USB port for software upload Menu map available TS 1 TSE 1 Console Black Touchscreen TS 1 PN 050 0129 35 TV Optional TSE 1 PN 050 0034 35 USB port for software upload Menu map available Last revised 10 5 15 ...

Page 19: ...s on the lower PCB board Begin moving the staircase If all three of the red LEDs on the relay board are illuminated but there is no resistance inspect the alternator brushes SM24557 if worn or the alternator SM22900 050 0154 050 0161 050 0201 050 0105 050 0039 050 0038 050 0236 ASSY SM23545 050 0232 Last revised 10 5 15 ...

Page 20: ... the field terminal If the field LED lights replace the alternator o If the voltage checks good remove the blue connector from the W 4 Tach terminal of the alternator Lightly scrape the connector and re install Re check If still bad replace the console 3 Staircase has resistance but is choppy during exercise Inspect Main Cable for Corrosion at all connections Check Load Resistor for a reading of 5...

Page 21: ...replace lower PCB board SM23545 Disconnect the black W 2 ground wire With power on now place a jumper on the WHT test point and with the other end touch the ALT C test point then jump the WHT to the FLD NC test point and then jump the WHT to the RES NO test point Once the test is completed re attach the black W 2 ground wire and the J 1 main cable socket which was removed at the beginning of the r...

Page 22: ...r The Field LED on the relay board will flicker at higher speed levels This is the PWM signal from the console to the field terminal of the alternator to control resistance speed If you experience full resistance through all levels and the field light doesn t flicker replace the console To verify that the load resistor is working correctly you must ohm the resistor out using your multi meter The l...

Page 23: ...Last revised 10 5 15 ...

Page 24: ...Last revised 10 5 15 ...

Page 25: ...Last revised 10 5 15 ...

Page 26: ...eld current The only situation where no field current would be present during a workout is if a very light weight person was attempting to achieve a step rate that could not be achieved by their weight overcoming the frictional resistance of the system In this case the console would keep field current off or no induced resistance During workouts the alternator s B increases as a function of speed ...

Page 27: ... cables are connected to the heart rate plates Perform a Continuity Check on Cables and Plates No All cables have continuity Reconnect all cables and test contact heart rate Is the heart rate working It is possible that the cable is not connected to the plate Check Connections at the Heart Rate Plates No All cables have continuity Yes Yes Replace the contact heart rate cable PN 050 0324 No Yes The...

Page 28: ...ams Drive System Electronically controlled brake generator and drive chain precisely controls the stair speed allowing users to exercise smoothly within their comfort zones Step Action Revolving staircase with six 6 inch steps Step Surface 9 x17 U S Commercial Warranty User Environment Residential Light Commercial Frame Lifetime 10 Years Mechanical 5 Years 2 Years Electronics 2 Years 1 Year Wear I...

Page 29: ...value STOP Navigate to IDLE MODE First press clears information second press navigates to IDLE MODE CLEAR RESET First press clears information second press navigates to IDLE MODE If there is no value input and confirmation for 1 minute then console returns to IDLE MODE Sleep Mode The console will enter SLEEP mode after 10 minutes of non activity In SLEEP mode there will be no display and the back ...

Page 30: ...RATE HEADQUARTERS Core Health Fitness 4400 NE 77th Avenue Suite 300 Vancouver WA 98662 888 678 2476 For further support on StairMaster products please visit http support stairmaster com Last revised 10 5 15 ...

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