4000 PT Manual

STAIRMASTER®
4000 PT
OWNER’S MANUAL
Printed in the United States.
®
© 2001 StairMaster Health & 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
P/N 22868-A
© 2001 StairMaster Health & Fitness Products, Inc. StairMaster and FreeClimber are
registered trademarks or trademarks of StairMaster Health & Fitness Products, Inc. in the United States
and/or other countries. All other trademarks are trademarks of their respective companies.
StairMaster is a Rutledge Capital Company
Page iii
WARRANTY
This is to certify that the StairMaster® 4000 PT® exercise system is warranted
by StairMaster Health & 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 non-transferable from the original owner.
If, within three years from the date of purchase, any part of the StairMaster
4000 PT exercise system should fail to operate properly (except any accessories), contact
our Customer Service Department to report the problem. When calling, please be
prepared to provide the customer service representative with the following information:
• Your name, customer number, shipping address, and telephone number

• The model and serial number of the inoperable machine
• The date(s) of purchase for the inoperable machine(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 parts. 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.
• StairMaster Health & Fitness Products, Inc. will incur all freight
charges for warranty parts ordered for a machine that is less than 45
days old. The parts will be shipped to you via an overnight courier.*
• You are responsible for freight charges on warranty parts for
machines that are more than 45 days old. You will not be responsible
for the return shipment of the inoperable parts.
• Some inoperable warranty parts must be promptly returned to our
Customer Service Department. We will pay the shipping cost for the
inoperable warranty parts. Detailed instructions are included with
each warranty replacement part.
StairMaster Health & Fitness Products, Inc. neither makes, assumes, nor
authorizes any representative or other person to make or assume for us, any other
warranty 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 parts can be used.
This warranty is void if parts other than those provided by StairMaster Health & Fitness
Products, Inc. are used.
* Note: Aerosol products cannot be transported via air.
Page iv
PREFACE
Regular use of the StairMaster® 4000 PT® exercise system is a safe and
effective way to develop aerobic fitness while conditioning the major muscles
of the lower body. 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.
Throughout this manual, console keypad keystrokes are enclosed in [ ].

The names of the keys and special console operational modes are shown in
capital letters. For example, your machine is ready to use when the console
displays "SELECT WORKOUT." Press [MANUAL] to start the MANUAL exercise
program.
WHAT IS THE STAIRMASTER 4000 PT EXERCISE SYSTEM?
The StairMaster 4000 PT exercise system is a vertical climbing machine with

an independent step action. The independent step action, combined with the
patented pedal geometry featured on all StairMaster steppers, provides an
aerobic workout equivalent to uphill running or climbing stairs, but without the
high-impact pounding to the joints and muscles.
Page v
CONTENTS
SAFFETY GUIDELINES ........................................................................................ 1
INTRODUCTION ................................................................................................... 3
INSTALLATION INSTRUCTIONS....................................................................... 4
BASIC OPERATING INSTRUCTIONS ................................................................ 6

General Guidelines for Safe Operation ......................................................... 6
Your First Workout .......................................................................................... 7
Begin Exercising ..................................................................................... 7
Rest Periods ............................................................................................ 8
Cool Down............................................................................................... 8
HEART RATE MONITORING .............................................................................. 9

Heart Rate Input ............................................................................................. 9
Locked/Non-locked Option ............................................................................ 9
Error Messages ............................................................................................ 10
TELEMETRY HEART RATE .................................. 11

Using the Transmitter Belt ........................................................................... 11
Maintaining the Transmitter Belt ................................................................ 12
4000 PT® CONSOLE ........................................................................................... 13

Display Window ........................................................................................... 13
Numeric Keypad ........................................................................................... 14
Entertainment Keypad ................................................................................. 14
Intensity Level Keys ..................................................................................... 14
Stop Key ....................................................................................................... 14
Workout Statistics ........................................................................................ 15
Exercise Program Keypad ............................................................................ 16
The Quick Start Program ...................................................................... 16
The Manual Program ........................................................................... 16
The Fat Burner Program ....................................................................... 17
The Aerobic Training Program ............................................................. 17
The Speed Intervals Program .............................................................. 17
The Constant Heart Rate Program ...................................................... 18
The Fitness Test Programs ................................................................... 19
Understanding Submaximal Exercise Testing .................................... 19
Pretest Screening ................................................................................. 21
Page vi
CONTENTS
The StairMaster® Submaximal Fit Test ............................................... 21
The Firefighter's Stair Climb Tests ....................................................... 24
Turning on the C.P.A.T. Test ........................................................... 25
Turning on the NYCFD Test ........................................................... 25
Console Codes ............................................................................................. 26
Custom Codes ...................................................................................... 26
Quick Scan Programming .............................................................. 27
Machine Status Codes ........................................................................ 28
Quick Scan Programming .............................................................. 29
Configuration Code .............................................................................. 29
MAINTENANCE INSTRUCTIONS .................................................................. 30

Helpful Hints ................................................................................................. 30
Tool List ......................................................................................................... 30
Maintenance Records ................................................................................. 30
Initial Service ................................................................................................ 31
Preventive Maintenance ............................................................................. 31
Cleaning ................................................................................................ 31
Inspecting ............................................................................................. 31
Lubrication ............................................................................................ 32
TROUBLESHOOTING ........................................................................................ 35
General Troubleshooting Guidelines ........................................................... 35
Electrical Troubleshooting ........................................................................... 35
Alternator Test ............................................................................... 36
Diode Test ....................................................................................... 37
Resistor Test................................................................................... 37
CONSOLE DIAGNOSTIC TESTS ...................................................................... 38

Display Test ................................................................................................... 38
Keypad Test .................................................................................................. 38
Serial Port Test ............................................................................................. 39
Alternator Test .............................................................................................. 39
Tach Test ....................................................................................................... 40
Error Reporting ............................................................................................. 40
Telemetry Heart Rate Test ............................................................................ 41
Page vii
CONTENTS
MECHANICAL TROUBLESHOOTING ............................................................. 42
PARTS REMOVAL AND REPLACEMENT ....................................................... 44

Alternator ...................................................................................................... 44
Alternator Belt .............................................................................................. 44
Console ......................................................................................................... 45
Covers ........................................................................................................... 45
Drive Chain ................................................................................................... 46
Drive Hub Assembly ..................................................................................... 47
Handgrips ...................................................................................................... 48
Handlebar ..................................................................................................... 48
Leveling Arm ................................................................................................. 49
Pedal ............................................................................................................. 49
Pedal Arm ...................................................................................................... 50
Pedal Arm Return Spring ............................................................................. 51
Spring Pulley ................................................................................................. 51
Step Chain .................................................................................................... 52
Step Chain Retainer ..................................................................................... 53
Transmission ................................................................................................. 53
GROUNDING INSTRUCTIONS ......................................................................... 54
FCC COMPLIANCE ............................................................................................. 55
APPENDICES
Canadian Doc Class B Compliance ............................................................. 55

Important Phone Numbers ........................................................................... 56
LIST OF TABLES
Table 1. Dimensions and Specifications for the

StairMaster® 4000 PT® Exercise Systems ...................................... 3
Table 2. Fitness Rating Norms (VO2max) ........................................................ 24
Table 3. Recommended Preventive Maintenance Schedule .................... 34
Page viii
CONTENTS
LIST OF ILLUSTRATIONS
Figure 1: Level Adjusting End Caps ............................................................... 6

Figure 2: Transmitter Belt ............................................................................. 16
Figure 3: 4000 PT® Console ......................................................................... 18
Figure 4: StairMaster Fitness Protocol ........................................................ 28
Figure 5: Grounding System......................................................................... 54
Figure 6: Final Assembly - Left Side ............................................................ 57
Figure 7: Final Assembly - Right Side .......................................................... 58
Figure 8: Belt Tension ................................................................................... 59
Figure 9: Drive Hub Assembly ...................................................................... 60
Figure 10: Drive Chain Tensioning ............................................................... 61
Figure 11: Left Pedal Arm Assembly ............................................................ 62
Figure 12: Transmission ............................................................................... 63
Page ix
SAFETY GUIDELINES
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:
IMPORTANT SAFETY INSTRUCTIONS

This symbol appearing throughout this manual means
! Attention! Be Alert! Your safety is involved.
The following definitions apply to the words “Danger” and “Warning”

found throughout this manual:
DANGER - Used to call attention to IMMEDIATE hazards which, if not

avoided, will result in immediate, serious personal injury or loss of life.
WARNING - Used to call attention to POTENTIAL hazards that could

result in personal injury or loss of life.
READ ALL INSTRUCTIONS BEFORE USING THE MACHINE.
! DANGER To reduce the risk of electrical shock, always unplug

the external power supply from the AC wall outlet
before cleaning, maintaining, or repairing.
! WARNING To reduce the risk of burns, electric shock, or injury

to persons:
1. The external power supply should always be unplugged from the AC wall
outlet before removing or installing parts. Never make adjustments or
repairs while an exercise program is in progress.
2. Close supervision is necessary whenever the machine is used by or near

children, invalids, or disabled persons.
3. Keep your hands away from all moving parts and keep your feet on the
pedals while exercising. Do not operate the machine with the side covers
removed.
Page 1
SAFETY GUIDELINES
4. Use this machine only for its intended use as described in this Manual. Do
not use parts, attachments, or accessories other than those provided by
StairMaster® Health & Fitness Products, Inc.
5. 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-
3571 to arrange for the return of damaged parts.
6. Connect the external power supply to a properly grounded AC wall

outlet; refer to the “Grounding Instructions” section. Keep all cords
away from heated surfaces.
7. To disconnect the external power supply, remove the plug from the AC
wall outlet.
8. Never drop or insert any object into any opening on the machine.
9. Do not operate where aerosol (spray) products are being used.
10. Always wear insulated gloves when handling batteries.
11. Do not crush, incinerate, or dismantle the battery. The electrolyte contains
sulfuric acid which can cause serious damage to eyes and skin. Should
this occur, flush profusely with water and seek medical attention.
12. Do not use the machine outdoors.
The safety level given by the design of this equipment can only be
maintained when the equipment is regularly examined for damage and wear.
Inoperable components shall be replaced immediately or the equipment shall
be put out of use until it is repaired. Failure to follow all guidelines may
compromise the effectiveness of the exercise experience, expose yourself
(and possibly others) to injury, and reduce the longevity of the machine. Follow
all training instructions listed in the manual and/or on the machine. Physical
injury may result from incorrect or excessive training.
SAVE THESE INSTRUCTIONS

Page 2
INTRODUCTION
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 external power supply is plugged into the connector on the
right side cover. The dimensions and general specifications of the machine are
listed in Table 1.
Table 1. Dimensions and Specifications for the StairMaster®

4000 PT® Exercise System
Physical Dimensions:
Length 41 inches (104 cm)
Width 32 inches (81 cm)
Height 58 inches (147 cm)
Weight 130 pounds (59 kg)
Power Supply Specifications:

U.S., Canada, Japan 120 VAC, 50/60 Hz, 2.5 Amp
International 230 VAC, 50/60 Hz, 2.5 Amp
* Optional power supplies, intended for use outside the United States, are
available for 220-240 VAC, 50/60 Hz power requirements.
Page 3
INSTALLATION INSTRUCTIONS
Your machine requires minor assembly before use. Machines shipped outside
the United States need to be uncrated before they can be assembled; refer to
the “Uncrating Instructions” included with your machine for the details.
1. Remove all shipping material from your machine including the box
that is strapped to the pedals.
2. The rubber end caps, one on each leg of the machine (see Figure 1),
are designed to compensate for uneven floors. Each face of the caps
is a different thickness and is numbered. Twist the caps, as needed,
to stabilize the machine. Make sure the machine is level before you
use it for the first time.
Figure 1: Level Adjusting End Caps
Page 4
INSTALLATION INSTRUCTIONS
3. Open the box you removed from the pedals and remove the external
power supply.
4. Connect the DC cable of the power supply to the power connector

near the bottom of the right side cover.
5. To reduce the hazard of electrical shock,place the power supply on

the floor in a location to avoid exposure to perspiration and near an
AC wall outlet. The power supply must rest on a solid surface like a
rubber mat or block of wood, do not place the power supply directly
on carpet.
6. 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 match
ing power supply from StairMaster® Health & Fitness Products, Inc.
before proceeding any further.
! WARNING
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO

PREVENT SEVERE DAMAGE TO THE MACHINE, USE ONLY THE POWER SUPPLY
APPROVED FOR USE WITH THIS EQUIPMENT. IN ADDITION,
YOUR MACHINE MUST BE PROPERLY GROUNDED.
7. 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.
8. 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.
9. The display “SELECT WORKOUT” tells you the machine is ready to

use.
Page 5
BASIC OPERATING INSTRUCTIONS
GENERAL GUIDELINES FOR SAFE OPERATION
! WARNING
THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE MACHINE.

YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAME GUIDELINES.
YOU SHOULD MAKE THIS MANUAL AVAILABLE 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 exercise
program at the lower speeds until you feel comfortable and capable
of faster speeds.
3. The speed and duration of your exercise program should always be

subject to how you feel. Never permit peer pressure to exceed your
personal judgment while exercising.
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.
5. Although all equipment manufactured by StairMaster® Health &

Fitness Products, Inc. has been thoroughly inspected by the manufac
turing facility prior to shipment, proper installation and regular
maintenance are required to ensure safety. Maintenance is the sole
responsibility of the owner.
Page 6
YOUR FIRST WORKOUT ON THE STAIRMASTER® FREECLIMBER®
EXERCISE SYSTEM
1. Warm up with light calisthenics and easy stretching exercises for at

least five minutes before beginning your exercise program.
! WARNING
IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN,
EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF
BREATH, STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU
SHOULD CONSULT YOUR MEDICAL DOCTOR IMMEDIATELY.
2. Hold onto the handlebars and step up onto the pedals. Stand up
straight. The pedals will sink slowly toward the floor.
3. Select the MANUAL exercise program so you can control the pace of
your first workout and get used to the exercise motion. Press
[MANUAL] and then press [ENTER]. The console will return to
the start screen if you do not press [ENTER] within 60 seconds.
4. The console will prompt you to enter your body weight. Enter your
weight in pounds (or kilograms if the console is set up for metric
units). Correct entry errors by pressing [CLEAR] before you press
[ENTER].
5. The console will prompt you to enter your intensity level. Enter your
desired intensity level. Correct entry errors by pressing [CLEAR] before
you press [ENTER].
6. 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.
Begin Exercising
7. Take deep, comfortable steps. Do not let the pedals touch the floor or
contact the upper stop. When you begin to exercise, the MANUAL
Page 7
program starts at level three.
8. As you become comfortable with exercise motion, press

[LEVEL: ∧] and [LEVEL: ∨] to adjust your climbing speed.
9. Relax and stand up straight while exercising. Use the

handlebars for balance (see Figure 5).
10. Select an intensity level that allows you to stay in the middle
of the pedal range of motion. Faster is not always better.
Exercise at a level that is consistent with your fitness level.
Rest Periods
11. You can stop and rest as many times as necessary for up to one
minute for each rest period during all programs. To stop, either press
[STOP] or step off the machine.The console returns to the start screen
if you rest longer than the allotted rest period. Follow the onscreen
prompt to continue your work out after a rest period.
Cool Down
12. When you are finished with your workout, the machine will slow
down and the message “GOAL ATTAINED” will be displayed. You can
cool down on the machine by continuing to step. The console timer
will continue to count up from the selected time to the maximum time,
and the intensity level will default to level 3. 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 is set, the console will count up to 99, return
to 0, and start counting up again. Press [STOP] to end the cool down.
13. You can also cool down by getting off the machine walking or
stretching for at least five minutes. Lift one foot slowly until the pedal
arm contacts the upper stop. Place that foot on the floor. Repeat for
the other foot. Do not let the pedals slam into the upper stops, since
this may cause unnecessary wear and tear.
Page 8
HEART RATE MONITORING
HEART RATE INPUT
The 4000 PT 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. The
duration of this shorter, initial “lock out” period differs between telemetry and
contact heart rate.
• 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. On the console keypad, press [LEVEL: Ù], [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 7000 PT; "Both HR Off", and
"Telemetry Only." Press the [SELECT] key to scroll past the other
options until you find either "Both HR Off" or "Telemetry Only."
Press the [ENTER] key to select the desired option.
“TELEMETRY ONLY“ - locks out contact heart rate signals

and will only detect telemetry signals. Set your console to
this default.
Page 9
HEART RATE MONITORING
“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 10
TELEMETRY HEART RATE
The StairMaster® 4000 PT 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 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
! WARNING
PACEMAKER 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
automatically. Your heart rate in beats per minute and a pulsing heart icon are
displayed on the console.
After the initial belt signal is detected, the console will enter a
validation phase in which four good heart beat signals lasting four seconds
each 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.
Page 11
• Tighten the elastic part of the chest belt.
• Adjust the belt higher or lower on your chest.
• Remoisten the electrodes.
• 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 console with a console
(from the same type of machine) that you know is working and
retest the machine.
• Visually check that the heart rate receiver is positioned correctly
in the neck cover. The heart rate receiver jack should point down.
Ensure that the heart rate receiver is connected to the console,
and that the connection is not loose. If possible, swap the heart
rate receiver with one from another machine.
Figure 2: 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 StairMaster, Polar Electro, Inc., or your local
fitness store:
StairMaster 800-331-3578 P/N 64000
Polar Electro, Inc. 800-227-1314
Page 12
4000 PT CONSOLE
The StairMaster® 4000 PT® systems 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 3).
Display Window
Entertainment Numeric
Keypad Workout Options Keypad
Workout Statistics Stop Intensity Level
Figure 3: 4000 PT Console
DISPLAY WINDOW
• Time - The selected workout time is displayed in

the upper left section of the display window. Once
the time is entered, the timer will count down, in
minutes 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
appears 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
column shows your current interval. The flashing column moves from left to
right across the display as you complete each interval.
Page 13
4000 PT CONSOLE
NUMERIC KEYPAD
The numeric keypad is located on the right side of the

console. 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 console memory if
pressed before [ENTER].
ENTERTAINMENT KEYPAD
The 4000 PT® comes equipped to facilitate the use of

commercial entertainment systems. Using any of these keys
will send an output signal through the Communication
Specification for Fitness Equipment (C.S.A.F.E.) port to a
connected C.S.A.F.E. 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
The exercise intensity level may be changed at any time

during a workout. Pressing the [ ∨ ] 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 14
4000 PT CONSOLE
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:
• Distance - Provides a cumulative total of the equivalent distance (in miles

or kilometers), you would have traveled while riding a bicycle outdoors at the
same relative intensity.
• Calories/Hour - Provides a running total of the number of calories burned
during a workout.
• Rate - Displays the current steps per minute.
• Floors - Displays the equivalent number of floors climbed with an 8-inch
step. There are 16 steps per floor, and 48 floors per mile.
• 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
multiples of the resting metabolic rate. While you are sitting quietly, your body
consumes oxygen at the rate of about 3.5 milliliters per kilogram of body mass
per minute. When you exercise, your body needs more oxygen in order to
function. For example, exercising at 10 METs requires ten times the resting
rate of oxygen consumption, or about 35 milliliters per kilogram per minute.
During a workout, this key shows the current MET level. During the workout
summary, the average MET level is displayed.
• Target Heart Rate - Available only during the Constant Heart Rate pro-
gram. 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 workout program, and not not
including the cool down period.
Page 15
4000 PT CONSOLE
EXERCISE PROGRAM KEYPAD
The exercise keypad is located below the display and to the left of the function
keypad. While the console is in the “SELECT WORKOUT” mode, press one of
the exercise program keys to preview the desired workout. There are six
workout programs with the following standard defaults (pressing [ENTER]
without inputting data first will prompt the console to enter these values):
• Weight - 175 lbs.

• Intensity Level - 3
• Workout Time - The default time in the programmed workouts
and Quick Start is 20 minutes. The Manual 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, and then return to 0.
• Age (Constant Heart Rate program only) - 40 years
Once you have selected a program, the prompts are:
• “ENTER BODY WEIGHT” - type in your body weight in

pounds (or kilograms if your console is set to metric units).
• “ENTER LEVEL 1 - 20” - select your intensity level with
level 1 being the easiest and level 20 the hardest.
• “ENTER TIME 5 - 99” - select the workout duration in one
minute increments from 5 to 99. Press 0 in the MANUAL and
CONSTANT HEART RATE program to workout for an unspecified
amount of time.
The Quick Start Program
Provides an immediate start, without having to enter any user information. This
program uses the standard default settings for derivation of calories burned.
The Manual Program
After pressing the [MANUAL] 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
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4000 PT 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 for people 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.
The 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.
The 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 indepen-
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
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4000 PT CONSOLE
the intensity level during an EXERCISE interval. The intensity level shown
during an EXERCISE interval is indicative of your current speed. However, the
current speed during a REST interval is equal to a scaled percentage of the
displayed 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
workout 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:
• “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 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.
• “HR MODE DISABLED” - No heart rate signal is allowed due to
the set up option that was chosen. Heart rate monitoring is not
possible.
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4000 PT CONSOLE
THE FITNESS TEST PROGRAMS
Understanding Submaximal Exercise Testing
Before using the StairMaster® 4000 PT® for submaximal exercise testing, it
should be noted that all submaximal fitness tests make several assumptions:
• That a steady-state heart rate is obtained for each exercise

workload.
• That a linear relationship exists between heart rate, oxygen
uptake and workload.
• That the maximal heart rate for a given age is uniform.
• 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 VO2 max will
occur.
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
individuals to achieve a true steady-state. To ensure 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. When 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
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4000 PT CONSOLE
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
relationship 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 humans:
• Maximal heart rate = 220 minus age (low estimate)

• Maximal heart rate = 210 minus [0.5 x age] (high estimate)
• Maximal heart rate = 226 minus age (estimate for older
individuals)
Maximal 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 VO2 max will be an overestimation of the correct or
actual value.
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
average oxygen consumption associated with a given workload may vary
significantly from one person to another. Thus, VO2 max predicted by submaximal
exercise 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 results 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
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4000 PT CONSOLE
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 VO2 max prediction.
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.
PHYSICAL ACTIVITY READINESS QUESTIONNAIRE (PAR-Q)
1. Has your doctor ever said you have a heart condition and recom-
mended only medically supervised physical activity?
2. Do you have chest pain brought on by physical activity?
3. Have you developed chest pain within the past month?
4. Do you tend to lose consciousness or fall over as a result of dizziness?
5. Do you have a bone or joint problem that could be aggravated by the
proposed physical activity?
6. Has a doctor ever recommended medication for your blood pressure
or a heart condition?
7. 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 StairMaster branching protocol is a series of 3-minute stages of

continuous exercise at increasing intensity. The first stage is a warmup at
approximately 4 METs. The intensity of the remaining stages is based on the
heart rate response to the warmup. The test is designed to raise the steady-
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4000 PT CONSOLE
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 VO2max.
The test typically lasts from 9 to 15 minutes.
In the StairMaster protocol, each work rate is performed for 3

minutes, with heart rates recorded during the final 4 seconds of the 2nd and 3rd
minutes of each stage. If the heart rates are within 5 beats/min, then the
heart rate during the last minute is plotted against the work rate, and the
program 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
obtained in 2 consecutive stages. The line generated from the plotted points is
then extended to the age-predicted maximal heart rate. A corresponding
maximal work rate and VO2max can then be calculated.
At the end of the 3rd minute of each stage, if the heart rates at the end
of the 2 and 3rd minute are not within 5 beats/min of each other, then that
nd
work rate is maintained for an additional minute. At the end of the 4th minute,
the heart rate is compared to the heart rate at the end of the 3rd minute. If the
heart rates are within 5 beats/min, then the heart rate during the 4th minute is
plotted against the work rate. If the heart rate at the end of the 3rd and 4th
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 4th and 5th minutes
are within 5 beats/min, then the heart rate at the end of the 5th minute is
plotted against the work rate. If the heart rate at the end of the 4th and 5th
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 to normative values for others of
the same age range and gender (see Table 2). Results are stored in the
console until the next person starts an exercise program.
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4000 PT CONSOLE
Figure 4: StairMaster® Fitness Protocol
FIT TEST PROTOCOL

StairMaster CV Products
First Work Level

4 METs
If HR < 100 If 100 <= HR <= 120 If HR > 120
Second Work Level Second Work Level Second Work Level

7 METs 6 METs 5 METs
Y
If HRs >115
Third Work Level Third Work Level

9 METs 8 METs
If HRs >115 Y If HRs >115 Y
Fourth Work Level Fourth Work Level

11 METs 10 METs
Test fails if 2 stages of

at least 115 bpm are not
obtained
Test Complete
- Display Results -
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4000 PT CONSOLE
Table 2. Fitness Rating Norms (VO2max)
MEN
Age High Good Average Fair Low
20 – 29 >51 51 – 47 47 – 43 42 – 40 <39
30 – 39 >50 50 – 45 45 – 41 41 – 37 <37
40 – 49 >48 48 – 42 42 – 38 38 – 35 <35
50 – 59 >45 45 – 39 38 – 35 35 – 32 <32
60+ >43 42 – 35 35 – 32 32 – 29 <29
WOMEN
Age High Good Average Fair Low
20 – 29 >44 44 – 38 38 – 35 35 – 32 <32
30 – 39 >41 41 – 37 37 – 34 34 – 31 <30
40 – 49 >40 39 – 34 34 – 31 31 – 28 <28
50 – 59 >35 35 – 31 31 – 28 28 – 26 <25
60+ >35 35 – 39 29 – 26 26 – 24 <24
The Firefighter’s Stair Climb Tests
The StairMaster® Stepmill® is routinely used to assess the aerobic fitness

levels of fire fighters in full protective gear carrying heavy equipment. The
Candidate’s Physical Ability Test (CPAT), approved by the International
Association of Fire Fighters (IAFF) and reviewed by the U.S. Justice Depart-
ment, requires each candidate to step on the Stepmill at a predetermined
stepping pace for a specific period of time. There are two fire fighter specific
Stair Climb Test programs. The first test is the CPAT Stair Climb Test. The
second test is a modified version of the CPAT test that is used by the New York
City Fire Department (NYCFD). Both tests can now be simulated on the
StairMaster 4000 PT machines.
• CPAT Stair Climb Test – (Fit Test #2) The first phase is a warmup
interval at intensity of 56 steps/min and lasts 20 seconds. At
the end of the first interval the time counter will reset to zero.
The second phase continues through nine 20 second
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4000 PT CONSOLE
intervals at an intensity of 68 steps/min. The CPAT Stair Climb
Test has a total of 10 intervals and lasts for 3 minutes, 20
seconds (including warmup).
Turning on the CPAT Stair Climb Test
1. Press [Ù], [9], [1], [ENTER], on the console keypad. Make sure to
press in the middle of each key and be aware that the corre-
sponding numbers will not show in the console display.
2. The console will prompt you to “BEGIN FIT TEST.” The test
can be stopped at any time by pressing [STOP].
• NYCFD Stair Climb Test – (Fit Test #3) The first phase is a warm-
up interval at an intensity of 56 steps/min and lasts 60 seconds,
followed by a 60 second rest period (no stepping). At the end
of the rest period the time counter will reset to zero. The second
phase is at an intensity of 68 steps/min and lasts for 5 minutes,
12 seconds.
Turning on the NYCFD Stair Climb Test
1. Press [Ù], [9], [2], [ENTER], on the console keypad. Make sure to
press in the middle of each key and be aware that the corre-
sponding numbers will not show in the console display.
2. The console will prompt you to “BEGIN FIT TEST.” The test
can be stopped at any time by pressing [STOP].
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4000 PT CONSOLE
CONSOLE CODES
There are 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
general 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 ∧], [ 1st # ], [ENTER] displays what group of codes is

being accessed.
• Pressing [SELECT] or [LEVEL ∧] at that point allows you to view all
possible selections. Once in this mode pressing [LEVEL ∨] 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 [∧] [1st #, or 2nd #], [ENTER ] selects that item directly.
• Pressing [CLEAR] exits any of the special access modes.
Custom Codes
[ ^][3][0] change workout time limit between 5 to 99 minutes

[ ^ ] [ 3] [ 1 ] change units (MPH or KMH)
[ ^][3][2] choose type of heart rate input and priority (telemetry
or contact)
[ ^][3][3] - N/A -
[ ^][3][4] choose console language
[ ^][3][5] change contrast on console
[ ^][3][6] - N/A -
[ ^][3][7] - N/A -
[ ^][3][8] - N/A -
[ ^][3][9] reset to factory defaults
1. Change the workout time by pressing [LEVEL: ^], [3], [0]. The console will
display “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."
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4000 PT 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].
3. 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.
4. 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.
5. 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: ∨] keys to increase or decrease the contrast. The changed value
will remain on exit.
6. Reset the console to factory defaults by pressing [LEVEL: ^], [3], [9]. The
console 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: ^],
[3], [ENTER]. The console will then display “CUSTOMIZE.” Scroll through the
following options:
[SELECT] “ MAX TIME” 0

[SELECT] “CHANGE UNITS” 1
[SELECT] “HR INPUTS” 2
[SELECT] “LANGUAGE” 4
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4000 PT CONSOLE
[SELECT] “CONTRAST ADJ” 5
[SELECT] “MAX SPEED” - N/A- 6
[SELECT] “CLINICAL MODE”-N/A- 7
[SELECT] “SET DEFAULTS “ 9
Machine Status Codes
[ ^][4][0] display machine run time in hours

[ ^][4][1] display number of workouts
[ ^][4][2] display distance traveled
[ ^][4][3] display software rev
[ ^][4][4] display machine type
[ ^][4][5] -N/A-
[ ^][4][6] display machine run time in hours since last cleared
(used for maintenance)
1. Display the machine run time by pressing [LEVEL: ^], [4], [0]. The console
will display “RUN HOURS XXXXX”.
2. Display the number of workouts by pressing [LEVEL: ^], [4], [1]. The console
will display “WORKOUTS XXXX.”
3. Display the total distance covered up to date by pressing [LEVEL: ^], [4], [2].
The console will then display “DISTANCE XXXX.”
4. Display the console software revision number by pressing [LEVEL: ^], [4],
[3]. The console will display “CONS 92111-XXX.”
5. Display the machine type by pressing [LEVEL: ^], [4], [4]. The console will
display “STEPPER (or other machine type).”
6. Display the machine run time since last cleared by pressing [LEVEL: ^], [4],
[6]. The console will display “MAINT HOURS XXXX.”
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4000 PT 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- XXX ” 3
[ SELECT ] “ STEPPER” 4
[ SELECT ] -N/A-
[ SELECT ] “ MAINT HOURS xxxx” 6
Resetting the Maintenance Hour Counter
For ease of maintenance records, the 4000 PT 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 dusplay “RESET SERVICE.” Press [ENTER]. The console will
display “DONE.” Press [CLEAR] to return to the starting screen.
Configuration Code
The 4000 PT® console supports other StairMaster® exercise systems. It

is important to verify that the machine configuration code matches the type of
machine you have.
[^][8][0] Change Machine
1. Change the machine type by pressing [LEVEL: ^], [8], [0]. The console will
display “CHANGE MACHINE.” Press [ENTER]. The console will then display
the current machine type. Use the [SELECT] key to toggle between
options. Press [ENTER] for the desired option.
Page 29
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.
TOOL LIST
The following tools are needed to perform service and maintenance:
• Torx screwdriver • 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 4400/4600 PT/CL 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: ^], [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- XXX ” 3
[ SELECT ] “ STEPPER” 4
[ SELECT ] -N/A-
[ SELECT ] “ MAINT HOURS xxxx” 6
*The machine may show a few hours of use due to testing at the
manufacturing facility.
Page 30
INITIAL SERVICE
Upon receiving your machine, use a soft, clean towel to wipe off the dust
which may have accumulated during shipping. Your new machine will require
minor assembly. Refer to the “Installation Instructions” section for details.
PREVENTIVE MAINTENANCE
Most of these preventive maintenance procedures can be performed after

removing the mid-cover. The preventive maintenance schedule is summarized
in Table 3. The schedule is based on normal usage in a commercial health club
environment; adjust the schedule to meet actual machine usage. Refer to the
“Parts Removal and Replacement” section for all disassembly and assembly
instructions.
Cleaning
1. DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD

CLEANERS ON THE CONSOLE. Clean the console daily with a water-
dampened cloth and wipe dry after cleaning.
2. Clean the exterior of the machine daily using soap and water or a
diluted household cleaner such as Fantastic®.
3. Thoroughly clean the entire machine, including the interior, at least

once a week (see Table 3).
Inspecting
1. Inspect the frame for any rust, bubbling, or paint chips during the
weekly cleaning. The salt in perspiration can damage the unpainted
surfaces.
2. Inspect the Poly-V belt and HTD belts for excessive wear during the
quarterly lubrication. Adjust the belt tension if necessary.
Page 31
Lubrication
There are nine components that need periodic lubrication: the drive chain, the
step chains, the pedal arm return springs, the step chain connection points,
the pedal arm bushings, the leveling arm bushings, the spring pulley shafts,
the pedal shafts and the leveling arm pins. Remove the bottom cover to get to
the components.
1. Place a protective mat on the floor while you lubricate your machine.
A rubber floor mat is available from StairMaster® Health & Fitness
Products, Inc.
2. Lubricate the drive chain and the step chains weekly. Try to penetrate
the entire length of the chains with 30W motor oil.
3. Remove the drive chain and step 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.
4. Unhook the pedal arm return springs from the spring hanger every
week. To protect them from corrosion, wipe the entire length of each
pedal arm return spring with a cloth dampened with 30W motor oil
before reconnecting it. Replace the spring if it is rusty or otherwise
damaged.
5. Remove the double pitch master link from the step chain connection
points every three months. Clean the master link and the bushing in
the pedal arm. Lubricate the master link and bushing with a thin coat
of multi-purpose grease before reassembling.
6. Remove the pedal arms and leveling arms every three months. Clean
the pedal arm and leveling arm shafts and bushings with a clean
cloth. Protect the shafts from corrosion by wiping them with a cloth
dampened with 30W motor oil.
Page 32
! WARNING
TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE THE PEDAL
AREA IS FREE OF GREASE OR OIL. WIPE ANY EXCESS OIL OFF
THE MACHINE SURFACES.
7. Remove the spring pulleys every three months. Clean the spring
pulley shafts with a dry cloth. Protect the shafts from corrosion with a
thin coat of multi-purpose grease before reassembling.
8. Remove the pedals every three months. Clean the pedal shaft and
leveling arm pin with a dry cloth. Protect the pedal shaft and leveling
arm pin from corrosion with a light coat of multi-purpose grease
before reassembling.
Page 33
Table 3: Recommended Preventive Maintenance Schedule
RECOMENDED
PART FREQUENCY CLEANER LUBRICANT
ACTION
Console Wipe Clean Daily Water N/A
Diluted
Clean and
Covers Daily household N/A
Inspect
cleaner
Monthly or
30W motor
Lubricate after 300 N/A
oil
Drive and hours of use
Step Chains Quarterly or
Clean and Mild 30W motor
after 900
lubricate degreaser oil
hours
Every 3
Step Chain Multi-
Clean and months or Clean, dry
Connection purpose
lubricate after 900 rag
Points grease
hours
Every 3
Spring Multi-
Clean and months or Clean, dry
Pulley purpose
lubricate after 900 rag
Shafts grease
hours
Pedal Every 3
Multi-
Shafts and Clean and months or Clean, dry
purpose
Leveling lubricate after 900 rag
grease
Arm Pins hours
Clean, oil-
Pedal Arm Inspect and Each week
N/A dampened
Springs wipe down or 70 hours
rag
Every 3
Pedal Arm Clean and months or Clean, dry 30W motor
Shafts lubricate after 900 rag oil
hours
Every 3
months or
Battery Check Voltage N/A N/A
after 900
hours
Every 3
Inspect & months or
Belts N/A N/A
Adjust Tension after 900
hours
*Note: Use of lubricants other than those specified will result in

diminished performance and a shorter life span for that part.
Page 34
TROUBLESHOOTING
GENERAL TROUBLESHOOTING GUIDELINES
This troubleshooting section is organized into three basic problem sections:

electrical troubleshooting, console diagnostic tests, and mechanical trouble-
shooting. Once you have identified the problem section, perform all the tests in
the same order as written. To order a replacement part or for help with
troubleshooting, contact our Customer Service Department. Refer to the
Appendix for the appropriate phone number.
ELECTRICAL TROUBLESHOOTING
The 4000 PT® electrical system has four major components: the alternator, the
power supply, the power cables, and the console. The console and power
supply are not serviceable by the owner. If any of these parts are inoperable,
they must be replaced. Opening the console or the power supply will void the
warranty.
1. Use a voltmeter set on VAC to verify that the AC wall outlet has 100
to 120 VAC (or 220 to 240 VAC, if applicable). If you do not have a
voltmeter plug in an alternate AC-powered device (e.g., a lamp). If the
device does not work when plugged into the electrical outlet, consult
an electrician for further assistance and then retest the electrical
outlet.
2. Plug the power supply into the wall outlet. The green Light Emitting
Diode (LED) on the power supply should be on. If the LED does not
light up, replace the power supply.
3. Disconnect the DC cable from the left side panel. Set the voltmeter to
VDC and test for 12 to 19 VDC in pins #1 (+) and #2 (-). Replace the
power supply if the voltage reading is outside the specified range.
4. Remove the bottom cover and connect the DC cable to the power
connector on the left side of the frame. Locate the black and white
wires on the backside of the power connector.
Page 35
5. 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.
6. 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.
7. 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.
8. Remove the console knobs from the back of the console, lift the
console up, and disconnect the 20-pin main cable from the console.
9. 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.
10. If all voltage readings have been within the specified range and the
console will not power up, the console 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:
• 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.
Page 36
• Place a short wire with alligator clips on the B+ 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.
Diode Test
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 (see Final Assembly Figure)
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%).
16. If the problem still exists, contact the Customer Service Department at
800-331-3578.
Page 37
CONSOLE DIAGNOSTIC TESTS
The following tests are performed while the console is in the “SELECT
WORKOUT” mode. If the console fails any 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
4000 PT® console is used on other StairMaster® 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][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 ], to start the test.
Page 38
2. 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 (commercial 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.
2. Press [ LEVEL: ^ ], [ 6 ], [ 2 ]. The console will display “SERIAL TESTS.”

Press [ENTER] to access the C.S.A.F.E. test.
3. 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. Press [ LEVEL: ^ ], [ 6 ], [ 3 ], to start the test.
2. 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.
3. 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 39
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 (RPMs), 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 RPMs 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 RPMs (+/- 200). If the tach signal
picked up by the console is less then 1,900 RPMs 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, TIMER ERROR, and STATIC RAM ERROR.
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 40
The Telemetry (Polar®) Heart Rate Test
The telemetry heart rate system is made up of the console, the heart rate
receiver, 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.
2. 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.
3. 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.
4. Test your chest strap with a machine that you know is working, or
with a heart rate watch that you know is working.
5. If possible, replace or exchange your console with a machine that you

know is working and retest the machine.
6. 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 41
MECHANICAL TROUBLESHOOTING
If you hear a grinding or clicking noise, experience excessive vibration during
exercise, or if the pedals are not functioning properly, you probably have a
problem in the drive train. Attempt to isolate the problem area by performing
the following tests in precisely the order listed below.
1. Unplug the machine and remove the bottom side covers.
! WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE

WHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE PEDALS WHILE
ANYONE'S HANDS ARE INSIDE THE MACHINE.
2. Noise can be generated by a Poly-V belt that is either too tight

or too loose. Check the condition and the tension of the belt.
Replace a worn belts. Adjust the belt tension according to the
instructions in the "Parts Removal and Replacement" section.
3. Remove the Poly-V belt and move the pedal arms. If the noise no
longer exists, check the condition of the alternator. If the noise is still
present, go to step #4. Do not reinstall the Poly-V belt if performing
step #4.
• Disconnect the DC power cable. Spin the alternator pulley with

your fingers. It should spin freely and remain spinning for at least
two revolutions. If it does not, the alternator should be replaced.
• If the alternator does spin freely, check the alternator for noise,
roughness, or the presence of an excessive amount of black
powder inside the alternator or near the outside of the case. If
any of these conditions exist, the brushes might be bad.
Replacement brushes are available as well as replacement
alternators.
4. Tighten the transmission pulley set screw onto the flat side of the
transmission output shaft. Tighten the transmission drive sprocket set
screw to the keyway in the transmission input shaft.
Page 42
MECHANICAL TROUBLESHOOTING
5. Remove the drive and step chains. Check the condition of the chains
by flexing each link up and down. Each link should move freely. Re-
place the chain if any stiff or inflexible links are found or if the chain is
rusty, corroded, or otherwise damaged. Do not reinstall the chains.
6. Spin the transmission drive sprocket input 1 complete revolution. The

transmission pulley output should turn 19 revolutions. Replace the
transmission if any clicking or grinding noises are heard during
rotation or the drive ratio is not 19 to 1.
7. Check the pedal arm and leveling arm shafts by removing both the
right and left pedal and leveling arms. Inspect the shafts and the
bushings for signs of wear and corrosion. Replace the bushing(s) if
worn.
8. Remove the pedals. Clean any corrosion off the pedal shaft with an
oil-dampened rag. Apply a thin coat of multi-purpose grease to the
shaft. If the noise persists, go to step 10. Check the step chain connec
tion point. Clean and grease the master link and bushing. Replace
damaged parts.
9. Check the drive hub assembly.
• Check the condition of the drive sprocket teeth. The teeth should
not be unevenly worn. Replace the worn sprocket(s).
• The drive sprockets work independently of one another. Each

sprocket should turn freely in one direction and lock when turned
in the other direction. Replace an inoperable drive sprocket.
• Remove the drive shaft. Inspect the bearings in the drive hub.
Replace the drive hub assembly if the shaft does not spin freely
or if there is excessive radial play at the shaft. Be careful not to
get dirt into the hub.
• Inspect the ends of the drive shaft (at the sprocket attachment
points) for signs of wear or scoring. Replace the shaft if it is
excessively worn.
Page 43
PARTS REMOVAL AND REPLACEMENT
ALTERNATOR
1. Remove the side panels.
2. Mark the location of each wire attached to the alternator then

remove the wires from the alternator (See figure 7).
3. Remove the alternator adjusting bolt on the slotted brace.
4. Remove the Poly-V belt and inspect the belt for wear. Replace the belt
if it is cracked, cut, or is otherwise damaged.
5. Support the alternator while removing the nyloc nut and the alterna
tor mounting bolt from the frame.
6. Remove the alternator from the frame.
7. Reverse the removal procedures to install the new alternator.
8. Verify that the alternator is wired correctly (See figure 7) and that
the Poly-V belt deflection is set to allow 1/4" (0.6 cm) of belt deflec-
tion before applying power to the machine (see Figure 8).
ALTERNATOR BELT
! WARNING
THE BELTS MUST BE PROPERLY TENSIONED. A BELT THAT IS TOO TIGHT

WILL CAUSE SLOW AND SLUGGISH OPERATION. A BELT THAT IS TOO LOOSE
WILL CAUSE EXCESSIVE NOISE AND BELT WEAR.
1. Remove the side covers.
2. Loosen the alternator adjustment screw that mounts the alternator

brace to the alternator, and the pivot adjusting bolt that mounts the
alternator to the frame.
Page 44
3. Pivot the alternator down and remove the Poly-V belt.
4. Make sure the Poly-V belt is centered on the pulleys during

installation.
5. Pivot the alternator up or down as necessary to allow 1/4"

(0.6 cm) of belt deflection with fingertip pressure at the midpoint
between the two pulleys (See figure 8).
6. Tighten the alternator adjustment bolt and the pivot adjustment bolt.
Verify 1/4" (0.6 cm) deflection in the belt.
7. Reinstall the covers.
CONSOLE
1. Remove the four mounting knobs from the back of the console.
2. Disconnect the main cable from the back of the console.
3. Remove the console.
4. Reverse the steps to reinstall the console.
COVERS
Each side cover is secured to the mainframe of the machine with three quarter
turn fasteners: two fasteners in the top of the side panel and one in the lower
portion of the panel near the floor.
1. Disconnect the power supply from the right side panel.
2. Use a phillips screwdriver to remove the lower fastener by

turning it counter clockwise one quarter of a full turn.
3. The fastener will remain attached to the panel when the

screw driver is removed.
Page 45
4. Support the panel while removing the two top fasteners the
same way the single lower fastener was removed.
! WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE

WHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE
PEDALS WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE.
5. Carefully lower the side panel to the floor and unplug the internal
power connector (right side only).
6. Once all three fasteners have been removed and the internal power
connector has been disconnected (right side only) you may remove
the panel from the machine
DRIVE CHAIN
1. Remove the bottom cover.
2. Remove the master link from the drive chain.
3. Remove the drive chain from the sprockets.
4. Reinstall the drive chain, ensuring the master link is properly installed.
5. Check the drive chain tension. There should be a total of 1" to

1-1/2" (2.5 to 4.0 cm) of play, up and down, at the slackest point in the
chain. If the drive chain tension needs adjustment, refer to the “Drive
Hub Assembly” section.
! WARNING
IF THE DRIVE CHAIN IS TOO TIGHT, THE DRIVE TRAIN WILL WEAR
EXCESSIVELY, SHORTENING THE LIFE OF THE DRIVE HUB. IF THE
CHAIN IS TOO LOOSE, THE MACHINE WILL BE NOISY AND WILL
OPERATE AT LESS THAN PEAK EFFICIENCY.
Page 46
6. Lubricate the chain with 30W motor oil and wipe off the excess.
DRIVE HUB ASSEMBLY
2. Remove the step chain retainers.
3. Support the pedal arm. Unhook the pedal arm return spring from the
spring hanger. Lift the step chain up and off the clutch sprocket and
lower the pedal arm to the floor. Repeat on the other side.
4. Remove the snap ring from the left end of the drive shaft (see Figure
9).
! WARNING
TO REDUCE THE RISK OF EYE INJURY, WEAR EYE
PROTECTION WHEN REMOVING SNAP RINGS.
5. Remove the drive chain.
6. Remove the sprocket and the other small parts from the left side of
the hub assembly (see Figure 9).
7. Slide the drive shaft to the right, out of the hub assembly. If you
remove the right-hand clutch sprocket from the drive shaft, do not
confuse it with the left-hand clutch sprocket.
8. Loosen and remove the two remaining bolts and nuts that hold the
hub assembly to the frame. Remove the hub assembly.
9. Inspect the drive shaft, bushings, thrust washers, and clutch sprock
ets for excessive wear or pitting. Replace any worn components.
Page 47
10. To reinstall the hub assembly, carefully reverse the disassembly
procedures. Be sure that the right- and left-hand clutch sprockets are
positioned correctly; the wide shoulder of the sprocket should be
facing away from the hub on both sides.
11. Chain Tension. The drive shaft is mounted in an eccentric hub (see
Figure 10). Rotate the hub so the marked hole is in the 12 o’clock
position, lining up four holes in the hub with the four holes in the
frame. Use this hub position when reinstalling the drive chain since
the distance between the drive and transmission shafts is at a
minimum. The hub is in the proper position when the drive chain has a
total of 1" to 1-1/2" (2.5 to 4.0 cm) of play at the slackest point. As the
drive chain stretches with use, increase the chain tension (and the
distance between the two shafts) by rotating the hub counterclock
wise. The distance between the two shafts is greatest when the
marked hole in the hub is at the 8 o’clock position.
HANDGRIPS
1. Order the field installable handgrip kit from your local

representative and follow the instructions included with the kit.
HANDLEBAR
1. Unscrew the main cable connector from the receptacle on the

back of the console.
2. Unscrew the four console mounting screws and remove the

console from the machine.
3. Lift the rear tube of the frame. Tip the machine forward so it is
resting on the front portion of the frame.
4. Remove the two bolts that hold the handrail to the frame tube.
Page 48
5. Stand the machine upright and remove the four bolts that secure the
handrail to the mainframe near the console mount.
6. Remove the handrail from the frame.
7. Reverse the removal procedures to reinstall the handrail.
LEVELING ARM
1. Remove the pedal.
3. Remove the snap ring that secures the leveling arm to the leveling
arm shaft.
! WARNING
4. Slide or gently tap the leveling arm off the shaft.
5. Clean the shaft and the pin with a cloth dampened with 30W motor
oil before reassembly. DO NOT SAND THE SHAFT.
6. Reverse the removal procedures to reinstall the leveling arm.
PEDAL
1. Remove the snap ring and flat washer from the leveling arm pin and
the pedal shaft.
! WARNING
Page 49
2. Slide the pedal off the pedal shaft and leveling arm pin.
3. Clean the pedal shaft and leveling arm pin with a dry cloth. Lubricate
the pedal shaft and the pin with a thin coat of multipurpose grease.
4. Reverse the removal procedures to reinstall the pedal.
PEDAL ARM
1. Remove the pedal.
lower the pedal arm to the floor.
5. Remove the master link from the step chain connection point (see
Figure 11).
6. Remove the snap ring from the pedal arm shaft.
! WARNING
7. Slide or gently tap the pedal arm off the mounting shaft.
8. Clean the pedal arm shaft with a cloth dampened with 30W motor oil
before reassembly. DO NOT SAND THE SHAFT.
9. Reverse the removal procedures to reinstall the pedal arm.
Page 50
PEDAL ARM RETURN SPRING
2. Unhook the pedal arm return spring from the spring hanger.
3. Detach the spring from the step chain by removing the master link
(see Figure 11). The spring-chain connector is in good condition if it
has an hour glass shape. Replace a worn spring-chain connector.
4. Check to ensure that the spring pulley turns freely and is not worn
excessively. Refer to the “Spring Pulley” section if you have to replace
the pulley.
5. To reinstall the spring, connect it to the end of the step chain using
the master link.
6. Route the spring under the spring pulley.
7. Hook the end of the pedal arm return spring onto the spring hanger.
! WARNING
DO NOT TWIST THE SPRING DURING INSTALLATION. IT WILL WEAR
EXCESSIVELY AND REDUCE THE LIFE OF THE SPRING.
SPRING PULLEY
2. Unhook the pedal arm return spring from the spring hanger.
3. Remove the snap ring from the pulley shaft.
Page 51
! WARNING
4. Slide the pulley and washer off the shaft.
5. Before reinstalling the pulley, clean the pulley shaft thoroughly with a
clean, dry cloth. Apply a thin coat of multipurpose grease to the pulley
shaft.
6. Slide the pulley and washer onto the shaft. Install the snap ring.
7. Route the spring under the spring pulley.
8. Hook the end of the spring over the spring hanger.
! WARNING
DO NOT TWIST THE SPRING DURING INSTALLATION. IT WILL WEAR
EXCESSIVELY AND REDUCE THE LIFE OF THE SPRING.
9. Reinstall the cover.
STEP CHAIN
lower the pedal arm to the floor.
4. Remove the double-pitch master link and bearing sleeve assembly

from the step chain connection point on the pedal arm (see Figure 9).
Page 52
5. Remove the master link from the spring-chain connection.
6. Reverse the procedures to reinstall the step chain. Lubricate the step
chain before reinstalling the covers.
STEP CHAIN RETAINER
2. Loosen and remove the two step chain retainer bolts. These bolts are
also the top two mounting bolts for the drive hub assembly.
3. Reverse the removal procedures to install. Make sure there is

adequate clearance between the step chain and the retainer.
TRANSMISSON
1. Remove the side covers
2. Remove the Poly-V belt.
3. Remove the drive chain.
4. Remove the two screws located on the transmission bracket.
5. Support the transmisson while removing the four mounting

screws from the back side of the transmisson.
6. Installation is the reverse of removal.
Page 53
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.
! DANGER
IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONNECTOR CAN
RESULT IN THE RISK OF ELECTRIC SHOCK. CHECK WITH A QUALIFIED
ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER
THE MACHINE IS PROPERLY GROUNDED. DO NOT MODIFY THE PLUG PROVIDED
WITH THIS MACHINE. IF IT WILL NOT FIT THE AVAILABLE OUTLET, HAVE A
PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN.
The 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
properly 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.
Figure 5: Grounding System

Page 54
FCC COMPLIANCE
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against harmful interference in a
residential installation. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular
installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off
and on, the user is encouraged to try to correct the interference by one or more
of the following measures:
• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
! WARNING
CHANGES OR MODIFICATIONS TO EQUIPMENT NOT
EXPRESSLY APPROVED BY STAIRMASTER® HEALTH & FITNESS
PRODUCTS, INC. COULD VOID THE USER'S AUTHORITY TO
OPERATE THIS EQUIPMENT.
CANADIAN DOC CLASS B COMPLIANCE
This digital apparatus does not exceed the Class B limits for radio emissions
from digital apparatus set out in the radio interference regulations of the
Canadian Department of Communications.
La présent appareil numérique ne dépasse pas les limites etablies pour les
bruits radioélectriques applicables aux appareils numériques de la Class B
prescrites dans les règlement sur le brouillage radioélectrique édicté par le
Ministère des Communications du Canada.
Page 55
IMPORTANT PHONE NUMBERS
If you need assistance, please have both the serial number of your machine
and the date of purchase available when you contact the appropriate
StairMaster® Health & 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-Mail: intlservice@stairmaster.com
EUROPE: HEADQUARTERS
+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-Mail: stairmaster.de@t-online.de
U.K.: HEADQUARTERS
+44-1908/267-345
FAX: 44-1908/267-346
E-mail: stairmasteruk@msn.com
Page 56
FIGURES
Figure 6: Final Assembly, Left Side
Page 57
FIGURES
Figure 7: Final Assembly, Right Side
Page 58
FIGURES
Figure 8: Belt Tension
Page 59
FIGURES
Figure 9: Drive Hub Assembly
Page 60
FIGURES
Figure 10: Drive Chain Tensioning
Page 61
FIGURES
Figure 11: Left Pedal Arm Assembly
Page 62
FIGURES
Figure 12: Transmission
Page 63

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STAIRMASTER®

• Your name, customer number, shipping address, and telephone number

• Please call our Customer Service Department to receive a Return

* Note: Aerosol products cannot be transported via air.

WHAT IS IN THIS MANUAL?

Throughout this manual, console keypad keystrokes are enclosed in [ ].

WHAT IS THE STAIRMASTER 4000 PT EXERCISE SYSTEM?

The StairMaster 4000 PT exercise system is a vertical climbing machine with

BASIC OPERATING INSTRUCTIONS ................................................................ 6

HEART RATE MONITORING .............................................................................. 9

TELEMETRY HEART RATE .................................. 11

4000 PT® CONSOLE ........................................................................................... 13

MAINTENANCE INSTRUCTIONS .................................................................. 30

CONSOLE DIAGNOSTIC TESTS ...................................................................... 38

PARTS REMOVAL AND REPLACEMENT ....................................................... 44

GROUNDING INSTRUCTIONS ......................................................................... 54

FCC COMPLIANCE ............................................................................................. 55

Canadian Doc Class B Compliance ............................................................. 55

Table 1. Dimensions and Specifications for the

Figure 1: Level Adjusting End Caps ............................................................... 6

WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:

IMPORTANT SAFETY INSTRUCTIONS

The following definitions apply to the words “Danger” and “Warning”

DANGER - Used to call attention to IMMEDIATE hazards which, if not

WARNING - Used to call attention to POTENTIAL hazards that could

READ ALL INSTRUCTIONS BEFORE USING THE MACHINE.

! DANGER To reduce the risk of electrical shock, always unplug

! WARNING To reduce the risk of burns, electric shock, or injury

2. Close supervision is necessary whenever the machine is used by or near

6. Connect the external power supply to a properly grounded AC wall

9. Do not operate where aerosol (spray) products are being used.

10. Always wear insulated gloves when handling batteries.

12. Do not use the machine outdoors.

SAVE THESE INSTRUCTIONS

Table 1. Dimensions and Specifications for the StairMaster®

Power Supply Specifications:

Figure 1: Level Adjusting End Caps

4. Connect the DC cable of the power supply to the power connector

5. To reduce the hazard of electrical shock,place the power supply on

TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO

7. Connect the AC power cord to the AC wall outlet. Refer to the

8. Watch the console. The console should display a software

9. The display “SELECT WORKOUT” tells you the machine is ready to

THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE MACHINE.

1. Obtain a complete physical examination from your medical doctor and

3. The speed and duration of your exercise program should always be

4. Overweight or severely deconditioned individuals should be particu

5. Although all equipment manufactured by StairMaster® Health &

1. Warm up with light calisthenics and easy stretching exercises for at

8. As you become comfortable with exercise motion, press

9. Relax and stand up straight while exercising. Use the

• Telemetry heart rate - after the initial belt signal is detected,

2. There are 4 options to handle heart rate input signals. Only 2 of

“TELEMETRY ONLY“ - locks out contact heart rate signals

The StairMaster® 4000 PT features telemetry (Polar®) heart rate monitoring.

Using the Transmitter Belt

• Move closer to the console.

Figure 2: Transmitter Belt

Maintaining the Transmitter Belt

Workout Statistics Stop Intensity Level