Stairmaster 4000 PT series User manual

STAIRMASTER
4000 PT
OWNER’SMANUAL
®

© 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
P/N 22868-A
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
[phone]
[phone]
Fax [phone]
www.stairmaster.com
Page iii

Page iv
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
andworkmanship.Thiswarrantydoesnotapplytoanydefectcausedbynegligence,
misuse, accident, alteration, improper maintenance, or an “act of God.” This warranty
isnon-transferablefromtheoriginal 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,andtelephone number
• Themodel and serial numberof the inoperable machine
• Thedate(s)of purchase for the inoperable machine(s)
• Your billing address
Thisinformationwillensurethatyouarethe only one ordering parts under your
warrantyprotection.If warranty replacement parts are shippedtoyou,youmaybe
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
machinesthatare more than 45 days old.You will not be responsible
forthereturnshipment of the inoperable parts.
• Someinoperablewarrantypartsmustbe promptly returned to our
CustomerServiceDepartment. Wewillpaytheshippingcost for the
inoperablewarrantyparts.Detailedinstructionsare includedwith
eachwarrantyreplacementpart.
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:Aerosolproducts cannot be transported via air.

Page v
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 vi
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 vii
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
TelemetryHeart Rate Test............................................................................ 41

Page viii
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
CONTENTS

Page ix
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
CONTENTS

Page 1
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.
To reduce the risk of electrical shock, always unplug
the external power supply from the AC wall outlet
before cleaning, maintaining, or repairing.
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.
!
DANGER
!
WARNING
!

Page 2
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 3
INTRODUCTION
Throughout this manual, all references to the left or right side and to
the front or back are made as if you were on the machine, ready to exercise.
For example, the 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 4
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 5
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.
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.
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO
PREVENTSEVERE DAMAGE TO THEMACHINE, USE ONLYTHE POWERSUPPLY
APPROVED FORUSEWITHTHIS EQUIPMENT. INADDITION,
YOURMACHINEMUSTBEPROPERLYGROUNDED.
!WARNING

Page 6
GENERAL GUIDELINES FOR SAFE OPERATION
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.
BASIC OPERATING INSTRUCTIONS
!WARNING
THESEGUIDELINES ARE DIRECTED TOYOU,ASTHEOWNER OF THE MACHINE.
YOU SHOULDINSISTTHATALLUSERSFOLLOWTHESAMEGUIDELINES.
YOUSHOULDMAKETHISMANUALAVAILABLETOALLUSERS.

Page 7
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.
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
BASIC OPERATING INSTRUCTIONS
!WARNING
IFATANYTIMEDURING YOURWORKOUTYOUFEELCHESTPAIN,
EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF
BREATH, STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU
SHOULDCONSULTYOURMEDICALDOCTORIMMEDIATELY.

Page 8
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.
BASIC OPERATING INSTRUCTIONS

Page 9
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.
HEART RATE MONITORING

Page 10
“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.
HEART RATE MONITORING

Page 11
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
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.
TELEMETRY HEART RATE
PACEMAKER USERS SHOULD NOT USE THE POLAR
TRANSMITTER BEFORE CONSULTING THEIR DOCTOR.
!WARNING

Page 12
•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
TELEMETRY HEART RATE