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1. 19 20 3 1 2 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 ELECTRICAL TROUBLESHOOTING e Place a short wire with alligator clips on the terminal and the field FLD terminal of the alternator Step on the machine for approximately 10 to 15 seconds e 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 14 Remove the brown wire and diode from the field terminal of the alternator and set your voltmeter to the Ohms setting 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 16 Remove one wire fr
2. 57 2 22 2 xz 9220 92412 7 Xt 99192 2 T6012 Aand bunds 1 66014 xz Puuds uolssiusued 88100 2 7 Wg 0g Ja depe bue 212 77 da 1a depe reapueH 66102 XZ dag 2 Ageuia 26112 1939 soinglsisig 33n10v3i ONIN v Wiad 335 Iespueg FIGURES CONSOLE MANUFACTURER DISTRIBUTOR DECAL HANDGRIP 20213 2x 2 5 i 8 S amp B 2 s E 5 8 Bo xx 2 9 b 5 8 d E 2 lt s E E E 5 8 4 5 a gt 5 S 8 E 2 2E Main cable Page 58 FIGURES Figure 8 Belt Tension nator E 59 FIGURES Figure 9 Drive Hub Assembly papojdyg yeys aruq 46102 X8 Jaysey 181141 Aquiessy qn 96102 X v 1511 2301 19120105 SAU el QU 90202 deus 60 FIGURES gre VES A LC N A12 o clock E xS AN g Pd P ina fs Page 61 FIGURES Figure 11 Left Pedal Arm Assembly master link w sleeve Thrust washer 2X21366 40 Master link 20157 20199 Pedal D
3. Unhook the pedal arm return spring from the spring hanger 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 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 To reinstall the spring connect it to the end of the step chain using the master link Route the spring under the spring pulley Hook the end of the pedal arm return spring onto the spring hanger DO NOT TWIST THE SPRING DURING INSTALLATION IT WILL WEAR EXCESSIVELY AND REDUCE THE LIFE OF THE SPRING 8 Reinstall the covers SPRING PULLEY 1 2 3 Remove the bottom cover Unhook the pedal arm return spring from the spring hanger Remove the snap ring from the pulley shaft Page 51 Slide the pulley and washer off the shaft 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 Slide the pulley and washer onto the shaft Install the snap ring Route the spring under the spring pulley Hook the end of the spring over the spring hanger Reinstall the cover STEP CHAIN 1 Remove the side covers 2 Remove the step chain retainers 3 Support the pedal arm Unhook the pedal arm return spring
4. Do not use abrasives or chemicals such as steel wool or alcohol for cleaning as they can damage the electrodes permanently You can order replacement belts from StairM aster Polar Electro Inc or your local fitness store StairM aster 800 331 3578 P N 64000 Polar Electro Inc 800 227 1314 Page 12 4000 PT CONSOLE The StairM aster 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 CALORIES Numeric Keypad Entertainmentr Keypad Workout Statistics sto Intensity Level Figure 3 4000 PT Console DISPLAY WINDOW EC 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 M ANUAL 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 prof
5. It should provide an audible sound and there should be a simulated EKG in the display If either indication is not present turn off the power and then restore it To remove power you can use the switch on the power supply disconnect the power supply from the AC outlet or press the power supply RESET switch and hold it for at least one second If the sound and or the display are still not present see the Troubleshooting Guide starting on page 30 12 When the console displays a simulated EKG your StairMaster 4000 PT Exercise System is fully operational The specifications for a fully assembled StairMaster 4000 PT Exercise System are listed in Table 1 The power supply provides 9 to 15 VDC at 2 5 amps to power the console The low voltage eliminates the danger of electrical shock as long as the power supply is located away from the machine and is not exposed to perspiration You should not place your power supply unit on a carpet because the power supply may overheat Custom length DC cables brackets for multiple power supplies and other accessories are available TABLE 1 SPECIFICATIONS Physical Length 40 5 inches 103 Width 32 inches 81 3 Height 58 5 inches 148 6 cm Weight 150 pounds 68 kg Power Supply Characteristics Output Voltage with load console connected 9 to 15 VDC Output Voltage no load 14 to 17 VDC Output Current Capacity 2 5 amps Input Power Consumption 55 watts HOW THE STAIRMASTE
6. SRE MECHANICAL TROUBLESHOOTING 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 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 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 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 Check the drive hub assembly e Check the condition of the drive sprocket teeth The teeth should not be unevenly worn Replace the worn sprocket s e 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 e Remove the drive shaft Inspect the bearings in the drive
7. 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 M ANUAL to start the M ANUAL exercise program WHAT IS THE STAIRM ASTER 4000 PT EXERCISE SYSTEM The StairM aster 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 StairM aster 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 BASIC OPERATING INSTRUCTIONS General Guidelines for Safe Operation our First Workout Begin Exercising EART RATE MONITORING Hear
8. plotted against the work rate If the heart rate at the end of the 3 and 4 minute are not within 5 beats min then the work rate is maintained for one more additional minute If the heart rate at the end of the 4 and 5 minutes are within 5 beats min then the heart rate at the end of the 57 minute is plotted against the work rate If the heart rate at the end of the 4 and 57 minutes are not within 5 beats min then the test failed Once 2 consecutive heart rate measurements are obtained in the 110 to 150 beats min range then the test ends successfully and the results are displayed The estimated maximum aerobic capacity is shown in ml kg min and METs Next the results are compared 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 Page 22 4000 CONSOLE Figure 4 StairMaster Fitness Protocol First Work Level 4 METs If HR 100 If 100 lt HR lt 120 If HR 120 v v v Second Work Level Second Work Level Second Work Level 7 METs 6 METs 5 METs Y EL v Third Work Level Third Work Level 9 METs 8 METs Quia i If HRs 115 gt inserts Rr ot v v Fourth Work Level Fourth Work Level 11 METs 10 METs Test fails if 2 stages of at least 115 bpm are not obtained Test Comple
9. test the diode on the alternator See the wiring diagrams in the Appendix pages 45 and 46 a Disconnect the ground terminal side of the diode Disconnect only the diode and not the black wire If the speed control returns to normal the diode is defective b If you have a multimeter place the dial on the proper setting Use the resistance setting R x 1 if you are using an analog meter or diode check gt if you are using a digital meter Disconnect the brown wire and diode from the field terminal of the alternator Connect the negative lead to the end of the diode with the white band and the positive or COM lead to the other end of the diode forward bias The meter should give a low reading Then reverse the leads reverse bias The meter should give a high reading High or low readings in both directions means the diode is defective 4 LOAD RESISTOR TEST a See Figure 2 page 20 for location of the resistor b Disconnect one lead from the resistor to the alternator c Set your multimeter for R x 1 or the lowest available resistance range Touch the two leads together and adjust the meter for a zero reading d Measure the resistance of the load resistor a good resistor will measure approximately 0 70 26 TROUBLESHOOTING THE POWER TRAIN Washer Thrust B Bearing Thrust If you are experiencing a grinding noise in your StairMaster 4000 PT 5 Mu Sprocket Exercise System or if the pedal steps are n
10. 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 CONSOLE DIAGNOSTIC TESTS 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 Press LEVEL 6 2 The console will display SERIAL TESTS Press ENTER to access the C S A F E test Press ENTER a second time The console will run a diagnostic test and then display either PASS or FAIL Replace the console if it fails this test Alternator Test Use this test to verify the alternator field routines of the console You will need to briefly exercise on the machine for this test 1 2 Press LEVEL 6 3 to start the test For Field on press LEVEL Step on the machine for approximately 10 to 15 seconds If full resistance is achieved during this time your console has correct current flow If no resistance is achieved either the console or the alternator is bad See the electrical troubleshooting portion of this manual to isol
11. ETs The intensity of the remaining stages is based on the heart rate response to the warmup The test is designed to raise the steady Page 21 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 VO The test typically lasts from 9 to 15 minutes In the StairM aster protocol each work rate is performed for 3 minutes with heart rates recorded during the final 4 seconds of the 2 and 3 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 VO can then be calculated At the end of the 3 minute of each stage if the heart rates at the end of the 2 and 3 minute are not within 5 beats min of each other then that Work rate is maintained for an additional minute At the end of the 4 minute the heart rate is compared to the heart rate at the end of the 3 minute If the heart rates are within 5 beats min then the heart rate during the 4 minute is
12. and or other countries All other trademarks are trademarks of their respective companies StairM aster is a Rutledge Capital Company Page iii WARRANTY This is to certify that the StairM aster 4000 PT exercise system is warranted by StairM aster Health amp Fitness Products Inc to be free of all defects in materials and workmanship This warranty does not apply to any defect caused by negligence misuse accident alteration improper maintenance or an act of God This warranty is non transferable from the original owner If within three years from the date of purchase any part of the StairM aster 4000 PT exercise system should fail to operate properly except any accessories contact our Customer Service Department to report the problem W hen calling please be prepared to provide the customer service representative with the following information Your name customer number shipping address and telephone number model and serial number of the inoperable machine e 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 RM A prior t
13. been entered We recommend that individual users other than the owner or operator be permitted to know the codes to access the customized programs but not to know how to further modify the programs this will prevent the users from tampering with these programs TO CUSTOM PROGRAM A WORKOUT The computer must be in the Attract mode Press 1650 followed by ENTER ENTER PROGRAM will appear on the display Enter the number of the program you wish to modify For a machine with the Rev 1 5 2 1 or 2 2 console the program numbers are 0 through 9 For a machine with any lower Rev level console the program numbers are 1 through 10 and you must press ENTER after you have selected the number If you select a number that has previously been programmed the program will appear and can be modified or completely rewritten If the number you entered has not previously been programmed when you press ENTER you will see a solid row of dots representing the lowest intensity level for all intervals The flashing dot or column indicates which interval can now be modified Use the SPEED UP and SLOW DOWN arrows to make the column taller or shorter use ENTER to move one column to the right and CLEAR to move one column to the left When all of the columns are correctly programmed press START to save the program ENTER TIME will appear on the display Enter the desired time between 1 to 45 minutes Note that unlike standard programs customized programs allo
14. chest strap or heart rate receiver Verify that the console software has been set up to receive telemetry see the heart rate monitoring section of this manual Note that holding the contact heart rate sensors if enabled can inhibit the telemetry heart rate input from working Test your chest strap with a machine that you know is working or With a heart rate watch that you know is working If possible replace or exchange your console with a machine that you know is working and retest the machine Excess false heart rate detection the telemetry receiver located in the console is susceptible to mechanical vibration as well as external electrical interference Hitting the console or the frame may momen tarily cause errant heart beat detection this is normal If excessive false heart beats appear only during workouts check that the console cable is not curled up behind the console Pull as much of the cable down and away from the console as possible False heart beats while the machine is idle are most likely due to external interference Try plugging the machine into a different outlet or moving it to a new location Page 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
15. efficient operation of your 4000 PT exercise system only use genuine StairMaster accessories and replacement parts StairMaster SPORTS MEDICAL PRODUCTS INC 12421 Willows Road N E Suite 100 Kirkland Washington 98034 Phone 800 635 2936 FAX 206 823 9490 StairMaster 4000 PT U S PATENT NO 4 708 338 EXERCISE SYSTEM Owner s Instruction Manual including Instructions for Users Console Serial Number Rev Frame Serial Number Power Supply Serial Number Date of Purchase 1992 StairMaster Sports Medical Products Inc Kirkland Washington U S A Introduction What is in this Manual What is the StairMaster 4000 PT Exercise System How to Install the StairMaster 4000 PT Exercise System How the StairMaster 4000 PT Exercise System Works Guidelines for Safe Operation i Important Safety Instructions How to Exercise on the StairMaster 4000 PT Exercise System How to Use the Computer Console The Operational Modes Changing the Length of Your Workout Customizing Your Exercise Program The Scrolling Message Option The Jackpot Option Changing the Sound Volume Clearing the Computer Memory Maintenance Helpful Hints Maintenance Records Initial Service Cleaning and Inspecting Lubrication Troubleshooting Guidelines Troubleshooting the Console Troubleshooting the Electrical System Troubleshooting the Power Train Parts Removal and Replacement Tools Needed to Work
16. expenditure 6 Relax as much as possible while climbing Stand up straight and let your arms hang naturally if possible After learning to climb comfortably you can experiment with the steps by adjusting your step height from short fast steps to long deep steps Also you may want to try different rhythms such as jogging at higher speeds You may take a free style approach to exercising as long as you adhere to the basic rules The 4000 PT Exercise System does not permit you to cheat Either you stay up with the speed of the program you selected or you will sink toward the floor You can stop once and rest for up to two minutes at any time during the workout but the program terminates if you rest more than two minutes or if you stop a second time If the program terminates and you wish to continue exercising you must start anew program To rest simply stop climbing and both pedal steps will sink to the floor To start after a rest period simply raise either foot and start to climb again Monitor the interval timer to be forewarned of upcoming sudden speed changes in the program you are following Changes are shown by a taller or shorter column of lights for the next interval To dismount stand still and allow the pedal steps to settle to the floor Lift one foot slowly until the step arm contacts the upper stop Place that foot on the floor Repeat for the other foot Do not let the pedal steps slam into the stop since t
17. from the spring hanger Lift the step chain up and off the clutch sprocket and 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 PAIS REM OVAL AND REPLACEMENT 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 1 Remove the side covers 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 M ake sure there is adequate clearance between the step chain and the retainer TRANSMISSON 1 Remove the side covers 2 Remove the Poly V belt Bi 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 groun
18. 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 Say PARTS REMOVAL AND REPLACEME ALTERNATOR 1 Remove the side panels 2 M ark 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 THE BELTS M UST BE PROPERLY TENSIONED BELT THAT IS TOO TIGHT WILL CAUSE SLOW AND SLUGGISH OPERATION A BELT THAT 15 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 an
19. 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 Do you have chest pain brought on by physical activity Have you developed chest pain within the past month Do you tend to lose consciousness or fall over as a result of dizziness Do you have a bone or joint problem that could be aggravated by the proposed physical activity 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 W The StairMaster Submaximal Fit Test The StairM aster branching protocol is a series of 3 minute stages of continuous exercise at increasing intensity The first stage is a warmup at approximately 4 M
20. 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 Press U 9 1 ENTER on the console keypad M ake sure to press in the middle of each key and be aware that the corre sponding numbers will not show in the console display 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 Press U 9 2 ENTER on the console keypad M ake sure to press in the middle of each key and be aware that the corre sponding numbers will not show in the console display The console will prompt you to BEGIN FIT TEST The test can be stopped at any time by pressing STOP Page 25 4000 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 cod
21. less than 115 many external factors e g talking laughing apprehension etc can greatly influence heart rate Once the heart rate reaches a level between 115 and Page 19 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 M aximal 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 M aximal heart rate can however vary greatly among different individuals of the same age One standard deviation is 12 bpm which means that two thirds of the population varies an average of plus or minus 12 heart beats from the average given by a prediction equation If an individual s age predicted maximal heart rate is higher than that person s true maximal heart rate then his her estimated VO will be an overestimation of the correct or actual value 2 max The final assumption addresses the issue of mechanical efficiency Oxygen uptake at any
22. not be allowed to contact the floor except at the beginning or the end of the workout or during a rest period Climb fast enough to stay in the middle of the range of motion for the pedal steps Step heights can range from 2 to 14 inches If you are sinking toward the bottom increase your climbing speed to get the height of your step back into the mid range area 2 The pedal steps should not be allowed to contact the upper stop since this will cause your foot to lift off the pedal step resulting 10 11 in a jerky and uncomfortable motion while you exercise Slow your step rate to operate the pedal steps near the center of their range 3 Never lean on the console or the rails Leaning on the console can damage the machine and result in possible user injury The handrails are intended to stabilize users not to support them Individuals who are exercising on the StairMaster 4000 PT Exercise System for the first time should be particularly aware of these procedures because they often have a tendency to support their weight on the handrails instead of keeping up with the machine 4 Do not pull on the handrails Pulling on the handrails will increase the amount of work you do resulting in a calorie count lower than the actual work performed and can cause premature wear of the components 5 Do not push on the handrails Pushing on the handrails will cause the calorie count to indicate higher than the actual level of calorie
23. position REPLACING THE HANDRAIL Remove the console from the frame Handle it with care Liftthe back leg of the machine far enough to have access to the bolts that attach the handrail to the back leg Support the back leg during this procedure Use a 7 16 socket wrench with an extension to remove the bolts that hold the handrail to the rear legs These bolts are accessed through holes in the bottom of the rear leg Remove the four 4 4 saddle bolts just beneath the console area Remove the handrail from the frame Reverse the procedure to replace the handrail REPLACING THE HANDGRIPS Two lengths of handgrips are available for the StairMaster 4000 PT Exercise System If you have the shorter 9 2 long handgrips you can replace them with the following instructions However if you have the longer handgrips they can be replaced only by factory authorized service technician 1 2 Remove the console from the frame Handle it with care Lift the back leg of the machine far enough to have access to the bolts that attach the handrail to the back leg Support the back leg during this procedure Use a 16 socket wrench with an extension to remove the bolts that hold the handrail to the rear legs These bolts are accessed through holes in the bottom of the rear leg MO N 10 11 12 Loosen do not remove the four saddle bolts just beneath the console area This will
24. power supply then wait 5 to 10 seconds and plug it in again Interval Timer interruption reads 19 but machine does Electronic Try console an another 4000 PT Exercise System Replace a defective not function Console console defective Loose Perform Alternator Tests page 26 connections on alternator Altemator Replace alternator defective Power supply power supply on another 4000 PT Exercise System Replace if defective defective Diode Perform Diode Test page 26 defective Will not Incompatible Replace with compatible console Rev or set console to proper control speed console Rev revision level Revision Level Test page 24 and 25 Incomplete Use a multimeter Check for continuity from alternator field terminal circuit to console connector pin 2 30 Problem Possible Remedy Cause Will not Defective Perform Diode Test page 26 control speed diode continued Defective Perform Load Resistor Test page 26 load resistor Machine runs Incompatible Replace with compatible console Rev or set console to proper slow all the console Rev Revision level see Revision Level Test page 24 and 25 time Timing belt Adjust timing belt tension page 35 too tight Poor ground Tighten ground connection at alternator see wiring diagrams connection in Appendix Open circuit Perform Electrical Circuit Test page 25 Defective Try console on another 4000 PT Exercise System Replace defective console console D
25. surface with mounting holes on surface tilt transmission toward opening and oil should run out before output side is raised 1 inch from surface Defective Perform Diode Test page 26 diode Machine rocks Floor not Move machine to a level floor location on floor level Pedal loose or Missing Replace washer slipping washer Loose pedal Tighten pedal bolt bolt Defective Replace pedal pedal 32 PARTS REMOVAL AND REPLACEMENT TOOLS NEEDED TO WORK ON THE 4000 PT EXERCISE SYSTEM Problem Possible Remedy Cause Pedal arm Defective Replace sprocket on drive shaft slipping and clutch or catching sprocket on drive shaft 1 Clicking noise Frozen link Clean and relubricate chain Replace chain if necessary 2 on one side on drive or step chain 3 4 Spring breaks Spring See Preventive Maintenance Guide page 23 5 frequently pulley not 6 roiating 7 Twisted Untwist spring 8 spring 9 10 11 12 13 14 1 2 3 4 33 Flat blade screwdriver Phillips screwdriver 7 16 open end wrench open end wrench he open end wrench 3 4 open end wrench Adjustable wrench Combination pliers Snap ring pliers Vise grips Wire stripper crimper tool Allen wrench set sizes 5 64 to 1 4 Socket set or nut driver set with the following sizes 3 4 16 10 he 3 3 5hg Ya Volt Ohm meter REMOVING THE SIDE PANELS Disconnect the electrical power from the power supply by removing t
26. 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 e Telemetry heart rate after the initial belt signal is detected the console will enter a validation phase in which four good heart beat signals within four seconds are required before locking on telemetry heart rate signals for the duration of the Workout session During the validation phase the console will not recognize contact heart rate signals Locked Non locked Option When the not locked option is selected the heart rate source signal is not fixed during the exercise if the signal is lost either input will be valid If the locked option is selected then the heart rate source si
27. we recommend that you do not share this information on how to change the length of the workout time Depending upon the situation such information could easily be abused Unless changes are otherwise needed we recommend that all programs remain 15 minutes in length WORKOUT TIME INTERVAL TIME MINUTES SECONDS 5 10 10 20 15 30 20 40 25 50 30 60 35 70 40 80 45 90 If you decide to change the time setting for a workout follow these steps 1 The computer must be in the Attract mode 2 Press 1010 followed by ENTER 3 Enter the desired time in minutes followed by ENTER 4 The computer then returns to the Attract mode The next time you exercise the interval time will reflect the revised time to perform a workout This time setting feature does not affect the length of any customized programs previously entered If you have the Revision 1 5 2 1 or 2 2 software you can lock in a maximum workout time When the computer asks the user for the time of his her workout the user will be able to select any time that is equal to or less than the locked in time If the user requests a time that exceeds the locked in time the computer will request the time again Once you lock in a time the time can not be changed by anyone except a StairMaster authorized service technician To lock in a time for Revision 2 1 software follow these steps 1 The computer must be in the Attract mode 2 Press 1010 followed by ENTER
28. 1 Table 1 Dimensions and Specifications for the StairM aster 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 J apan 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 M achines 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 M ake sure the machine is level before you use it for the first time Rotate cap to adjust Level Adjusting End Cap 24329 Frame m d 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 botto
29. 3 Enter the desired time in minutes followed by ENTER 4 The computer will return to the Attract mode 5 Press 97405 followed by ENTER 6 The computer will now be locked to the time you entered in step 3 The procedure for time locking Revision 1 5 and 2 2 software differs slightly from Revision 2 1 The 107 enter 4 code will display the Revision level of your console 1 The computer must be in the Attract mode 2 Press 1010 followed by ENTER 3 Enter the desired time in minutes followed by ENTER 4 The computer will return to the Attract mode 5 Press 97405 followed by ENTER 6 The computer will display the time you entered in step 3 7 If the time displayed is the time you want press any key except ENTER and begin at step 1 again 8 If the time displayed is the time you want press ENTER 9 The computer will now be locked to the time you entered in step 3 We suggest that you lock in the time you want when you receive the 4000 PT Exercise System CUSTOMIZING YOUR EXERCISE PROGRAM The StairMaster 4000 PT Exercise System offers you the capability of inputting user designed workouts that can be retained in the computer s memory After entering the code to access customized programs the computer will prompt for a program number There is room for ten customized programs This section of the manual presents instructions on both how to input custom designed programs and how to use these programs once they have
30. DING PIN A ADAPTER NS 9 c A FOR GROUNDING SCREW METAL SCREW Figure 5 Grounding Instructions 43 APPENDIX Wiring Diagram Motorola Prestolite Alternator Wiring Diagram Bosch Alternator To Order Parts and Obtain Troubleshooting Help United States Sales Offices List of Codes 44 LOAD RESISTOR 10393 Wiring Diagram StairMaster 4000 PT Exercise System with Motorola Prestolite Alternator 45 LOAD RESISTOR 10391 10393 Wiring Diagram StairMaster 4000 PT Exercise System with Bosch Alternator 46 40 41 105 109 1010 1650 2121 2123 3121 4101 7607 7703 8089 9750 9751 9760 9761 97405 Speed up 15 107 107 107 107 107 ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER 1 ENTER 2 ENTER 3 ENTER 4 ENTER 5 LIST OF CODES Turn on teletype sound for scrolling messages only Turn off teletype sound for scrolling messages only Clear the entire memory scrolling messages and custom workouts Display summary for partial workouts Rev 1 2 1 3 1 5 2 1 and 2 2 only Change a workout length Program a custom workout Turn off EKG symbol and turns on scrolling message display is blank if no scrolling message has been programmed Turn off scrolling message and turns on EKG symbol Display current odds for jackpot option Ru
31. E DIRECTED TO YOU AS THE OWNER OF THE M ACHINE YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAM E GUIDELINES YOU SHOULD M AKE THIS M ANUALAVAILABLE TO ALL USERS 1 Obtain a complete physical examination from your medical doctor and enlist a health fitness professional s aid in developing an exercise program suitable for your current health status 2 When working out for the first time use the MANUAL 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 StairM aster Health amp 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 M aintenance is the sole responsibility of the owner Page 6 59 i BASIC OPERATING INSTRUCTIONS YOUR FIRST WORKOUT ON THE STAIRM ASTER FREECLIM BER EXERCISE SYSTEM 1 Warm up with light ca
32. E 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 MAINTENANCE INSTRUCTIONS Table 3 Recommended Preventive Maintenance Schedule PART Console Covers RECOMENDED ACTION Wipe Clean Daily Water Clean and Inspect FREQUENCY CLEANER Diluted household cleaner LUBRICANT N A N A Drive and Step Chains Step Chain Connection Points Spring Pulley Shafts Pedal Shafts and Leveling Arm Pins Pedal Arm Springs Pedal Arm Shafts Battery Lubricate Clean and lubricate Clean and lubricate Clean and lubricate Clean and lubricate Inspect and wipe down Clean and lubricate Check Voltage Inspect amp Adjust Tension Every 3 months or after 900 hours Every 3 months or after 900 hours Every 3 months or after 900 hours Each week or 70 hours Every 3 months or after 900 hours Every 3 months or after 900 hours Every 3 months or after 900 hours N A Mild degreaser Clean dry rag Clean dry rag Clean dry rag Clean dry r
33. Eg ze af 5 cota Com 3 28 eo ESS Q B o SET 1 0 o EG 2 St 4 Pl 2 So lt 9 afg g gt os SQ N ex AWN m 28 po 5 5 gt 62 Left 10993 03 Right 10992 03 FIGURES Lu m lt 2 lt e 2 T 2 ee cc Page 63
34. 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 7096 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 e 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 MODE DISABLED No heart rate signal is allowed due to the set up option that was chosen Heart rate monitoring is not possible I Page 18 4000 CONSOLE THE FITNESS TEST PROGRAMS Understanding Submaximal Exercise Testing Before using the StairM aster 4000 for submaximal exercise testing it should be noted that all submaximal fitness tests make several assumptions e That a steady state heart rate is obtained for each exercise workload e That a linear relationship exists between heart rate oxygen upt
35. OWNER S MANUAL StairMaster 4000 P EXERCISE SYSTEM Ce WARRANTY INFORMATION This is to certify that the StairMaster 4000 PT Exercise System is warranted by StairMaster Sports Medical 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 or improper maintenance This warranty is non transferable from the original owner If within one year from date of purchase the StairMaster 4000 PT Exercise System should prove defective contact our customer service headquarters and report the defective part be prepared to tell us your date of purchase and the frame serial number A purchase receipt or other proof of the date of the original purchase will be required before any warranty parts are sent We will send you a replacement part and you will send us the defective part Upon receipt of the defective part we will inspect it and determine the cause of the defect Shipping charges are paid by the customer after 45 days We neither assume nor authorize any representative or other person to assume for us any other warranties in connection with the sale 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 To maintain product warranties and to assure the safe and
36. R 4000 PT EXERCISE SYSTEM WORKS The StairMaster 4000 PT Exercise System operates on the basis of kinetic energy The work performed by the user kinetic energy drives an alternator that generates the physical resistance against step movement No motors are involved The power supplied to the unit is necessary only for the electronic console When you exercise your body weight provides the kinetic energy needed to control speed and overcome resistance This is achieved by a chain drive system that sums the vertical motion of the steps into a continuous rotary motion The rotary motion drives a gearbox that drives an alternator at a sufficient RPM to provide a smooth reliable means of exercise control The computer in the console measures the AC frequency which is dependent on RPM from the alternator The computer electronics convert the AC frequency into the equivalent vertical climbing rate at which the user would be climbing if his her steps were eight inches per step The computer also compares the user s step rate to the programmed rate during the active interval and generates an appropriate field current for the alternator This small field current determines the amount of physical resistance provided by the alternator and this is the resistance that is fed back through the chain linkage to the pedal steps The alternator circuits include a DC output that needs an external load for normal operation In this machine a large resistor is co
37. Remove the snap ring from the left end of the drive shaft see Figure 9 JN WARNING TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING 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 11 12 PARTS REMOVAL AND REPLACEM EN 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 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
38. SOLE 2 Change the units to either or USA units by pressing LEVEL 3 1 ENTER The console will display the current units either USA UNITS or M ETRIC UNITS Use the SELECT key to change option and then press ENTER 3 Choose the desired heart rate input preference by pressing LEVEL 7 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 v 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 7 3 ENTER The console will then display CUSTOMIZE
39. Scroll through the following options SELECT MAX TIME SELECT CHANGE UNITS SELECT INPUTS SELECT LANGUAGE gt Fr Page 27 4000 PT CONSOLE SELECT CONTRAST SELECT MAX SPEED N A SELECT CLINICAL M ODE N A SELECT SET DEFAULTS Machine Status Codes 1410 display machine run time in hours 1 4 1 display number of workouts 4 2 display distance traveled 1 4 3 display software rev 4 4 display machine type 114115 N A 114116 display machine run time in hours since last cleared used for maintenance l 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 M AINT HOURS XXXX Page 28 4000 CONSOLE Quick Scan Programming You can quickly acces
40. The black wire is connected to the alternator ground The voltage at these connections should be 14 to 17 volts DC e Disconnect the 6 pin connector on the grey cable from the console You should have between 14 and 17 volts DC between pins 4 and 5 4 is positive 5 is negative f Inspect the power connector and grey cable wires to locate and eliminate any pinching or crimping of the wires 25 2 ALTERNATOR TESTS Two alternator tests are also available that can be performed without using a voltmeter If either test fails this indicates either a broken circuit broken wire loose connection or badly _ crimped wire or a bad alternator ALTERNATOR CIRCUIT TEST 1 a Press 107 followed by ENTER and 1 b Press down on either pedal The lower left LED should light in the panel indicating a good circuit If the LED fails to light the circuit is defective Check for a loose connection of the blue wire at the alternator c Press START to clear the test ALTERNATOR CIRCUIT TEST 2 a Press 107 followed by ENTER and 2 b Press down on either pedal and then press the SPEED UP arrow You should get full resistance and the lower left LED should light again If this does not happen there is a break in the circuit Check for a loose connection of the brown wire at the alternator Press the SLOW DOWN arrow The LED should turn off and there should be no resistance 3 DIODE TEST If you have problems with fluctuating speed control
41. VED 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 IF THE DRIVE CHAIN IS TOO TIGHT THE DRIVE TRAIN WILL WEAR EXCESSIVELY SHORTENING THE LIFE OF THE DRIVE IF THE CHAIN IS TOO LOOSE THE MACHINE WILL BE NOISY AND WILL OPERATE AT LESS THAN PEAK EFFICIEN CY Page 46 ven REM OVAL AND REPLACEM ENT 6 Lubricate the chain with 30W motor oil and wipe off the excess 1 Reinstall the covers DRIVE HUB ASSEMBLY 1 Remove the side covers 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
42. ach code has two digits The computer will automatically accept and display the character after the second digit is pressed Pressing ENTER after each number code is not necessary If you make a mistake press CLEAR to remove the last digit pressed If you want to remove more characters from the display in reverse order simply continue to press CLEAR It is not necessary to leave a space at the beginning or the end of your message because the computer will do this automatically Your message may contain up to 128 characters including spaces TABLE 2 CHARACTER CODES FOR SCROLLING MESSAGES TT 771 50 63 Space 76 22 51 54 0 00 23 C 52 P 65 1 01 24 D 53 Q 66 2 02 25 54 67 3 03 7 26 55 68 4 04 27 G 56 T 69 5 05 28 57 U 70 6 06 29 Iz 58 71 7 07 30 J 59 W 72 8 08 31 K 60 X 73 9 09 32 L 61 74 20 62 Z 75 21 TO PROGRAM THE SCROLLING MESSAGE The computer must be in the Attract mode Press 7607 followed by ENTER You should verify each character of your message it appears on the display as you enter it Sample message EXERCISE BE FUN Press 7607 followed by ENTER then press the following numbers 54 73 54 67 52 58 68 54 76 52 50 63 76 51 54 76 55 70 63 ENTER When your message is complete press ENTER Your message will now
43. afts 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 StairM aster Health amp Fitness Products Inc Lubricate the drive chain and the step chains weekly Try to penetrate the entire length of the chains with 30W motor oil 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 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 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 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 TO REDUCE THE POSSIBILITY OF SLIPPING BE SURE THE PEDAL AREA 5 FREE OF GREASE OR OIL WIPE ANY EXCESS OIL OFF THE MACHIN
44. ag 30W motor oil 30W motor oil Multi purpose grease Multi purpose grease Multi purpose grease Clean oil dampened rag 30W motor oil 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 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 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 r
45. ake and workload That the maximal heart rate for a given age is uniform e That the mechanical efficiency of the physical activity performed i e oxygen uptake at a given workload is the same for everyone It should be kept in mind that any one or all of the above mentioned assumptions may not be met during a submaximal exercise test If for any reason one of the assumptions is not met then errors in predicting 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
46. al Shafts Timing Belt Hub Assembly amp Thrust Washers Clean amp Lubricate Clean amp Lubricate Clean amp Lubricate Remove Clean amp Relubricate Remove Clean amp Relubricate Clean amp Relubricate Clean Only Clean Only Clean Only Clean Only Inspect and Adjust Lubricate 23 TROUBLESHOOTING GUIDELINES The three primary components of the StairMaster 4000 PT Exercise System that may require troubleshooting are the console the electrical system and the power train Several tests and guidelines that you can use are presented below Also see the Troubleshooting Table page 30 to help identify causes and remedies for various possible trouble symptoms TROUBLESHOOTING THE CONSOLE NOTE Perform all tests while the computer console is in the Attract Mode 1 THE DISPLAY TEST If you have blank spots on your console display perform the display test This checks for bad LEDs If any LED will not light replace the console b d Press the SPEED UP arrow then press 15 and ENTER All LEDs in all 30 columns should be lit and the Interval Timer should read 88 The test will time out on its own or if you wish you can press the SLOW DOWN atrow to turn out the LEDs and the Interval Timer Press the SPEED UP arrow to light the LEDs and the Interval Timer again Press ENTER to terminate the display check 2 THE KEYPAD TEST Perform this test if you are unable to enter data i
47. all controls to the off position then remove plug from outlet SAVE THESE INSTRUCTIONS HOW TO EXERCISE ON THE STAIRMASTER 4000 PT EXERCISE SYSTEM WARNING IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL PAIN OR FEEL FAINT OR ARE SHORT OF BREATH STOP EXERCISING IMMEDIATELY Before exercising on the StairMaster 4000 PT Exercise System you should verify that power is available to the machine by observing the display area on the computer console it should have either a simulated EKG or a scrolling message Having confirmed that the power is on you are now ready to exercise Follow the steps in this list to ensure that you achieve maximum results from your workout 1 2 Warm up by doing light calisthenics and stretching for at least five minutes prior to exercising Grasp the handrails and step up onto the pedals Stand erect The pedals will sink slowly and settle to the bottom The message ENTER WEIGHT with an arrow pointing to the numeric key pad will appear Enter your weight in pounds or if you have a Metric Console in kilograms on the key pad and press the ENTER key after you have verified that the numbers which are displayed are correct Entry errors may be erased by simply pressing the CLEAR key Next the screen will display the message SELECT PROGRAM with an arrow pointing to the top three rows of the key pad Select your program Ifyou are working out for the first time w
48. apped and are either boxed or attached to the pedals of the machine 1 Remove and discard the cardboard protector attached to the frame 2 Remove and discard the box that protects the power supply and the DC cable 3 Disconnect the grey cable and remove the two knobs below the electronic console that hold it to the handrail Remove and discard the ziplock bag 4 Mount the electronic console back onto the handrail and attach the grey cable end to the connector on the bottom of the console 5 Place the StairMaster 4000 PT Exercise System at its intended location this must be near a source of AC power 6 Connect the DC power cable from the power connector near the bottom of the right side panel to the DC output connector on the power supply 7 Plug the AC power cord into the power supply until you feel it snap into place 8 Place the power supply on a floor surface near the AC outlet that you will use StairMaster recommends that you place a mat under your 4000 PT Exercise System and place the power supply on the mat 9 Check to be sure that the input AC power rating marked on the power supply matches the available power If it does not obtain the matching power supply from StairMaster before proceeding any further WARNING USE ONLY THE PROPER POWER SUPPLY ANY OTHER CAN CAUSE SEVERE DAMAGE AND CREATE A POSSIBLE FIRE HAZARD 10 Connect the power supply to the AC outlet 11 Observe the electronic console
49. ase zerk at the 7 00 o clock position See the drawings page 28 Figure 3 Drive Hub Assembly Lubricate the new hub See Lubrication on page 22 REPLACING THE GREY CABLE 1 Remove the right side panel Note and mark by color the location of each wire attached to the alternator Detach wires from alternator Unscrew wire nuts or detach the connector to disconnect the black and white wires Disconnect the grey cable from the console Tie alength of string about five feet long to the wires at the lower end of the grey cable Pull the grey cable up out of the center frame Be careful to retain the rubber grommets Do not pull it far enough to lose the string through the lower holes Tie the wire ends of the new cable to the top of the string Feed the new cable down into the center frame pulling it down with the string When the wire ends reach the lower hole pull them out through the hole and seat the rubber grommets in the holes in the frame to prevent damage to the cable Crimp a lug onto each bared wire end and attach wires to the proper alternator terminals Attach the wires to the alternator case or adjusting bracket with a wire tie to prevent them from damage by moving parts Reconnect the black and white wires from the power connector on the right side panel with the wire nuts or connectors Attach the connector at the upper end of the grey cable to the console and take a test run If the machine o
50. ate and test the alternator Replace the console if the alternator is good For Field off press LEVEL V Step on the machine for approximately 10 to 15 seconds You should not get resistance with the field turned off Press CLEAR to end the test Page 39 CONSOLE DIAGNOSTIC TESTS Tach Test If you do not have resistance perform the tach test The tach test will tell you the tach signal in revolutions per minute RPM s picked up by the console 1 Press LEVEL 6 J 6 ENTER The console will display TAR TACH ACT The target tach speed of 2 000 RPM s will be shown in the upper left corner of the display window The actual tach picked up by the console will be shown in the upper right corner of the display window 2 Start stepping on the pedals The number in the right hand corner of the console should increase to 2 000 RPM s 4 200 If the tach signal picked up by the console is less then 1 900 RPM s then there is a problem in the AC tach circuit either with the console software alternator check the AC tach wire the field wire the diode and the terminal posts or the main cable Error Reporting The console will display various error messages in the display window The total amount of errors will be displayed in the upper right numeric window Note that only the highest priority reported error will be displayed Errors are handled in two ways One as a non fatal WARNING which will display the
51. 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 J N WARNING TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS Page 49 PARTS REM OVAL AND REPLACE 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 2 Remove the side covers 3 Remove the step chain retainers 4 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 5 Remove the master link from the step chain connection point see Figure 11 6 Remove the snap ring from the pedal arm shaft J N WARNING TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS 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 1 2 PARTS REM OVAL AND REPLACEM ENT PEDAL ARM RETURN SPRING Remove the bottom cover
52. begin scrolling The machine will have returned to the Attract mode TO EDIT THE SCROLLING MESSAGE If you have the 1 5 2 1 or 2 2 version you can edit an existing message Press 7607 and ENTER to bring the message onto the screen Then use SPEED UP and SLOW DOWN arrows to scroll through the message The CLEAR key deletes the right most character on the screen new character is inserted in the right most position Enter 99 to erase all of the previous message to the right of the current display TO ACHIEVE OPTIONAL CONTROL OF THE SCROLLING MESSAGE Press 40 followed by ENTER This will turn on the teletype sound Press 41 followed by ENTER This will turn off the teletype sound Press 2123 and ENTER This turns your scrolling message off but retains the message in the computer s memory The simulated EKG will then be displayed Press 2121 and ENTER This turns your scrolling message on again To erase the entire message on revisions prior to and including 1 3 press 7607 ENTER ENTER The console display will be blank Press 2123 and ENTER to turn the EKG symbol on again To erase the message on 1 5 2 1 and 2 2 versions press 7607 press 99 to erase the message to the right of the display and then continue to press the CLEAR key to delete each remaining character in the message Press ENTER The console display will be blank Press 2123 and ENTER to turn the EKG symbol on again THE JACKPOT OPTION When you finish your workout a G
53. d 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 M ake 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 L 2i Disconnect the power supply from the right side panel Use a phillips screwdriver to remove the lower fastener by turning it counter clockwise one quarter of a full turn The fastener will remain attached to the panel when the screw driver is removed Page 45 i05 PARTS REM OVAL AND REPLACEM ENT 4 Support the panel while removing the two top fasteners the same way the single lower fastener was removed TO REDUCE THE RISK OF INJ URY DO NOT OPERATE THE M ACHINE WHILE THE COVERS ARE REM O
54. ded in accordance with all local codes and ordinances IM PROPER CONNECTION OF THE EQUIPM ENT GROUNDIN G CONNECTOR CAN RESULT IN THE RISK OF ELECTRIC SHOCK CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE M ACHINE IS PROPERLY GROUNDED DO NOT M ODIFY THE PLUG PROVIDED WITH THIS M ACHINE IF IT WILL NOT FIT THE AVAILABLE OUTLET HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN The grounding plug on the power supply and the battery charger is shown in sketch A below A temporary adapter shown in sketches B and C may be used to connect the plug to a two pole receptacle if a properly grounded outlet is not available The adapter should be used only until a 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 _ grounded 2 prong outlet box outlet box Adapter N ri MXN D Brounded KAA 7477 N e 1 11y 2 c n Tab for grounding screw A Grounding pin Metal screw Figure 5 Grounding System Page 54 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
55. e 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 TELEM ETRY HEART RATE TELEM ETRY HEART RATE The StairM aster 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 J N 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 c
56. e both step return springs from their hangers and carefully lower both steps to the floor Lift the step chains up and remove them from the sprockets Locate and remove the master link for the drive chain and remove the drive chain Remove the snap ring from the left end of the drive shaft See Figure 3 page 28 and remove the parts to the left of the hub assembly Slide the drive shaft to the right out of the hub assembly If you remove the right hand drive sprocket from the drive shaft do not permit it to become confused with the left hand drive sprocket Use Ae wrench to remove the four inch bolts that hold the hub assembly to the frame Remove the hub assembly Install the new hub carefully reversing the disassembly procedure Be sure that the right hand sprocket and the left hand sprocket are positioned correctly with the sprockets toward the hub on both sides If the hub has eight 8 holes instead of four 4 it is possible to reposition the hub to accommodate a slightly different length chain Placing the grease zerk on the hub at the 11 30 o clock position will provide the shortest distance between the center of the hub assembly and the transmission shaft With every hole position counter clockwise the distance will be increased by approximately 30 thousandths of an inch 030 The longest distance between the hub assembly and the transmission may be obtained by positioning the 36 gre
57. e current interval After completing an entire workout you should have developed a feel for your abilities on the StairMaster 4000 PT Exercise System 6 If you selected any of the eight workout programs other than Manual at the upper right of the console the computer will next display the message ENTER LEVEL Enter the Intensity Level 1 for easiest to 10 for most difficult at which you will work out and press ENTER 1 If you have a Rev 2 1 or 2 2 console the machine will ask you for the time of your workout in minutes press 15 and ENTER to select a 15 minute workout with 30 seconds for each interval For any other revision level the computer will use the workout time that has already been entered and each segment will have a duration of of the total time See page 12 to change the time of your workout 2 The display alternates between Start Exercise the total time for the workout and the workout contour this is your instruction to start to exercise If you do not start to exercise within 30 seconds the console will return to the Attract mode 3 As soon as you start to climb the column of lights for the first interval will flash The Interval Timer at the top of the console counts down in seconds When it is near zero a signal sounds to alert the user that the next interval is about to start When climbing adhere closely to the following proper climbing techniques 1 The pedal steps should
58. e pedal arm 1f the bearings are difficult to remove use WD40 to loosen the rust and corrosion and a hammer and punch to remove the bearings Install the new bearings Place one bearing on each side of the pedal arm and use a construction style C clamp to press the bearings Be sure the C clamp covers the outer race of the bearing to prevent bearing damage See Figure 4 on page 29 REPLACING THE TRANSMISSION ASSEMBLY Remove both side panels Locate and remove master link from drive chain closed loop chain on right side Remove the drive chain Loosen the bolt that holds the alternator to the support brace Remove the alternator timing belt Detach the altemator support brace from the transmission by removing the two mounting bolts from the forward face of the transmission 39 Remove the four 1e bolts that secure the transmission to the frame Remove the transmission Attach the new transmission to the frame with the four bolts Do not tighten to more than 14 inch pounds Attach the support brace to the new transmission with two mounting bolts Install the timing belt around the transmission and alternator pulleys Loosen the set screw on the transmission pulley and align it with the alternator pulley Position the alternator so that the timing belt has inch of deflection from the center line at the center between the pulleys Tighten the bolt to hold the alternator in the proper
59. e recommend that you select MANUAL CONTROL in order to familiarize yourself with the machine The computer will automatically select the slowest speed for the first interval and you can then change intensity levels during operation 1 When you press MANUAL CONTROL and you have Rev 2 1 or 2 2 console the machine will ask you for the time of your workout in minutes press 15 and ENTER to select a 15 minute workout with 30 seconds for each interval For any other revision level the computer will use the workout time that has already been entered and each segment will have a duration of of the total time See page 12 for instructions to change to total workout time 2 The display will alternate between Start Exercise and the total for the workout this is your instruction to start exercising If you do not exercise within 30 seconds the console will return to the Attract mode 3 When you begin to exercise the console will display a flashing light at the lowest level in the first interval You are stepping at a pace of 26 eight inch steps per minute As you become comfortable you should try using the SPEED UP and SLOW DOWN arrows to adjust your speed Except for Rev 2 1 and 22 Manual Control is the only program which allows speed changes with the arrow keys The flashing column shows which interval is active Everything to the left indicates completed intervals The interval timer shows how many seconds remain in th
60. edal arm from the pedal arm shaft and inspecting the shaft and bushing for wear and corrosion Replace the bushing if it is worn Clean any corrosion off the shaft and bushing before reassembling Check the step chain by flexing each link Clean and lubricate the chain Figure 3 Drive Hub Assembly 27 28 STAMOS Snap Ring s Flat Washer Pedal L H RH Bolt Shoulder Modified Assy Leveling Arm Spring Chain Connector Pedal Return Spring Master Link 40 Chain Step Pedai Arm Sleeve Bearing Insert Link Master Double Pitch Bearing 4 Steel Pedal Arm Bushing Leveling Arm Bushing Pedal Shaft h Nut Wave Washer AO VOSS A Figure 4 Pedal Arm and Attachments 29 TABLE 4 TROUBLESHOOTING CHART Problem Possible Remedy Cause No display or EKG off Press 2123 and ENTER to tum on EKG sound on power up Power not Connect power supply to known good AC power outlet with available proper rating Circuit Press red reset button on power supply to illuminate red LED or breaker reset rocker switch type circuit breaker tripped Bad power Try power supply on another 4000 PT Exercise System Replace supply defective power supply Electrical See the Electrical Circuit Test page 25 and check for bad electrical wires connections disconnected or open Defective Try console on another 4000 PT Exercise System Replace console if Console defective Some dots lit AC power Unplug
61. efective Replace defective alternator alternator Defective Perform Power Train Test page 27 Hub Assembly Defective Perform Load Resistor Test page 26 Load Resistor Machine starts Defective Try console in another 4000 PT Exercise System Replace defective exercise but console console will not continue Open circuit Perform Electrical Circuit Test page 25 Defective Perform Diode Test page 26 diode Defective Replace defective alternator altemator Defective Try power supply on another 4000 PT Exercise System Replace Power defective power supply Supply 31 Problem Possible Remedy Cause Step does not Retum Replace broken spring return to top spring broken Step binding Clean pedal arm bushing and shaft If pedal arm bushing is worn replace bushing and or pedal arm Defective Disassemble drive hub assembly and replace defective parts drive hub see page 28 assembly Machine Need for See Lubrication section page 22 develops lubrication squeaks Machine noise Power train Perform Power Train Test page 27 excessive problem especially at high speeds Belt tension Belt too loose page 35 Machine Incompatible Replace with compatible console Rev Revision Level Test operates console Rev page 24 sluggishly Timing belt Adjust timing belt page 35 too tight Remove transmission To check fluid level remove 2 16 hex head Transmission screw from input shaft side place transmission on flat
62. ernator Note the brand name of the alternator and check the wiring against the appropriate wiring diagram in the Appendix 41 NOTICE OF EMI COMPLIANCE This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense THIS DIGITAL APPARATUS DOES NOT EXCEED THE CLASS A LIMITS FOR RADIO EMISSIONS FROM DIGITAL APPARATUS SET OUT IN THE RADIO INTERFERENCE REGULATIONS OF THE CANADIAN DEPARTMENT OF COMMUNICATIONS LE PRESENT APPAROIL NUM RIQUE N MNT PAS DE BRUITS RADIO LECTRIQUES D PASSANT LES LIMITES APPLICABLES AUX APPAROILS NUM RIQUES DE LE CLASSE PRESCRITES DANS LE REGLEMENT SUR LE BROUILLAGE RADIOELECTRIQUE EDICTE PAR LE MINISTERE DES COMMUNICATIONS DU CANADA GROUNDING INSTRUCTIONS The 4000 PT exercise system must be grounded If it should malfunction or breakdown grounding provides a path of least resistance for electric current to reduce the r
63. es 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 e Pressing LEVEL A 1 ENTER displays what group of codes is being accessed e Pressing SELECT or LEVEL A at that point allows you to view all possible selections Once in this mode pressing LEVEL v backs up through the selections pressing ENTER then selects that item If another test level is available at this point the SELECT ENTER process is repeated Pressing A 15 or 2 ENTER selects that item directly e 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 M PH or KMH 1 3 2 choose type of heart rate input and priority telemetry or contact 3 3 N A 31 4 choose console language 3 5 change contrast on console 3 6 N A 1 3 7 3 8 1 3 9 reset to factory defaults 1 Change the workout time by pressing LEVEL 3 0 The console will display MAX TIM E 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 TIM E LIMIT OFF Page 26 4000 CON
64. etest 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 ELECTRICAL TROUBLESHOOTING 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
65. ge 14 The exercise intensity level may be changed at any time during a workout Pressing the v key decreases the intensity and pressing the key increases the intensity 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 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 t
66. 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 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 Page 20 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 VO prediction 2 max Pretest Screening Prior to any exercise test maximal or submaximal participants should complete a brief health medical questionnaire have their resting blood pressure and heart rate measured and provide an
67. gnal 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 Onthe console keypad press LEVEL U 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 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 TELEM ETRY 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 tim
68. he power connector that is plugged into the lower face of the right side panel Check to see how the panel is mounted There are two mounted connections at the top and another at the bottom of each panel These may be screws or captive nuts and must be removed or they may be snap fasteners that can be pulled loose When you remove the right side panel lay it on the floor next to the machine Be careful to prevent damage to the wires from the power connector mounted on the panel to connections at the alternator NOTE If the power wiring includes a disconnect separate the connectors to completely remove the side panel from the machine Reverse the procedure for reassembly 34 REPLACING THE TIMING BELT CAUTION The timing belt must be adjusted so that the center of either side can be deflected 4 from its center line A tighter belt will cause slow and sluggish operation a looser belt will cause excessive noise and belt wear Use wrench to loosen the adjustment bolt that mounts the alternator to the slotted alternator brace Remove the timing belt Install the new belt Move the alternator down or up as necessary to allow 4 of play at the center of the vertical portion of either side of the belt 5 Tighten the alternator to the brace 4 99 REPLACING THE STEP RETURN SPRING 1 Remove the side panel Detach the return spring from the spring hanger on the center wall in the machine a
69. he relative energy cost of exercise M ET 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 M ETs requires ten times the resting rate of oxygen consumption or about 35 milliliters per kilogram per minute During a workout this key shows the current M ET level During the workout summary the average 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 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 Ibs Intensity Level 3 Workout Time The default time in the programmed workouts and Quick Start is 20 minutes The M anual and Constant Heart Rate program
70. his may cause unnecessary wear and tear 12 When you have completed the last interval of the exercise bout the console will display a summary of your workout Then step off the machine and cool down by walking or stretching for five minutes before showering HOW TO USE THE COMPUTER CONSOLE The purpose of the computer console is to provide an automated workout and a friendly method for obtaining necessary data and displaying workout results Before your initial workout on the StairMaster 4000 PT Exercise System it is valuable for you to become familiar with the computer console and its operation The console has three areas that provide the user with an interface to the System the keypad which allows data entry and program selection the display area which provides information to the user either by charting workout progress or by providing written questions and statements the interval timer which displays the time remaining in the current exercise interval KEYPAD MTERA TIME EQUI 8 INCH STEPS PER MINUTE 129 DISPLAY 46000009 600006006 mE CAUTION STOP EXERCISE 5 1 H k 1 1 bee IP YOU FEEL PAIN FAINT i ARM e 2 opta OR SHORT BREATH INTERVAL rd Figure 1 The StairMaster 4000 PT Console 10 THE OPERATIONAL MODES 1 THE ATTRACT MODE The Att
71. icate the drive hub assembly see Figure 3 page 28 every three months or more frequently if necessary 1f your hub has a Zerk fitting add two or three squirts of heavy multi purpose grease through the fitting If your hub does not have this fitting it is necessary to disassemble the hub to repack it with the grease see Replacing the Drive Hub Assembly page 36 for the procedure Coat the thrust bearing in the drive hub assembly with a heavy multi purpose grease Do not lubricate the clutches in the sprockets 22 WARNING Be sure the step area is free of grease or oil and wipe any excess off machine surfaces WARNING Never lubricate the bushings for the step arm L in figure 2 or for the leveling arm Z in figure 2 These are permanently lubricated and may fail if you add lubricants 7 If you suspect that any of the permanently lubricated bushings has lost its oil impregnation heat the bearing with a lighter or other similar heat source Droplets of oil should appear on the bushing surface to show that it still has lubricant If no oil appears on the heated surface you may apply some light mineral oil to restore lubricant to the bushing TABLE 3 RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE Weekly or 70 hours of use 3 Months or 900 hours of use Step Chain Drive Chain Step Chain Connection Points Pedal Arm Shafts Leveling Arm Attachment Bolts Spring Pulley Shafts Ped
72. ile 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 S CN 2 2 K D H H Volume Channel NS 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 The 4000 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 FE or compatible system If a system is not connected pressing these keys will have no effect Volume Up Down Increases or decreases the volume level of the audio Source Mute Removes the audio sound from the headphones Channel Up Down Changes the channel of the commercial entertainment system INTENSITY LEVEL KEYS LEVEL OO STOP KEY Pa
73. isk of electric shock This machine is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician or serviceman if you are in doubt as to whether the machine is properly grounded Do not modify the plug provided with the machine If it will not fit the outlet have a proper outlet installed by a qualified electrician The 4000 PT exercise system is for use on a nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated in sketch A in Figure 5 page 43 A temporary adapter that looks like the adapter illustrated in sketches B and C also in Figure 5 may be used to connect this plug to a 2 pole receptacle as shown in sketch B if a properly grounded outlet is not available The temporary adapter should be used only until a properly grounded outlet sketch A can be installed by a qualified electrician The green colored rigid ear lug or the like extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box cover Whenever the adapter is used it must be held in place by a metal screw 42 NDED OUTLET BOX GROUNDED GROU OUTLET GROUNDED OUTLET BOX GROUN
74. listed below 1 Unplug the machine and remove the bottom side covers TO REDUCE THE RISK OF INJ URY DO NOT OPERATE THE M ACHINE WHILE THE COVERS ARE REM OVED DO NOT DEPRESS OR RAISE THE PEDALS W HILE ANYONE S HANDS ARE INSIDE THE M ACHINE 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 f the alternator does spin freely check the alternator for noise roughness or the presence of an excessive amount of black pow der 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
75. listhenics and easy stretching exercises for at least five minutes before beginning your exercise program IF AT ANY TIM E DURING YOUR W ORKOUT YOU FEEL CHEST PAIN EXPERIENCE SEVERE M USCULAR DISCOM FORT FEEL FAINT OR ARE SHORT OF BREATH STOP EXERCISING IM M EDIATELY IF THE CONDITION PERSISTS YOU SHOULD CONSULT YOUR M EDICAL DOCTOR IM M EDIATELY 2 Hold onto the handlebars and step up onto the pedals Stand up straight The pedals will sink slowly toward the floor 3 Select the M ANUAL exercise program so you can control the pace of your first workout and get used to the exercise motion Press M ANUAL and then press ENTER The console will return to the start screen if you do not press ENTER within 60 seconds 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 EN TER 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
76. ll require minor assembly Refer to the Installation Instructions section for details PREVENTIVE MAINTENANCE M ost 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 MAINTENANCE INSTRUCTIONS 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 sh
77. lowing are some guidelines regarding proper lubrication procedures bo GS 4 A 6 For a chain lubricant use 30W motor oil or a lower unit gear lube for outboard motors that is made to operate a salt water environment If you use any oil place a protective mat on the floor during the oiling process you may wish to purchase a protective floor mat from StairMaster To clean the components listed below use a mild degreaser to remove dirt and corrosion Read the instructions on the degreaser container before using some degreasers are harsh and can damage painted surfaces Clean and lubricate the step chains W in Figure 2 once a week Remove the chains to thoroughly clean and re lubricate every three months This schedule will minimize deterioration of the chain that may be caused by perspiration Clean and lubricate the drive chain D in Figure 2 once a week Remove the chain to thoroughly clean and relubricate every three months Remove side panels for access Clean and lubricate both step chain connection points FF in Figure 2 every three months or if a squeak develops in this area See Replacing the Bearings in the step chain connection for the procedure to access the bearings It is not necessary to remove the bearings to relubricate them Lubricate the connection point bushings with a liberal amount of a multi purpose grease Then re attach the step chains in the reverse order Lubr
78. m of the right side cover 5 To reduce the hazard of electrical shock place the power supply 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 StairM aster Health amp Fitness Products Inc before proceeding any further TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO PREVENT SEVERE DAM AGE TO THE M ACHINE USE ONLY THE POW ER SUPPLY APPROVED FOR USE WITH THIS EQUIPM ENT IN ADDITION YOUR M ACHINE M UST BE PROPERLY GROUN DED 1 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 W ORKOUT 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 ves BASIC OPERATING INSTRUCTIONS GENERAL GUIDELINES FOR SAFE OPERATION THESE GUIDELINES AR
79. mized workouts that can be created and stored in the computer All of the workout programs on the StairMaster 4000 PT exercise system feature computer controlled speeds from 26 steps minute to 138 steps minute based on 8 inch steps The faster the speed the greater the intensity level at which you are working At the conclusion of your completed workout the computer console displays the number of calories you burned while exercising the equivalent number of floors you climbed and the equivalent number of miles that you covered If your machine has Revision 2 1 or 2 2 software you can request this information and also request elapsed time KGMs and watts at any time during your workout and then return to the standard workout display The 4000 PT exercise system strengthens and conditions the heart and the following lower body muscle groups Erectus Spinae Group Gluteus Medius Gluteus Maximus Tensor Fascia Latae Iliopsoas Hip Abductors Hip Adductors Quadricep Group Hamstring Group Gastrocneumius and Soleus HOW TO INSTALL THE STAIRMASTER 4000 PT EXERCISE SYSTEM Before leaving the factory your StairMaster 4000 PT Exercise System was thoroughly inspected and tested for proper operation To minimize shipping damage careful attention was given to making your machine ready for shipment Each computer console is packed with an anti static ziplock bag to protect the console during shipping The power supply unit and DC cable are shrink wr
80. n a custom workout Program a scrolling message Display number of hours and floors Rev 2 1 and 2 2 only Program odds for jackpot option Change console to Rev E Rev 1 5 2 1 and 2 2 only Change console to Rev D Rev 1 5 2 1 and 2 2 only Change console to English system Rev 1 5 2 1 and 2 2 only Change console to Metric system Rev 1 5 2 1 and 2 2 only Lock in a workout length Rev 1 5 2 1 and 2 2 only Display Test Alternator Circuit Test 1 Alternator Circuit Test 2 Keypad Test Revision Level test Variables test display whether the console is time locked the units of measure English or metric and the alternator version Rev 1 5 and 2 2 only 49 tairMaster SPORTS MEDICAL PRODUCTS INC 12421 Willows Road N E Suite 100 jm Kirkland Washington 98034 800 635 2936 FAX 206 823 9490 STAIRMASTER 4000 PT OWNER S MANUAL StairMaster THE RESULTS YOU WANT StairMaster Printed in the United States 2001 StairM aster Health amp Fitness Products Inc All rights reserved Corporate Headquarters 12421 Willows Road N E Suite 100 Kirkland WA 98034 800 635 2936 425 823 1825 Fax 425 823 9490 www stairmaster com P N 22868 A 2001 StairM aster Health amp Fitness Products Inc StairM aster and FreeClimber are registered trademarks or trademarks of StairM aster Health amp Fitness Products Inc in the United States
81. nd lower the pedal arm to the floor Liftthe step chain up off the sprocket 4 Detach the spring from the step chain at the connecting point by removing the master link Do not lose the retaining clip that holds the link parts together 5 Check to ensure that spring pulley turns freely If not remove pulley clean the shaft and replace the pulley 6 Connect the new spring to the end of the chain 7 Pass the step chain over the sprocket and the spring under the spring pulley Reconnect the end of the spring to the spring hanger CAUTION Do not introduce a twist in the spring or it will wear excessively and break during use 8 Reattach the side panel 35 CA amp DO eM REPLACING THE DRIVE CHAIN Remove the right side panel Remove the master link from the chain Remove the chain from the sprockets Install new chain using reverse procedure If you have problems installing the chain check the size of the links they should be 41A 61 pitch and the chain length it should be 30 without the master link Additionally if the hub has eight 8 holes instead of four 4 it is possible to reposition the hub to accommodate a slightly different length chain See section below Replacing the Drive Hub Assembly for instructions Lubricate the new chain See Lubrication on page 22 REPLACING THE DRIVE HUB ASSEMBLY Remove both side panels Remov
82. nnected as the DC load and converts the output current to heat which is easily dissipated GUIDELINES FOR SAFE OPERATION Your StairMaster 4000 PT Exercise System is a carefully engineered tool that will provide a physical workout program tailored to your particular require ments We hope that you will use it wisely and obtain all of the benefits it can offer you To maximize the results you can achieve and minimize the possibility of injury always adhere closely to the following guidelines If you compromise any of these guidelines you compromise the effectiveness of the exercise experience expose yourself and possibly others to injury and reduce the longevity of your StairMaster 4000 PT Exercise System Suggestion These guidelines are directed to you as the owner of the machine You should insist on instructing all users so that they will follow the same guidelines 1 Obtain a complete physical examination from your medical doctor and enlist health fitness professional s aid in developing an exercise program suitable for your current health status When working out for the first time exercise at the lower speeds until you feel comfortable and capable of faster speeds 3 Speed and duration of exercise should always be subject to how a person feels Apparent heart rate or any other external influence should never override your judgment when exercising t3 4 Overweight people working out for the first time should
83. nt to use the best available exercise method to develop a high level of physical fitness In order to attain the most from your StairMaster 4000 PT Exercise System read this manual thoroughly and adhere closely to the instructions WHAT IS IN THIS MANUAL Following the installation information and a brief explanation of how the 4000 PT exercise system works this manual contains two major sections The first How to Use the StairMaster 4000 PT exercise system provides an explanation of how the machine should be used to achieve maximum results The second How to Maintain the StairMaster 4000 PT exercise system includes instructions and advice on how to property maintain your machine There is also a special Appendix section which offers additional information for the owner WHATIS THE STAIRMASTER 4000 PT EXERCISE SYSTEM The StairMaster 4000 PT exercise system is a vertical climbing machine which provides an aerobic workout equivalent to climbing stairs without the inertial loads and skeletal trauma common to most aerobic activities The 4000 PT exercise system is computer controlled to offer automated timed workouts from 5 to 45 minutes as selected by the user There is a choice of eight preprogrammed workouts each with ten levels of intensity In addition there is also a non programmed manual workout which allows you to pace yourself or experiment with the various speeds Also users have the option of designing up to ten custo
84. nto the console If the keypad does not operate properly replace the console 8 b Press 107 followed by ENTER and 3 Press the console keys If a light a LED in the console display blinks each time a key is pressed the keypad is good If there is no blink the keypad is defective 1 Start at upper left corner of the keypad and press the first preprogrammed selection key A light should go out while the key is pressed and then turn on again when the key is released 2 Repeat step 1 for each of the seven remaining preprogrammed selection keys and the MANUAL CONTROL key 3 Repeat step 1 for each of the number keys 0 through 9 4 Repeat step 1 for the SPEED UP and SLOW DOWN arrow keys Press START to clear the test 3 THE REVISION LEVEL TEST If you want to test the compatibility of your console with one on another machine perform this revision level test a Press 107 followed by ENTER and 4 24 The screen will display which revision identifies your console Rev D Rev E Rev M Rev 1 1 Rev 1 2 1 3 1 5 Rev 2 1 2 2 The Rev D console is not compatible with any of the later revisions because this 4000 PT Exercise System will have a Motorcraft alternator while all of the later revisions have either a Motorola Prestolite or a Bosch alternator Rev E Rev M Rev 1 1 Rev 1 2 and Rev 1 3 are directly interchangeable b Press START to clear the test If you have Revision 1 5 2 1 or 2 2 software the c
85. o disconnect the external power supply remove the plug from the AC wall outlet Never drop or insert any object into any opening on the machine Do not operate where aerosol spray products are being used Always wear insulated gloves when handling batteries 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 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
86. o shipment StairM aster Health amp 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 e 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 StairM aster Health amp 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 StairM aster Health amp Fitness Products Inc are used Note Aerosol products cannot be transported via air Page iv PREFACE Regular use of the StairM aster 4000
87. oal Attained message is normally displayed on the computer console This message may be replaced by a Las Vegas style slot machine When the wheels of the slots stop turning the window will spell out either THE END or YOU WIN The odds of winning may be programmed anywhere from 1 in 5 to 1 in 9 999 The computer will then randomly select a winner and display YOU WIN instead of the usual THE END After displaying YOU WIN the computer will wait for the START button to be pressed and then display the current odds This allows the owner to confirm there has been no tampering odds are modified by the computer to allow a lengthy workout to have the same win potential as several short workouts The entered odds are based on the standard 15 minute workout Commercial owners often use the jackpot option to further stimulate consumer interest in their establishment and to add variety to their overall workout program Many such owners offer a prize or some tangible incentive for individuals who win while using the jackpot option If there is only one prize you should remember to disable the option after there is a winner The jackpot option remains in effect until disabled by entering zero odds StairMaster assumes no liability stemming from the use of the jackpot option The use of this option may also be governed by laws or ordinances in your area TO TURN THE JACKPOT OPTION ON OR OFF Program odds of five or more turn the jackpot option on Prog
88. om 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 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 console is used on other StairM aster equipment DIAGNOSTIC CODES 6 0 Test display 6 1 Test keyboard 6 2 Test serial port 6 3 Test alternator 6 4 N A 61 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
89. omputer is compatible with all revisions Use the codes listed below to make the computer compatible with your machine 1 Rev D press 9751 followed by ENTER 2 other revisions press 9750 followed by ENTER TROUBLESHOOTING THE ELECTRICAL SYSTEM 1 ELECTRICAL CIRCUIT TEST If you have problems with the console going blank in the middle of a workout have random dots in the display or the console fails to prompt you to enter your weight you need to test the electrical circuits in a systematic way YOU MUST test the electrical circuits in precisely the same order as listed below in order to identify the problem During these tests when you disconnect a wire and find that the test shows that the circuit is ok reconnect the wire before you proceed This test requires the use of a volt ohm meter a Disconnect the AC power cord from the back of the power supply and measure the AC voltage in the cord should be 105 to 125 volts AC b Disconnect the DC cable from the power supply and check the power supply output good power supply will have an output of 14 to 17 volts DC with no load c Disconnect the DC cable from the power connector Check the DC cable output the same DC voltage should be available at this end of the cable d Check the wiring connections from the power connector assembly to the grey cable The white wire from the power connector is connected to the white wire in the grey cable that leads to the console
90. on the 4000 PT Exercise System Removing the Side Panels Replacing the Timing Belt Replacing the Step Return Spring Replacing the Drive Train Replacing the Drive Hub Assembly Replacing the Grey Cable Replacing a Leveling Arm Replacing a Pedal Step Replacing a Pedal Arm Replacing a Spring Pulley Replacing a Step Chain Replacing the Bearings in the Step Chain Connection Replacing the Transmission Assembly Replacing the Handrail Replacing the Handgrips Replacing the Alternator Grounding Instructions Appendix Wiring Diagram Motorola Prestolite Alternator Wiring Diagram Bosch Alternator To Order Parts and Obtain Troubleshooting Help United States Sales Offices List of Codes LIST OF ILLUSTRATIONS Figure 1 The Console Figure 2 Parts Location Figure 3 Drive Hub Assembly Figure 4 Pedal Arm amp Attachments Figure 5 Grounding Instructions LIST OF TABLES Table 1 Specifications Table 2 Character Codes for Scrolling Messages Table 3 Recommended Preventive Maintenance Schedule Table 4 Troubleshooting Procedures PAGE 15 23 30 33 INTRODUCTION The StairMaster 4000 PT Exercise System is a highly effective tool for developing aerobic fitness Designed for use by individuals of all ages and fitness levels it provides a clinically proven means for achieving aerobic fitness without the impact stress associated with most other forms of aerobic exercise Your purchase is a positive affirmation of your commitme
91. one of the preprogrammed workouts the computer will ask for the length of your workout in minutes before completing the data entry 3 THE EXERCISE MODE The Exercise mode for the program always follows the Data Entry mode The workout begins with a START EXERCISE prompt This prompt will rotate through START EXERCISE length of workout and a graphic display of the workout unless you have selected the Manual Control or a custom workout program Once you start to move the pedal steps the prompt disappears and the workout profile contour is displayed The workout is divided into 30 intervals each lasting 30 seconds assuming a 15 minute workout they always represent soth of the actual total time The flashing column is the current interval and the interval timer shows the number of seconds remaining in that interval The workout level is represented by the height of the column of dots example 5 dots high equals sixty 8 inch steps per minute If you have the Revision 2 1 or 2 2 software you can request summary data at any time during the workout by pressing the key marked with the parameter you wish to check CALORIES MILES FLOORS ELAPSED TIME KGM WATTS Of STEPS PER MINUTE Then you can return to the normal display by pressing DISPLAY 11 4 THE EXERCISE SUMMARY AND GOAL ATTAINED MODE Atthe end of a completed exercise program the Exercise Summary and Goal Attained mode is displayed automatically The Summary displays in sequence
92. onsole 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 TELEM ETRY HEART RATE e Tighten the elastic part of the chest belt Adjust the belt higher or lower on your chest Remoisten the electrodes e Test your chest strap with a machine that you know is working or With a heart rate watch that you know is working 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 e 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 Elastic Strap 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
93. or contact the upper stop When you begin to exercise the M ANUAL Page 7 BASIC OPERATING INSTRUCTIONS program starts at level three 8 As you become comfortable with exercise motion press LEVEL and LEVEL v 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 W hen 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
94. ot functioning properly you probably Drive Sprocket RH have problem in the power train You should attempt to isolate the area in which Drive Shaft the problem is occurring the alternator the transmission the drive hub assembly G SnapRing 1 the drive chain or step chains Perform these tests in precisely the order listed Grease Fitting I Drive Shaft Sprocket below J Drive Plate 1 Check the condition and tension of the alternator belt Replace it if it is worn Adjust the tension so that you can deflect either side of the belt 4 inch at the center between the alternator and transmission pulleys Noise can be generated by a belt that is too tight or too loose 2 Disconnect the alternator belt and work the pedal steps With the alternator belt removed there is normally little pedal resistance If the noise is no longer present replace the alternator 3 Remove the drive chain and then work the pedal steps Again there will be no resistance If the noise disappears the problem is the transmission assembly replace it 4 Tf a grinding noise is still present the problem is in the drive hub assembly a binding in the shaft of one of the pedal steps or in the step chains a Check the drive hub assembly by inspecting the clutches in the drive sprockets and the bearings in the hub see Figure 3 page 28 Inspect the drive shaft for signs of wear or scoring b Check the pedal arm shafts by removing the p
95. ou may have entered into the memory MAINTENANCE HELPFUL HINTS If you keep your StairMaster 4000 PT Exercise System serviced and in good condition it will operate more efficiently and last longer We recommend that you use the following service guidelines Additionally only use genuine StairMaster accessories and replacement parts to maintain product warranties and to assure the safe and efficient operation of your equipment MAINTENANCE RECORDS If you have the Revision 2 1 or 2 2 software the computer will keep track of the following data on machine usage 1 The number of hours the machine is on 2 The number of hours the machine is in use 3 The total number of floors climbed To access the data press 7703 followed by ENTER when the computer is in the Attract mode The computer will display the data in the sequence listed above These numbers can only be reset by the factory Maintenance personnel should find this data helpful in designing preventative maintenance programs INITIAL SERVICE We recommend that you wax your 4000 PT Exercise System as soon as youreceive it Apply a coat of good quality protective car wax to all white powder coated metal surfaces This will protect the finish and simplify cleaning CLEANING AND INSPECTING 1 DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANER ON THE CONSOLE Use only a water dampened cloth when you clean the electronic parts and wipe dry after cleaning 2 Clean
96. perates properly this completes the replacement If necessary check your wiring against the wiring diagrams in the appendix REPLACING A LEVELING ARM Remove the side panel from the same side as the leveling arm to be replaced Remove the step return spring from the spring hanger and lower the pedal arm to the floor Remove the 7 16 shoulder bolt and 2 nut that attach the leveling arm to the pedal step 37 CA CA RR OUO N t RR Remove the snap ring that holds the leveling arm to its mounting post Slide or gently tap the level arm off the mounting post Clean the post and shoulder bolt before reassembly Reverse the procedure to reinstall the leveling arm DO NOT LUBRICATE THE BUSHING REPLACING A PEDAL STEP Remove the leveling arm attachment 2 16 shoulder bolt and 2 nut Remove the step retaining snap ring or bolt and washer Slide pedal step off pedal arm shaft Clean the shaft before reassembly Reverse the procedure to install the pedal step Do not overtighten the bolts REPLACING A PEDAL ARM Remove the side panel from the same side as the pedal arm to be replaced Remove the step return spring from the spring hanger and lower the pedal arm to the floor Remove the 716 shoulder bolt and nut that attach the leveling arm to the pedal step Remove step retaining snap ring or bolt and washer Remove pedal
97. permit you to lift the handrail free from the rear leg Carefully cutoff or slide off if possible the old grips Soak the new grips in hot not boiling water for five minutes Apply soapy solution to handrails and inside the new grips Slide new grips into place and wipe handrails until dry Toensure that the handgrips do not move slide the grips away from their intended location dry the handrail and apply a hairspray and slide the grips back into place Reattach the handrails to the rear leg with the bolts that were removed in step 3 Tighten the four saddle bolts below the console area Mount the console in place and attach the connector from the grey cable to the connector on the bottom of the console REPLACING THE ALTERNATOR Disconnect the DC power cable from the right side cover Remove both right and left side covers Note the origin and color of each wire at the alternator terminals remove the wires Use a 2 socket or wrench to remove alternator adjustment screw Use a 2 4 or adjustable wrench to loosen the self locking nut from the alternator post Allow alternator to pivot downward until timing belt is loose Remove the timing belt Inspect the belt for wear and replace if the belt is cracked worn cut or is missing any timing notches Remove the self locking nut from the alternator mounting post Remove the alternator 9 10 Reverse the procedure to replace the alt
98. pervision is necessary when the 4000 PT exercise system is used by or near children invalids or disabled persons Keep children away from the pedal arm assembly or other similar moving parts Serious injury could result from an infant s or a small child s fascination with the moving components of the exercise machine c Keep your hands away from all moving parts and keep your feet in the center of the pedal steps Do not operate with side panels removed Use the 4000 PT exercise system only for its intended use as described in this manual Do not use attachments not recommended by the manufacturer Never operate the 4000 PT exercise system if it has a damaged cord or plug if the power is not applied if the computer or machine does not appear to be operating properly if it has been dropped or damaged or if the power supply has been dropped into water Call Product Support at 1 800 331 3578 to arrange for damaged parts to be returned to our factory for examination and repair Do not attempt to use the equipment until all faults have been corrected Connect the power supply to a properly grounded outlet only See Grounding Instruction page 42 Keep the power supply cord and DC cable away from heated surfaces Never drop or insert any object into any opening i Do not use outdoors j Do not operate where aerosol spray products are being used or where oxygen is being administered To disconnect turn
99. prescrites dans les r glement sur le brouillage radio lectrique dict par le Minist re 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 StairM aster Health amp Fitness Products Inc office listed below OFFICES IN THE UNITED STATES CORPORATE HEADQUARTERS CUSTOM ER SERVICE 12421 Willows Road NE Suite 100 12421 Willows Road NE Suite 100 Kirkland WA 98034 Kirkland WA 98034 800 635 2936 or 425 823 1825 800 331 3578 FAX 425 823 9490 FAX 425 814 0601 www stairmaster com E mail customerservice stairmaster com INTERNATIONAL OFFICES AND DISTRIBUTORS For technical assistance and a list of distributors in your area please call or fax one of the following numbers INTERNATIONAL DIVISION ASIA PACIFIC HEADQUARTERS 425 823 1825 Telephone Fax 81 45 590 5686 FAX 425 820 7505 E mail stairintl aol com E M ail intlservice stairmaster com EUROPE 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 M ail stairmaster deQ t online de U K HEADQUARTERS 44 1908 267 345 FAX 44 1908 267 346 E mail stairmasteruk msn com Page 56 FIGURES Assembly Left Side ina F Figure 6 68112 xc 8811 viz 2
100. proceed cautiously Even though an overweight individual may not have a history of a serious physical problem the individual may perceive the exercise to be far less intense than it really is resulting in overexertion 5 Although all equipment manufactured by StairMaster Sports Medical Products Inc has been thoroughly inspected prior to shipment proper installation and regular maintenance are required for safety Maintenance is the sole responsibility of the owner 6 StairMaster Sports Medical Products Inc does not recommend user servicing of the electronic components in the console They have been designed to be free of adjustments and do not require any maintenance Opening the console or power supply will void the warranty IMPORTANT SAFETY INSTRUCTIONS When using any electrical equipment basic precautions should always be followed Listed below are several of these safety precautions 1 Read all instructions before using the StairMaster 4000 PT exercise system DANGER To reduce the risk of electric shock a Always unplug the machine from the electrical outlet before cleaning performing maintenance or making repairs WARNING To reduce the risk of burns fire electric shock or injury to persons a The 4000 PT exercise system should always be unplugged from the outlet before putting on or taking off parts Never attempt any adjustments or repairs while an exercise program is in progress b Close su
101. ract mode is the machine s idle time and is characterized in the display area by either the simulated EKG or a scrolling message Pressing the START button from any other mode will return the computer to the Attract mode 2 THE DATA ENTRY MODE In the Data Entry mode the user must furnish information the computer needs to control the speed of the workout and to accurately calculate the physiological and performance feedback This mode is entered only from the Attract mode by pressing START or by stepping on one of the pedal steps The first prompt on the screen is ENTER WEIGHT To respond simply press the appropriate numbers on the keypad and then press ENTER The range for weight is any number from 1 to 999 pounds or for the metric console 1 to 999 kilograms Your weight is used to calculate the number of calories you used while exercising The next prompt is SELECT PROGRAM You have the choice of exercise programs in the top three rows of the keypad see Figure 1 The outlines on the keys correspond to the relative profile of the particular program If you select MANUAL CONTROL or one of the custom programs the computer has completed the data entry If you have selected any of the other eight preprogrammed workouts the console will prompt with ENTER LEVEL and wait for you to enter a difficulty level between 1 and 10 with 1 being the lowest workout intensity If you have the Revision 2 1 or 2 2 software and you have selected MANUAL CONTROL or
102. ram the odds to zero to turn the jackpot option off and to return to having the Goal Attained message appear after you finish your workout TO ENTER ODDS The computer must be in the mode Press 8089 followed by ENTER The prompt ENTER ODDS will appear on the screen Enter the numeric odds you have selected between 5 and 9999 Then press ENTER When the computer has a winner the YOU WIN display will remain active until START is pressed The current odds will display after START is pressed This step gives the owner a chance to verify the win Pressing START a second time will return the computer to the Attract mode OTHER JACKPOT CODES Press 3121 followed by ENTER to display the current odds Press START to return the computer to the Attract mode Press 8089 followed by ENTER and then 0 and ENTER to disable the jackpot option CHANGING THE SOUND VOLUME The sound volume is set at the factory but may be adjusted by the owner To set the volume use a small flat blade screwdriver to adjust the volume control through the hole in the bottom of the console Facing the bottom of the console clockwise rotation increases the volume level while counter clockwise rotation decreases the volume level CLEARING THE COMPUTER MEMORY If you want to clear all data that has been entered into the computer memory press 105 followed by ENTER Be advised that this procedure will also erase any customized programs and scrolling messages y
103. 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 How ever 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 e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help CHANGES OR M ODIFICATIONS TO EQUIPM ENT NOT EXPRESSLY APPROVED BY STAIRM ASTER HEALTH amp FITNESS PRODUCTS INC COULD VOID THE USER S AUTHORITY TO OPERATE THIS EQUIPM ENT CANADIAN DOC CLASS B COMPLIANCE This digital apparatus does not exceed the Class B limits for radio emissions from digital apparatus set out in the radio interference regulations of the Canadian Department of Communications La pr sent appareil num rique ne d passe pas les limites etablies pour les bruits radio lectriques applicables aux appareils num riques de la Class B
104. 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 e phillips screwdriver combination wrenches sizes 7 16 3 4 wonder bar included w unit Combination pliers locking pliers volt ohm meter multimeter wire stripper crimper tool allen wrench set sizes 5 64 1 4 external snap ring pliers Shop goggles or other eye protection torque wrench socket set or nut driver set sizes 1 4 3 4 in 1 16 increments MAINTENANCE RECORDS For ease of maintenance the 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 J 4 ENTER The console will then display M ACHINE STATUS Scroll through the following options SELECT RUN HOURS XXXX 0 SELECT WORKOUTS XXXX 1 SELECT DISTANCE XXXX 2 SELECT CONS 90211 3 SELECT STEPPER 4 SELECT N A SELECT MAINT HOURS 6 The machine may show a few hours of use due to testing at the manufacturing facility Page 30 MAINTENANCE INSTRUCTIONS 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 wi
105. s any of the custom menus by pressing LEVEL 4 ENTER The console will then display MACHINE STATUS Scroll through the following options SELECT RUN HOURS XXXX 0 SELECT WORKOUTS XXXX 1 SELECT DISTANCE XXXX 2 SELECT CONS 90211 3 SELECT STEPPER 4 SELECT N A SELECT MAINT HOURS 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 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 StairM aster exercise systems It is important to verify that the machine configuration code matches the type of machine you have 81 0 Change M achine 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
106. s 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 M ANUAL and CONSTANT HEART RATE program to workout for an unspecified amount of time The Quick Start Program Provides an immediate start without having to enter any user information This program uses the standard default settings for derivation of calories burned The Manual Program After pressing the M ANUAL key enter user and workout information Begin exercising at the selected level If desired adjust the workout manually by using the intensity level arrow keys The profile in the display window is divided into 15 equal intervals within the workout time The profile is based Page 16 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 inten
107. sembly 3 per side Handgrip Handrail Drive Plate Handrail Adapter Step Chain Connection ug goa BB Figure 2 Parts Locations Right side view side panel removed 20 b If you are painting over base metal spray on a metal primer before you use the touch up paint C PAINTING Read and follow all directions on the StairMaster paint spray can failure to do this will result in a poor overall finish Hold the can 7 to 9 inches away from the surface and spray using a steady even back and forth motion Use overlapping strokes to get a complete light uniform coat that looks glossy wet rather than a heavy coat that might run or sag If runs or sags are visible repeat surface preparation as defined above and repeat the paint application When applying more than one coat allow at least 30 minutes drying time per coat 4 FINISH PROTECTION After 30 days of curing time for the new paint apply a thin coat of good quality car wax to prolong the finish and give added protection from perspiration Figure 2 Parts Location Left side view side panel removed 21 LUBRICATION The StairMaster 4000 PT Exercise System has five components that require periodic lubrication The callouts for these parts are circled in Figure 2on pages 20 and 21 Table 3 on page 23 is a recommended lubrication and preventive maintenance schedule that assumes moderate to heavy usage in a commercial club environment Fol
108. sity 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 HHHH H N ng NEM 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 Page 17 4000 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
109. ss of life READ ALL INSTRUCTIONS BEFORE USING THE MACHINE DANGER reduce the risk of electrical shock always unplug the external power supply from the AC wall outlet before cleaning maintaining or repairing WARNING 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 4 10 11 12 SAFETY GUIDELINES Use this machine only for its intended use as described in this M anual Do not use parts attachments or accessories other than those provided by StairM aster Health amp Fitness Products Inc Do not use the external power supply if it has a damaged cord or plug or if it is not working properly if it has been dropped or damaged or dropped into water Contact our Customer Service Department at 1 800 331 3571 to arrange for the return of damaged parts Connect the external power supply to a properly grounded AC wall outlet refer to the Grounding Instructions section Keep all cords away from heated surfaces T
110. step Remove master link from step chain connection bushing Remove snap ring from pedal arm mounting post Slide or gently tap the pedal arm off the mounting post Clean the pedal arm mounting post before reassembly Reverse the procedure to reinstall the pedal arm DO NOT LUBRICATE THE BUSHING REPLACING A SPRING PULLEY Remove the side panel 2 Detach the pedal return spring from the hanger Lower the pedal arm to the floor Remove the nut or snap ring that holds the pulley on the shaft Pull the pulley off 38 Cn Clean the pulley shaft DO NOT LUBRICATE Slide the new pulley onto the shaft Fasten the pulley on the shaft with the nut or snap ring Do not overtighten or the pulley will not turn freely REPLACING STEP CHAIN Remove the side panel Detach the pedal return spring from its hanger and lower the pedal arm to the floor Remove master link between the spring and the step chain Retain the sleeve for reassembly Remove the master link step chain connection at the pedal arm Reverse the procedure to install the new step chain Lubricate the step chain See Lubrication on page 22 REPLACING BEARINGS IN THE STEP CHAIN CONNECTION US Remove the side panel Remove the step return spring from the spring hanger and lower the pedal arm to the floor Remove the master link from the step chain connection Remove the bearings from th
111. t Rate Input Locked Non locked Option ELEM ETRY HEART RATE 4400 4600 PT CL ONLY Using the Transmitter Belt Exercise Program Keypad The Quick Start Program The M anual Program he Fat Burner Program he Aerobic Training Program he Speed Intervals Program he Constant Heart Rate Program he Fitness Test Programs nderstanding Submaximal Exercise Testing Pretest Screening Page vi urning on the Test urning on the NYCFD Test Quick Scan Programming onfiguration Code AINTENANCE INSTRUCTIONS Helpful Hints Tool List M aintenance Records nitial Service Preventive M aintenance Cleaning ROUBLESHOOTING General Troubleshooting Guidelines Electrical Troubleshooting ONSOLE DIAGNOSTIC TESTS sn 38 Display Test Keypad Test Page vii able 1 Dimensions and Specifications for the StairM aster 4000 PT Exercise Systems Page viii 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 IM M EDIATE 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 lo
112. te gt Display Results lt 23 4000 PT CONSOLE Table 2 Fitness Rating Norms VO nad High Good Average Fair gt 51 51 47 41 43 42 40 gt 50 50 45 45 41 41 37 gt 48 48 42 42 38 38 35 gt 45 45 39 38 35 35 32 gt 43 42 35 35 32 32 29 WOMEN Good Average Fair 44 38 38 35 35 32 41 37 37 34 34 31 39 34 34 31 31 28 35 31 31 28 28 26 35 39 29 26 26 24 The Firefighter s Stair Climb Tests The StairM aster 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 ustice 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 StairM aster 4000 PT machines e 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 Page 24 4000 PT CONSOLE
113. text message but continue system operation until the user presses the CLEAR key The second way is as a fatal ERROR which will stop the exercise and return the system to an idle intensity state The console will display the error text and not let the user restart the programs unless power has been turned off and then back on The following microprocessor errors require a console replacement ALU ERROR TIM ER ERROR and STATIC RAM ERROR 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 CONSOLE DIAGNOSTIC TESTS 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 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
114. the exterior of your 4000 PT Exercise System daily using any common household cleaner such as Fantastic 409 etc 3 Thoroughly clean the entire 4000 PT Exercise System including the interior at least once a week 19 4 Inspect for any rust bubbling or paint chips during your weekly cleaning Salt contained in perspiration can affect the paint surface so that it requires a slight touch up 5 StairMaster has a special paint touch up kit If your machine needs a touch up obtain the kit and follow these steps SURFACE PREPARATION Sand the surface with a fine grade sandpaper until smooth Feather the edge until you have a smooth transition between the sanded and painted surfaces Remove all rust or corrosion from the surface The area to be painted must be clean and free of oil and grease Mask any area that could receive overspray LEGEND FOR FIGURE 2 Lubricate circled parts AA A Console BB Grey Cable CC Load Resistor DD Drive Chain EE Transmission FF Ne xzxddueuo wuzzgzumwmocuuom mtuuost Hu U H dH H UH HU Ho Ho GB Wot s m gg H Hn Ho dog Transmission Drive Sprocket Step Chain Return Spring Connector Clutch Sprocket Drive Shaft Sprocket Pedal Step Pedal Arm Assembly Spring Pulley Console Knob Alternator Pulley Alternator Alternator Adjuster Brace Alternator Timing Belt Transmission Pulley Step Return Spring Return Spring Hanger Step Chain Drive Shaft Shock Mount Step Leveling Arm Stud As
115. the number of calories you expend while exercising the number of equivalent floors you climbed and the number of equivalent miles you covered Each new display is accompanied by a ringing sound to alert you to the new display For the 1 2 1 3 1 5 2 1 and 2 2 versions of the console if you desire a summary for partially completed program press START to select the Attract mode and then press 109 and ENTER The program will be interrupted so if you desire to continue exercising you must start a new program Following the summary is a Goal Attained message or the jackpot display depending on an owner selected option If the jackpot option is in use the computer then returns to the Attract mode If the jackpot option is in use the message YOU WIN remains until START is pressed then the programmed odds are shown Press START one more time to return to the Attract mode CHANGING THE LENGTH OF YOUR WORKOUT The standard workout time is 15 minutes for all except customized programs The workout time is the sum of all 30 interval times shown on the workout display Each column in a standard 15 minute workout represents a 30 second interval Each interval time is adjusted to soth of the total time if a new time is selected The workout length may be adjusted by using this option to change to any number of minutes between 5 and 45 The new time remains in effect for all standard programs until it is modified again a general rule
116. 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 Reinstall the covers 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 Unscrew the four console mounting screws and remove the console from the machine Lift the rear tube of the frame Tip the machine forward so it is resting on the front portion of the frame 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 2 Remove the side covers 3 Remove the snap ring that secures the leveling arm to the leveling arm shaft J N WARNING TO REDUCE THE RISK OF EYE INJ URY WEAR EYE PROTECTION WHEN REM OVING SNAP RINGS 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
117. w the time to go down to one minute and this allows only two seconds per interval Press ENTER Your program has now been saved and the computer will return to the Attract mode TO USE A CUSTOMIZED PROGRAM For revisions prior to and including 1 3 press 4101 followed by ENTER Enter the desired program number The program number will be between 1 and 10 Press ENTER You can only select a number that has been previously programmed Otherwise the computer will ask you to reselect the program number For the Revision 1 5 2 1 and 2 2 console the custom programs are accessed by entering the program number the number will be between 0 and 9 when the computer displays the message SELECT PROGRAM The custom programs cannot be accessed by pressing 4101 Continue as with a standard exercise program THE SCROLLING MESSAGE OPTION The scrolling message option permits you to replace the simulated EKG seen on the display during the Attract mode with a scrolling message which you enter into the computer This message may involve special announcements birthday greetings specific messages etc This option is automatically inserted when a message is entered but then can be disabled without losing the message The message can also be accompanied by an optional teletype sound effect Your first step is to identify what you want your message to say and to code your message using the codes for letters numbers and symbols presented in Table 2 E

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