Product Support Stairmaster Manuals 7000PT Stepmill Manual

STEPMILL 7000 PT
ASSEMBLY
INSTRUCTIONS
PART NUMBER 27698 1

ASSEMBLY INSTRUCTIONS
TOOLS REQUIRED:
•KNIFE
•2-9/16” WRENCHES
•5/32” ALLEN WRENCH
1. USE KNIFE TO CUT AND REMOVE
PLASTIC STRAPS.
TOP COVER
PLASTIC STRAPS
2. REMOVE TOP COVER FROM CARTON,

THEN REMOVE CARTON. DISCARD COVER
AND CARTON.
2
3. REMOVE PLASTIC BAG FROM

STEPMILL.
PLASTIC BAG
4. USE KNIFE TO REMOVE PLASTIC

TYRAPS SECURING FRAME TO PALLET.
USE CLAW HAMMER TO REMOVE
WOODEN PACKING BLOCKS
WOOD BLOCK
TYRAPS
5. REMOVE STEPMILL FROM PALLET:

SLIDE THE MACHINE FORWARD SO THAT
THE FRONT EDGE OF THE MACHINE
HANGS OFF THE FRONT OF THE PALLET.
CAREFULLY TIP THE STEPMILL FORWARD
UNTIL THE FRONT EDGE OF THE MACHINE
TOUCHES THE FLOOR. CONTINUE TO
PULL THE MACHINE FORWARD UNTIL IT
IS CLEAR OF THE PALLET. GENTLY TIP
THE STEPMILL BACK SO THAT THE
MACHINE RESTS ON THE BASE OF THE
FRAME. DISCARD PALLET.
3
6. REMOVE BUBBLE PACK AND CARTON

FROM STEPMILL. ALSO REMOVE
PACKING MATERIALS FROM HANDRAILS.
PACKING MATERIAL
CARTON
BUBBLE PACK
7. REMOVE CONSOLE FROM BUBBLE

WRAP. DISCARD BUBBLE WRAP.
CONSOLE
4
8. USE A KNIFE TO OPEN CARTON.

CARTON
9. THE CARTON CONTAINS OWNER’S

MANUAL, WHEELS, HARDWARE PLASTIC
BAG, MAGAZINE RACK, CONSOLE
BRACKET, AND POWER SUPPLY CARTON.
5
10. THE HARDWARE PLASTIC BAG

CONTAINS DRINK HOLDER BRACKET,
SCREW FOR MOUNTING DRINK HOLDER
BRACKET, WHEEL AXLES, CLIPS,
CONSOLE SCREWS, LOCK WASHERS, AND
PLASTIC COVERS.
DRINK HOLDER BRACKET SCREW
DRINK HOLDER BRACKET
PLASTIC COVER
CONSOLE SCREW
LOCK WASHER
CLIPS
WHEEL AXEL
11. TWO WHEELS ARE USED TO MOVE

THE STEP MILL TO IT’S FINAL LOCATION.
WHEEL
CONSOLE BRACKET
6
12. USE KNIFE TO REMOVE STRETCH

WRAP FROM POWER SUPPLY BOX AND
OWNER’S MANUAL. SAVE OWNER’S
MANUAL FOR LATER USE. OPEN POWER
SUPPLY CARTON.
OWNER’S MANUAL
POWER SUPPLY CARTON
13. THE POWER SUPPLY CARTON

CONTAIN FOUR LEVELING PADS, BAG OF
SPARE PUSH RIVETS, RIVET REMOVAL
TOOL, AND POWER SUPPLY.
POWER SUPPLY
LEVEL PAD
BAG OF SPARE PUSH RIVETS
RIVET REMOVAL TOOL
7
14. USE TWO 9/16” WRENCHES AND

REMOVE TWO BOLTS , FOUR FINISH
WASHERS, AND TWO NUTS FROM
HANDRAILS.
BOLT
FINISH WASHER
NUT
15. GET CONSOLE BRACKET FROM

CARTON AND POSITION OVER
HANDRAILS. INSTALL BOLTS, FINISH
WASHERS, AND NUTS TO SECURE
CONSOLE BRACKET TO HANDRAILS. USE
9/16” WRENCHES TO TIGHTEN BOLTS.
HANDRAIL
CONSOLE BRACKET
BOLT
FINISH WASHER
8
16. GET FOUR PLASTIC COVERS AND SNAP

ONTO THE FINISH WASHERS TO COVER
THE TWO BOLT HEADS AND NUTS.
PLASTIC COVER
17. USE A 5/32” ALLEN WRENCH TO

ATTACH THE DRINK HOLDER BRACKET
TO THE CONSOLE USING THE DRINK
HOLDER BRACKET SCREW.
DRINK HOLDER BRACKET
DRINK HOLDER BRACKET SCREW
CONSOLE
9
18. GET MAGAZINE RACK AND POSITION

IN GROOVES IN REAR OF CONSOLE.
CONSOLE
MAGAZINE RACK
19. GET FOUR CONSOLE SCREWS AND

LOCK WASHERS. HOLD MAGAZINE RACK
INTO GROOVES IN CONSOLE WHILE
POSITIONING THE CONSOLE OVER THE
CONSOLE BRACKET. USE THE CONSOLE
SCREWS AND LOCK WASHER TO SECURE
THE CONSOLE TO THE CONSOLE
BRACKET. ATTACH THE FEMALE
CONNECTOR ON THE CABLE TO THE
MALE CONNECTOR AT THE REAR OF THE
CONSOLE. MAKE SURE TO POSITION THE
CONNECTORS CORRECTLY WITH THE
ALIGNING TAB ON THE FEMALE
CONNECTOR WITH TH ALIGNING SLOT ON
THE MALE CONNECTOR.
CONSOLE
CONSOLE KNOB
CONSOLE BRACKET
CABLE
10
20. GET TWO WHEELS, TWO AXLES, AND

TWO CLIPS. SLIDE AXLE INTO HOLE IN
BOTTOM OF FRAME. TILT STEPMILL TO
ONE SIDE, SLIDE WHEEL ONTO AXLE.
WHEEL
AXLE
FRAME
21. INSTALL CLIP INTO HOLE IN AXLE TO

RETAIN WHEEL ON AXLE.
WHEEL
CLIP
22. SLIDE AXLE INTO HOLE ON OTHER
SIDE OF STEPMILL BOTTOM FRAME, TILT
STEPMILL TO ONE SIDE, SLIDE WHEEL
ONTO AXLE. INSTALL CLIP INTO HOLE IN
AXLE TO RETAIN WHEEL ON AXLE.
WHEEL
CLIP
11
23. REMOVE ALL PACKING MATERIALS

FROM STEPMILL. ROLL STEPMILL TO
FINAL LOCATION.
24. INSTALL FOUR LEVELING PADS INTO
THREADED HOLES IN THE BOTTOM
SURFACE OF THE STEPMILL. TILT
STEPMILL AND REMOVE THE WHEELS,
AXLES, AND CLIPS. RETAIN THESE ITEMS
FOR FUTURE USE IF THE STEPMILL WILL
BE MOVED TO A NEW LOCATION. PLUG IN
POWER SUPPLY TO RIGHT SIDE OF
STEPMILL AND POWER SOURCE.
POWER SUPPLY
LEVEL PADS
25. SEE OWNER’S MANUAL FOR SET UP

AND OPERATING INSTRUCTIONS.
12
FreeClimber~
7000 PT
Owner's Manual
~ StairMaster
Printed in the United States.
© 1996 StairMaster ~ Sports/Medical 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
II
PIN 22440-A
© 1996 StairMaster Sports/Medical Products, Inc.. StairMaster and Stepmill are

reg istered trademarks and 7000 PT is a trademark of StairMaster Sports/Medical Products. Inc.
Page iii
• WARRANTY
This is to certify that the StairMaster@Stepmill @7000 PT™exercise system is war-
ranted 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, improper maintenance, or an "act of God ". This warranty is
non-transferable from the original owner.
If, within three years from the date of purchase, any part of the StairMaster
Stepmill 7000 PT exercise system should fail to operate properly contact our Customer
Service Department to report the problem. International customers may contact their local
distributor. When calling, please be prepared to provide the customer service representa-
tive with the following information:
• Your name, shipping address, and telephone number;

• The model and serial number of the inoperable machine;
• The date(s) of purchase for the inoperable machine(s);
• Your billing address.
This information will ensure that you are the only one ordering parts under your
warranty protection. If warranty replacement parts are shipped to you, you may be
required to return the inoperable part. To facilitate this process, the following policy has
been established:
•
• Please call our Customer Service Department to receive a return goods
authorization prior to shipment.
• StairMaster Sports/Medical Products, Inc. will incur all freight charges for
warranty parts ordered for a machine that is less than 45 days old. The parts
will be shipped to you via an overnight courier. *
• You are responsible for freight charges on warranty parts for machines that
are more than 45 days old. You will not be responsible for the return
shipment of the inoperable parts.
• Some inoperable warranty parts must be promptly returned to our Customer
Service Department. We will pay the return shipping cost for the inoperable
warranty parts. Detailed shipping instructions are included with each
warranty replacement part.
StairMaster Sports/Medical Products, Inc. neither makes, assumes nor

authorizes any representative or other person to make or assume for us, any other
warranty whatsoever, whether expressed or implied, in connection with the sale, service,
or shipment of our products. We reserve the right to make changes and improvements in
our products without incurring any obligation to similarly alter products previously
purchased. In order to maintain your product warranty and to ensure the safe and efficient
operation of your machine, only authorized replacement parts can be used. This warranty
is void if parts other than those provided by StairMaster Sports/Medical Products, Inc. are
used.
* Note: Aerosol products cannot be transported via air.
•
Pageiv
• INTRODUCTION
The StairMaster ® Stepmill ® 7000 PT™ exercise system is a safe, functional, and
effective exercise modality for developing aerobic fitness and increasing the strength of
the major muscle groups of the lower body. It is designed for use by individuals of all ages
and fitness levels. Your purchase of this machine is a positive affirmation of your
commitment to use the best available methods for enhancing your functional fitness
capabilities. In order to derive optimal benefits from your machine, you should read this
manual thoroughly and adhere closely to the instructions.
WHAT IS IN THIS MANUAL?
Following the information on installation and a brief explanation of how the

Stepmill7000 PT exercise system works, this manual contains two major sections. The
first section provides an explanation of how the machine should be used to achieve
maximum results. The second section offers instructions and advice on how to properly
maintain your machine. The "Appendix" contains additional information for the owner.
Throughout this Manual, whenever you are required to enter information into the
console, the console keypad keystrokes are enclosed in []. The names of the buttons and
•
special console operational modes are shown in capital letters. For example, your
machine is ready for use when the console is in the ATIRACT mode. You are then reqUired
to press the [MANUAL] button to start the MANUAL exercise program. .
WHAT IS THE STAIRMASTER STEPMILL 7000 PT EXERCISE SYSTEM?
The StairMaster Stepmill7000 PT exercise system is avertical climbing machine with a

rotating staircase which provides an aerobic workout equivalent to climbing stairs,
without the impact loads and skeletal trauma common to most aerobic activities. RegUlar
use of the Stepmill 7000 PT exercise system strengthens and conditions the heart and the
following lower body muscle groups: gluteals, quadriceps, hamstrings, and calf muscles.
Page v
•
• CONTENTS
SAFETY GUIDELINES 1
INSTALLATION INSTRUCTIONS 3
BASIC OPERATING INSTRUCTIONS 6

General Guidelines For Safe Operation 6
Your First Workout 6
CONSOLE 9
The Text Bar 9
The Display 9
The Function Keypad 10
The Exercise Program Keypad 11
Customizing Your Exercise Program 20
Customizing the Text Bar Scrolling Message 20
Console Codes 23
MAINTENANCE INSTRUCTIONS 24
•
Helpful Hints 24
Tool List 24
Maintenance Records 24
Initial Service 25
Preventive Maintenance 25
TROUBLESHOOTING 28
General Troubleshooting Guidelines 28
Electrical System 28
Console Diagnostic Tests 31
Speed Control Problems 33
Load Resistor Test 36
Drive Train 37
PARTS REMOVAL AND REPLACEMENT 40

Alternator Assembly 47
Cable Assembly 45
Console 41
Covers 40
Drive Chain 42
Poly-V Belt 41
Relay/Resistor Assembly 47
Step Assembly 42
Step Chain Assembly 43
•
Page vi
CONTENTS
Transmission Assembly 46
Upper (and Lower) Sprocket Assembly 44
GROUNDING INSTRUCTIONS 48
FCC COMPLIANCE 49
APPENDICES
How to Order Parts 50
Figures 10 -17 51
Wiring Diagram 1 - 3 60
Key to Figures and Wiring Diagrams 63
LIST OF TABLES
Table 1: Dimensions and Specifications 3
Table 2: Fitness Rating Norms 13
Table 3: Character Codes for Scrolling Messages 21
Table 4: Console Codes 23
•
Table 5: Recommended Preventive Maintenance Schedule 27
LIST OF ILLUSTRATIONS
Figure 1: Console Diagram 9
Figure 2: Fat Burner 14
Figure 3: Fat Burner Plus 15
Figure 4: Steady Pace 16
Figure 5: Rolling Hills 16
Figure 6: Aerobic Training 17
Figure 7: Cross-Country 18
Figure 8:Speed Training 19
Figure 9: Grounding System 48
Figure 10: Installation Diagram 51
Figure 11: Parts Needing Periodic Lubrication 52
Figure 12: Side Cover and Handrail Assemblies 53
Figure 13: Cover Fasteners 54
Figure 14: Poly-V Belt Tension 55
Figure 15: Drive Chain Assembly 56
Figure 16: Step Assembly 57
Figure 17: Step Chain and Sprocket Assemblies 58
Figure 18: Transmission and Alternator Assemblies 59
Wiring Diagram 1 60
Wiring Diagram 2 61
Wiring Diagram 3 62
Page vii
•
• SAFETY GUIDELINES
IMPORTANT SAFETY INSTRUCTIONS

When using electrical equipment, basic precautions should always be followed.
including:
Read all instructions before using the machine.
IDANGERI
To reduce the risk of electric shock, always unplug the external power supply from the
AC wall outlet before cleaning, maintaining, or repairing.
IWARNINGI
• To reduce the risk of burns, electric shock, or injury to persons:
1. The external power supply should always be unplugged from the AC

wall outlet before removing or installing parts. Never make adjust
ments or repairs while an exercise program is in progress.
2. Close supervision is necessary whenever the machine is used by. on,

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 with the side covers
removed.
4. Use this machine only for its intended use as described in this
Manual. Do not use attachments or accessories other than those
provided by StairMaster Sports/Medical Products, Inc.
5. Do not use the external power supply if it has a damaged cord or plug,
if it is not working properly, if it has been dropped or damaged, or
dropped into water. Contact our Customer Service Department at
(800) 331-3578 to arrange for the return of damaged parts. International
customers should contact their local distributor; refer to the
Appendix for the appropriate phone number.
Page 1
•
• SAFETY GUIDELINES
6. Connect the external power supply to a properly grounded AC wall outlet;
refer to the "Grounding Instructions" section of this Manual. Keep all cords
away from heated surfaces.
7. Never drop or insert any object into any opening on the machine.
8. Do not use the machine outdoors.
9. Do not operate where aerosol (spray) products are being used.
10. To disconnect the external power supply, remove the plug from the AC wall
outlet.
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 compo-
nents 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.
I SAVE THESE INSTRUCTIONS I
Page 2
•
• INSTALLATION INSTRUCTIONS
Before leaving the manufacturing facility in Tulsa, Oklahoma, your StairMaster®
Stepmill(]l) 7000 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.
The dimensions of the machine are listed in Table 1. Throughout the Owner's
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 white function keypad is
located on the right side of the console.
Table 1. Dimensions and Specifications for the

StairMaster 7000 PT Exercise System
Physical Dimensions:
Length 50.0 inches (127 cm)
Width 29.0 inches (74 cm)
Height 78.0 inches (198 cm)
•
Weight 409 pounds (186 kg)
Power Supply Specifications, PS 7:

Output Voltage 10 to 16 VDC
Output Current Capacity 2.5 amps
Input Power Consumption 55 watts
The machine requires minor assembly before operation. You will need a pair of diagonal
cutters or a pair of heavy-duty scissors. The Stepmill 7000 PT exercise system must be
placed on a solid, level floor near an AC wall outlet. A minimum ceiling height of 9 feet
(2.8 meters) and a doorway width of 29 inches (74 cm) is required .
1. Roll the machine to its desired location on its temporary wheels.
2. Have an assistant tilt the machine forward until the wheels are off the floor.
Make sure the assistant can support the machine so you can remove the
temporary wheels (refer to Figure 10).
3. Remove the pin from each axle. Remove both axles and wheels from the
frame.
Page 3
•
4. Help your assistant lower the machine to the floor.
5. A<!just the leg levelers as necessary to level the machine.
6. If your machine was shipped outside North America, it will need additional
assembly (if this is not the case, skip to step #7).
• Use the fastener removal tool to remove the 10 fasteners on the back
cover.
• Mount both handrails using the hardware as shown in Figure 10.
• Push the console cable assembly through the grommet in the frame and
connect it to the main cable assembly (refer to Wiring Diagram 1).
• Install the console mount onto the handrails (refer to Figure 10).
• Install the console and connect the console cable.
• Reinstall the back cover.
• Go to step #9.
7. Unwrap the power supply assembly from the console.
• 8.
9.
Connect the DC power cable to the power connector located on the bottom
cover.
Place the power supply on the floor near an AC wall outlet. To reduce the
hazard of electrical shock, place the power supply in a location away from the
machine and away from exposure to perspiration. You should not place your
power supply on a carpet because it may overheat.
10. 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 ~ Sports/Medical Products, Inc. before proceeding any
further.
.&WARNING
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO PREVENT SEVERE
DAMAGE TO THE MACHINE, USE ONLY THE POWER SUPPLY APPROVED FOR USE
WITH THIS EQUIPMENT. IN ADDITION, YOUR MACHINE MUST BE
PROPERLY GROUNDED.
Page 4
•
11. Connect the AC power cord to the AC wall outlet. Refer to the "Grounding
Instructions" section of the Owner's Manual if the AC wall outlet does not
accept a three-prong plug.
12. Watch the console. It should produce an audible sound when plugged in and
then display a simulated EKG after the software revision level scrolling
message. If it does not, unplug the power supply and then plug it back in. If
the sound and/or the display are still not present, contact the Customer
Service Department at (800) 331 -3578. International customers should call
their local distributor; refer to the Appendix "How to Order Parts" for the
phone number of the office nearest you.
13. When the console displays the simulated EKG, your StepmilrlP 7000 PT'"
exercise system is in the ATIRACT mode.
14. The console is set at the manufacturing facility to English language prompts
and English units. While the console is in the ATTRACT mode, you can set the
console for foreign language prompts or metric units. To change the language
•
of the prompts, press [+ ARROW], [7], [4], [2], [4], [ENTER]. Press the code
number corresponding to the desired language according to Table 4 and then
[ENTER].
To change the console to metric units, press [+ ARROW], [9], [7], [6], [0),
[ENTER] . Press [1], [ENTER] to set the console to metric units. Press [0],
[ENTER] to set the console to English units.
15. Custom-length DC cables, brackets for multiple power supplies and other
accessories are available. Refer to the Appendix "How to Order Parts" for the
Page 5
•
• BASIC OPERATING INSTRUCTIONS
GENERAL GUIDELINES FOR SAFE OPERATION
&.WARNING
THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE MACHINE.
YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAME GUIDELINES. YOU
SHOULD MAKE THIS MANUAL AVAILABLE TO ALL USERS.
1. Obtain a complete physical examination from your medical doctor and enlist a
health/fitness professional's aid in developing an exercise program suitable
for your current health status.
2. When working out for the first time, use the MANUAL exercise program at the
lower speeds until you feel comfortable and capable of faster speeds.
3. The speed and duration of your exercise program should always be subject to
how you feel. Never permit peer pressure to exceed your personal judgment
while exercising.
• 4. Overweight or severely deconditioned individuals should be particularly

cautious when using the machine for the first time. Even though such
individuals may not have histories of serious physical problems, they may
perceive the exercise to be far less intense than it really is, resulting in the
possibility of overexertion or injury.
5. Although all equipment manufactured by StairMaster Sports/Medical

Products, Inc. has been thoroughly inspected by the manufacturing facility
prior to shipment, proper installation and regUlar maintenance are
required to ensure safety. Maintenance is the sole responsibility of the
owner.
YOUR FIRST WORKOUT ON THE STAIRMASTER~ STEPMILL ~ 7000 PT

110
EXERCISE SYSTEM
The ATIRACT Mode
The StairMaster Stepmill 7000 PT exercise system is ready to use when the console is in
the inactive or ATTRACT mode. The ATIRACT mode is denoted by a simulated EKG
signal in the display and/or a typewritten message that scrolls across the text bar.
You can program your own message to scroll across the text bar. Refer to the
"Customizing the Text Bar Scrolling Message" section of this Manual. A diagram of the
Page 6
•
console is shown in Figure 1.
Basic Instructions for First-Time Users
1. Warm up with light calisthenics and easy stretching exercises for at least five
.&.WARNING
IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN, EXPERIENCE
SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF BREATH,
STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU SHOULD
2. Hold onto the handrails and step up onto the staircase. Stand up straight. The
steps will rotate sloWly.
3. Select the MANUAL exercise program so you can control the pace of your first
workout and get used to the exercise motion.
• 4.
5.
Press [MANUAL] and then [ENTER]. The console will return to the ATIRACT
mode if you do not press [ENTER] within ten seconds.
The console will prompt you to enter your body weight. Enter your weight in
pounds (or kilograms if the console is set up for metric units). Correct entry
errors by pressing [CLEAR] before you press [ENTER].
6. The console will prompt you to enter the workout time in one-minute
increments between five and 45 minutes. Press [1], [0], [ENTER] to exercise for
ten minutes.
7. Step up with one foot at a time. Try to step at the top of the staircase. When
you begin to exercise, the console will display a single flashing light in the
first interval.
8. The flashing column shows which interval is active. Everything to the left of
the active interval indicates completed intervals. As you become comfortable
with the exercise motion, try pressing [+ ARROW] and [- ARROW] to ac!iust
your speed.
9. Relax as much as possible while exercising and maintain an erect posture. Use
the handrails for balance. Don't lock your elbows or lean on the console.
Supporting your weight will reduce the exercise intensity and the console will
Page 7
•
overestimate the number of calories burned.
, O. Select a speed (or intensity level) that allows you to step towards the top of
the staircase. Faster is not always better. Exercise at a level that is consistent
with your fitness level.
" . You can stop once and rest for up to two minutes at any time during the
workout. To rest, simply stop climbing and step down to the floor or press
[RESET] (the stairs will continue to rotate very slowly). To resume your
workout, press [YES] and begin climbing. To return the console the ATTRACT
mode, press [NO] during the pause. The console returns to the ATTRACT mode
if you rest longer than two minutes or take two rest breaks.
, 2. When you have completed the last interval of the workout, the machine will
slow down to the slowest speed. Step off the machine and cool down by
walking or stretching for at least five minutes.
End-ot-Workout Summary
,.
•
At the end of your workout, the message "GOAL ATTAINED" will scroll across
the text bar. The total number of Calories you burned during your workout is
then displayed for ten seconds. During this time, you may press any of the
function keypad buttons to receive feedback concerning your workout. Refer to
the "Function Keypad " section of this Manual for details.
2. The summary information is stored in the console memory until the next
person begins an exercise program. Press [WORKOUT STATS] to recall the
summary for the last workout.
Page 8
•
• 7000 PT CONSOLE
The StairMaster Stepmill ~ 7000 PT'" exercise system console is divided into four
sections: the text bar, display, the function keypad, and the exercise program keypad
(refer to Figure 2).
• Figure 1: Console Diagram
TEXT BAR
Information regarding workout statistics and data entry is displayed or scrolled across
the text bar. A countdown timer is located directly above the words "Interval Time". The
timer shows the number of seconds remaining in the current interval.
DISPLAY
For all exercise program options except MANUAL, a profile of the selected program
appears in the display. A flashing interval column indicates where on the profile you are
currently exercising (the active interval). The flashing, active column moves left to right
across the display area as you complete each interval.
Page 9
•
• 7000 PT CONSOLE
THE FUNCTION KEYPAD
The function keypad is located on the right side of the console. Eight of the buttons have
two pieces of information on them-a number and a workout statistic. Before the
exercise program begins, the numbers are used to enter data in response to the console
prompts. During the exercise program, the buttons are used to display workout statistics
on the text bar.
1. TIME displays the elapsed time, in minutes and seconds, of your workout.
2. FLOORS is the cumu lative number of floors you have climbed based on an
average eight-inch step and 16 steps per floor.
3. DISTANCE provides a cumulative total of the equivalent distance, in miles (or

kilometers if your console is set to metric units), you would have traveled at
the same relative intensity of exercise.
4. WATTS displays the physical power output of the machine. Power output is
•
measured in units known as watts (746 watts = 1 horsepower). Since power is
a rate, the watts do not accumulate over time. During a workout, this button
provides the power output at that moment. After a workout, the average
power output over the entire workout is shown.
5. INTENSITY LEVEL shows the current level between 1 (the easiest) and 20
(the hardest).
6. METs gives you the relative energy cost of exercise. One MET is equivalent to
the resting oxygen consumption of about 3.5 milliliters of oxygen per kilogram
of body mass per minute (ml 02kg'l min'l). For example, exercising at 10 METs
requires ten times the resting metabolic rate or about 35 ml 02kg'l min,l.
During the exercise program, this button displays the current MET level. After
your exercise program, the average MET level is displayed.
7. CALORIES provides a running total of the Calories burned during a workout.

Calories expended is a common way to measure the energy cost of exercise.
Since the energy content of food is expressed in Calories, a convenient way
exists to control or manage your body weight. When your total energy intake i
s less than your total energy output, you lose weight and vice versa. Techni-
cally, a Calorie is the amount of heat needed to raise the temperature of one
liter (or one kilogram) of water one degree Celsius.
Page 10
•
• 7000 PT CONSOLE
8. STEP RATE indicates the exercise speed, using the number of eight-inch
steps per minute for units.
9. The ENTER button confirms selections and stores the information used to
calculate the workout statistics in the console memory.
10. The CLEAR button erases data from the console before the ENTER button is
pressed.
11. The + and • ARROWS increase or decrease, respectively, the workout

intensity level (or the number of lights during MANUAL). The intensity level
ranges from 1 (the easiest) to 20 (the hardest).
12. The WORKOUT STATS button scrolls the eight statistics continuously across
the text bar. You can press any function keypad button during the scrolling
summary and stop at that statistic.
If you press [WORKOUT STATS] while the total Calories are shown
•
on the text bar immediately after your workout, the eight statistics scroll once
across the text bar. You can press any function keypad button during the
scrolling summary and stop at that statistic.
Pressing [WORKOUT STATS] while the console is in the ATIRACT

mode will recall the final totals of the last workout. Your workout statistics
are stored in the console memory until another exercise program is started.
13. The YES and NO buttons are used to respond to data entry prompts.
14. If the START/STOP button is pressed while the console is in the ATIRACT
mode, the "ENTER WEIGHT" prompt will appear in the display area . If it is
pressed during a workout or during data entry, the console will return to the
ATIRACT mode, ending the workout.
EXERCISE PROGRAM KEYPAD
The purple exercise keypad is located below the display and to the left of the function
keypad. While the console is in the ATIRACT mode, press one of the exercise program
keys to preview the desired workout.
The sequence of prompts for the preset exercise programs is slightly different
than the sequence described earlier for the MANUAL program. After you press one of
the exercise program buttons, the exercise program profile is scrolled across the display.
Page 11
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• 7000 PT CONSOLE
After the profile is scrolled, the prompts are:
"PRESS ENTER KEY TO SELECT"

"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 - 45" -- select the workout duration in one minute
increments from five to 45.
The Quick Start Option
You can quickly start any workout by first pressing one of the purple exercise program
keys and then pressing [ENTER] twice. You do not have to enter any other information.
The length of the workout is set automatically and varies with the program. Quick
starting MANUAL gives you a 15 minute workout. The preprogrammed workouts last five
minutes for every thirty intervals. So, a 60 interval program will last 10 minutes. The
only workout stats available are time, floors, distance, level, and step rate. The Fit Test
•
does not have a qUick start option.
The Fit Test
The Fit Test is a program that estimates your maximal aerobic capacity based on your
heart rate response to submaximal exercise. Start the Fit Test by pressing [FIT TESn,
[ENTER] while the console is in the ATIRACT mode. You will be prompted to enter your
age and gender after a short message is scrolled across the display.
Once you have entered the required information, you will step at the rate of
43 steps per minute for three minutes. At the end of the three minutes, you will need to
enter your heart rate. The console will prompt you to find your pulse; use the artery
below your thumb in your wrist or the artery in the side of your neck. Start counting the
beats when the console prompts you-the first beat you feel is zero and then one and
so on. Enter the number of beats you counted in the ten seconds. If you are using a
heart rate monitor, enter your heart rate directly into the console.
You will continue to exercise for three minute bouts of increasing intensity
until you reach a point where you have entered two heart rate responses between 19
and 25 counts (115-150 beats per minute). The test typically lasts from nine to 15
minutes.
At the end of the Fit Test, your results scroll across the display area. Prior to a
three-minute cool down, your estimated aerobic capacity, expressed in metabolic
Page 12
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• 7000 PT CONSOLE
equivalents (METs) , is shown in the display area. Next, your results will be compared to
normative values for others of your age and gender. These normative values are based
on values developed by the world renowned exercise physiologist, Dr. Per Olaf Astrand,
and are shown in Table 2. Your results are stored in the console until the next person
starts an exercise program. Press [WORKOUT STATS] to review your results.
Table 2. Fitness Rating Norms
Above Avera e
en
29-?9 <10.8 I
11.1,-1,2) " , ·12.6-16.0
.... " ,
16.3-19.7 ~ ?O:O~ ,
30-39 <9.7 10.0-11.1 11.4-14.6 14.8-18.3 , 18.6+
40-49 "
~8:6 8:8-i6.0 i6.3~ 13.4 ;3.'7-'11.1 : i7:4+ '
50-59 <7 .'1 7.'4-8.8 9.;-i2:3 i2.'6-'15.7 : ;6:0';' ,
•
:
60-69 <6.0 6,'3-7.4 7.7- i fl ; 1.'4-'14.0' : i4:3~ ,
: · ....
omen
20-29 <8.0 8.3-9.7 ·10.0-13.7
.... " ,
14.0-16.8
. . . . . ·, 17.1+
....
30-39 <7.7 8.0-9.4 9.7-13.4 13.7-16.6 , 16.8+
,40-49' <7:1 ' '7:4-8.B 9.1-12:8'
· .... " ,
13.'1-'10.0'
. . . . . · 16:Ji·
~
. ...'
50-59 <6.0 6.3-7.7 8.0-11 .7 12.0-14.0 , 14.3+
:
60-69 ~4.'8 5:1-6.3 6.6- i 0:3 i 0:6-'12.6' : ii8+ '
PRESET EXERCISE PROGRAMS
There are seven preset exercise programs. The exercise speed during the programs
varies automatically over 14 increments within each of the 20 different intensity levels.
Varying the intensity of an exercise program does not change the profile shown on the
display. Change the intensity level of your workout by pressing [+ ARROW] or [- ARROW].
The average energy cost of the exercise programs is about the same.
Page 13
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• 7000 PT CONSOLE
The Fat Burner program (Figure 2) is a 60 interval workout designed for people
just starting a weight control program. The Fat Burner Plus program (Figure 3) is similar
but has 90 intervals. It is meant for the longer workouts you will need as your fitness
level increases.
••• •• •
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• Figure 2a: Fat Burner, Screen 1
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Figure 2b: Fat Burner, Screen 2
Page 14
•
• 7000 PT CONSOLE
•• •
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Figure 3a: Fat Burner Plus, Screen 1
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Figure 3b: Fat Burner Plus, Screen 2
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Figure 3c: Fat Burner Plus, Screen 3
Page 15
•
• 7000 PT CONSOLE
Steady Pace and Roll ing Hills (Figures 4 and 5) are 30 interval workouts with
gradual speed changes. They are geared for those who are just starting to exercise or
for those who need an easy day of recovery exercise.
.....
••••••••••••• .
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~ ~
•
Figure 4: Steady Pace
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~ ~
Figure 5: Rolling Hills
Page 16
•
• 7000 PT CONSOLE
Aerobic Training (Figure 6) is a 60 interval workout with slightly more varied
speed changes. It is ideal for those long, slow workouts to increase your aerobic
capacity.
•
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Figure 6a: Aerobic Training, Screen 1
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Figure 6b: Aerobic Training, Screen 2
Page 17
•
• 7000 PT CONSOLE
Cross Country and Speed Training (Figures 7 and 8) are 90 interval workouts
with lots of speed changes to get your legs moving. Think of the terrain you would find
on a hike cross country.
•
•••••
• • ••••••••
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Figure 7a: Cross-Country, Screen 1
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Figure 7c: Cross-Country, Screen 3
Page 18
•
• 7000 PT CONSOLE
•• ••
•
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Figure Sa: Speed Training, Screen 1
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Figure 8b: Speed Training, Screen 2
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Figure Be: Speed Training, Screen 3
~._
Page 19
•
• 7000 PT CONSOLE
CUSTOMIZING YOUR EXERCISE PROGRAM
The StairMasterlBl Stepmill lBl 7000 PT TM exercise system console has enough memory
space for nine exercise programs of your design. Only the exercise profile is saved, your
body weight, the intensity level and the workout time must be entered each time the
custom program is used.
Programming Your Workout
1. The console must be in the ATIRACT mode. Press [+ ARROW), [1), [6), [5], [0],
[ENTER]. Press the exercise program keypad button that you want to assign to
your custom program.
2. If you select an exercise program keypad button that is already programmed,

the profile will appear; it can be modified or completely rewritten. If the
exercise program keypad button was not previously programmed, you will see
a single row of dots along the bottom of the display.
•
3. The flashing dot or column indicates which interval can be modified. Press the
[+ ARROW] or [- ARROW] to make the column taller or shorter. Press [ENTER]
to move one column to the right and [CLEAR] to move one column to the left.
4. When all of the intervals are correctly programmed, press [YES] to save the
profile. Press [START/STOP] to abort the programming process without saving
the profile.
Using a Custom Program
1. Press [- ARROW] and the exercise program keypad button you assigned to the
custom program.
2. Enter your body weight, the intensity level and the workout time in response to
the prompts.
CUSTOMIZING THE TEXT BAR SCROLLING MESSAGE
The message that scrolls across the text bar during the ATTRACT mode can be replaced
with a message of your choice. The console accepts messages up to 128 characters in
length, including spaces. To program your message:
1. Encode your message using the character codes listed in Table 3.
Page 20
•
• 7000 PT CONSOLE
2. While the console is in the ATIRACT mode, press [+ ARROW], [7], [6], [0], [7],
[ENTER].
3. Enter the two-digit code for each letter of your message. The letter will
appear in the text bar as you press the second digit of each code. Do not press
[ENTER] between the code numbers.
4. For example, to program the message "EXERCISE IS FUN", press [+ ARROW],

[7], [6], [0], [7], [ENTER]. Then press [1], [5], [3], [4], [1], [5], [2], [8], [1], [3], [1],
[9], [2], [9], [1], [5], [1], [0], [1], [9], [2], [9], [1], [0], [1], [6], [3], [1], [2], [4],
[ENTER]. At that point, your message will begin scrolling. The console is again
in the ATTRACT mode.
5. If you make a mistake while entering the codes, press [CLEAR] to erase the
last character entered.
Table 3. Character Codes for the Scrolling Message

Character Code Character Code Character Code
• 1
2
3
4
5
a 00
01
02
03
04
as
M
N
0
P
Q
R
23
24
25
26
27
28
r
A
i
E
A
C
46
47
48
49
50
51
6 06 S 29 E 52
7 07 T 30 L 53
8 08 U 31 + 54
9 09 V 32 $ 55
SPACE 10 W 33 56
A 11 X 34 57
B 12 Y 35 % 58
C 13 Z 36 ? 59
0 14 A 37 60
E 15 0 38 ! 61
F 16 0 39 - 62
G 17 B 40 # 63
H 18 A 41 64
I 19 A 42 65
J 20 0 43 ) 66
K 21 ~ 44 ( 67
L 22 f\J 45 / 68
Page 21
•
• 7000 PT CONSOLE
Editing the Scrolling Message
1. While the console is in the ATIRACT mode, press [+ ARROW], [7], [6), [0), [7],
[ENTER] to display the first character of the message onto the text bar.
2. Press [+ ARROW] or [- ARROW] to scroll through the message character-by-

character.
3. Press [CLEAR] to delete the last character displayed on the text bar. Press
[ENTER] to end the editing process.
4. To edit multiple characters at one time, press [9), [9), [ENTER] to erase all of
the characters to the right of the last character displayed on the text bar.
5. To erase the entire message, press [+ ARROW], [1], [0), [5], [ENTER] while in
the ATIRACT mode.
6. The edited message will scroll across the text bar. If you have erased the
•
entire message, the text bar area will be blank during the ATIRACT mode.
7. Press [+ ARROW], [2], [1], [2), [3], [ENTER] to display the default scrolling
message on the text bar.
8. Press [+ ARROW], [2], [1], [2], [1), [ENTER] to display your custom scrolling
Page 22
•
• 7000 PT CONSOLE
CONSOLE CODES
The console codes and the corresponding functions are listed in Table 4.
Table 4. Console Codes

Code FWlCtion
+ ARROW, 105,
Clears the custom programmed scroll ing message
ENTER
+ARROW, 107, Activates the Diagnostic mode
ENTER
0 Display test
1 Speaker test
2 Keypad test
3 Speed Test
4 Software revision level test
+ARROW, 1650,
Programs a custom workout
ENTER
+ARROW, 2121 ,
Tums on the custom scroll ing message
•
ENTER
+ARROW, 2123,
Turns off the custom scroll ing message
ENTER
+ARROW, 7424, Changes the language of the console prompts
ENTER
0 English
1 German
2 French
3 Italian
4 Spanish
5 Swedish
6 Danish
7 Japanese
+ARROW, 7607,
ENTER Turns on the custom message option
99, ENTER Text bar scrolling message editing function
+ARROW, 7703,
Displays machine usage information
ENTER
+ARROW, 7704,
Allows you to turn the console speaker on or off
ENTER
Turns the speaker on
0
Turns the speaker off
1
+ARROW, 9760,
Allows you to change the units displayed by the console
ENTER
Changes the console to English units
0
Changes the console to metric units
1
Page 23
•
MAINTENANCE INSTRUCTIONS
HELPFUL HINTS
Read all maintenance instructions thoroughly before beginning work. In some cases, an
assistant is required to perform the necessary tasks. 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 .
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. For example, the power supply is plugged
into the connector near the bottom of the right side cover. The circled numbers in the
figures identify parts that are referenced in the Parts Key of the Appendix.
TOOL LIST
The following tools are needed to perform service and maintenance:
•
• standard screwdriver • phillips screwdriver
01
• combination wrenches (sizes 7/16 - 3/4 ) • ac!justable wrench
• combination pliers • external snap ring pliers
• locking pliers • wire stripper/crimper tool
01
• allen wrench set (sizes 5/64 _1/4 ) • volt-ohm meter (multimeter)
• socket set or nut driver set • shop goggles
01 01
(sizes 1/4 - 3/4 in 1/16 increments)
MAINTENANCE RECORDS
The console will keep track of the following data on machine usage:
• The number of hours the power supply was turned on.

• The number of hours the machine was in use.
• The total number of floors climbed .
• The number of exercise programs started.
• The hours of MANUAL use.
To display the data, press [t ARROW), [7], [7), [0), [3), [ENTER] while the console is in the
ATIRACT mode. The console will display the data in the sequence listed above. The
machine may show a few hours of use due to testing at the manufacturing facility.
Page 24
• 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 will require minor assembly. Refer
to the "Installation Instructions" section of this Manual for details.
PREVENTIVE MAINTENANCE
The procedures for performing the recommended preventive maintenance are summa-
rized in Table 5. 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 of this Manual for all disassembly and assembly
instructions.
Cleaning and Inspecting
1. DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANER ON THE
•
CONSOLE. Clean the console daily with a water-dampened cloth and wipe dry
after cleaning.
2. Clean the exterior of your Stepmill ~ 7000 PT'" exercise system daily with soap
and water.
3. Thoroughly clean the entire machine at least once a week.
4. Inspect the painted surfaces of the exposed frame for any rust, bubbling or
chips during the weekly cleaning. The salt in perspiration can damage the
unpainted surfaces. Repair the damaged area with a touch-up kit provided by
StairMaster ~ Sports/Medical Products, Inc. Refer to the Parts Key for the
touch-up kit part number.
5. Clean the step hinges carefully. Perspiration tends to accumulate in the

hinges, and this can lead to eventual corrosion.
6. Inspect the Poly-V belt for excessive wear during the weekly cleaning. Adjust
WARNING
TO AVOID INJURY DUE TO SLIPPERY PEDAL SURFACES, DO NOT USE
PETROLEUM-BASED CLEANERS OR ARMORALL-TYPE PROTECTANTS
Page 25
•
ANYWHERE ON THIS MACHINE OR THE FLOOR MATS.
Lubrication
The StairMaster$ StepmiW~ 7000 PT'" exercise system has six components that require
periodic lubrication: the drive chain, the two step chains, the bearing plates and the
step hinges. These parts are shown in Figure 11. You will need to remove the side
cover(s) to lubricate the chains and the bearing plates.
1. Place a protective mat on the floor while you are lubricating your machine. A
rubber floor mat is available from StairMaster Sports/Medical Products, Inc.
2. Lubricate the chains monthly with 30W motor oil. Drip the oil onto the chain
plates and rollers. Let the oil soak in for a few minutes and then remove any
excess oil with a dry rag.
3. Remove the chains every three months to thoroughly clean and relubricate
them. Use a mild degreaser and a stiff brush to remove dirt and corrosion from
the chain. Read the instructions on the degreaser container before using.
• 4.
5.
Clean each bearing plate and lubricate it with multi-purpose grease every
three months. The plate is lubricated to reduce friction when the step shaft
bearings roll over the plate.
Once per month, use 30W motor oil or brush light bearing grease into the step
hinges to lubricate the hinges and to prevent corrosion. Wipe off all excess
.&WARNING
TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE THE STEP AREA IS FREE OF
Page 26
•
Table 5. Recommended Preventive Maintenance Schedule
RECCOMENDED
PART FREQUENCY CLEANER LUBRICANT
ACTION
Exterior Soap &
Clean Daily N/A
Surfaces water
Console Wipe Clean Daily Water N/A
Monthly or
30W motor
Lubricate after 300 N/A
oil
Step Chain hours of use
Assembly Quarterly or Multi
Clean and Clean, dry
after 900 purpose
lubricate rag
hours of use grease
• Drive Chain
Lubricate
Clean and
Weekly or
after 70hours
of use
Quarterly or
after 900
N/A
Mild
30W motor
oil
30W motor
lubricate Degreaser oil
hours of use
Monthly or
30W motor
Step Hinges Lubricate after 300 N/A
oil
hours of use
Quarterly or
Bearing Clean and Mild 30W motor
after 900
Plate lubricate Degreaser oil
hours of use
*Note: Use of lubricants other than those so specified will result in diminished
performance and a shorter life span for that part.
Page 27
•
• TROUBLESHOOTING
GENERAL TROUBLESHOOTING GUIDELINES
This section outlines several tests to systematically identify and isolate the cause of
problems in the electrical system and the drive train. This troubleshooting section is
organized into four basic problem sections: Electrical System, Console Diagnostics,
Speed Control, and the Drive Train. The first step is to identify the problem. Once you
have identified the problem, perform all the tests in exactly the same order as written.
Refer to the "Parts Removal and Replacement" section of this Manualfor all disassem-
bly and assembly instructions. To order a replacement part, or to get help with the
troubleshooting process, contact our Customer Service Department at (800) 331-3578.
International customers should contact their local distributor or call (206) 823-1825.
TROUBLESHOOTING THE ELECTRICAL SYSTEM
The electrical system consists of: the power supply and the console. In order to identify
the component that is causing the problem, you must systematically test the system.
You will need a volt-ohm meter (multimeter) to conduct portions of the following
procedures. The console and power supply are not serviceable by the owner. If either of
•
these parts are inoperable, they must be replaced . Opening the console or the power
supply will void the warranty.
The Console Fails to Power Up
A. Perform a visual check of the machine. Check the following things first:
1. Is the power supply plugged in?
2. Is the indicator light lit on the power supply? If it is, proceed to step #3. If the
light is not on, reset the circuit breaker. If the light is still not on, replace the
power supply.
3. Replace or exchange your console with a console you know is good and retest
the machine.
B. Verify AC power.
1. Disconnect the AC power cord from the AC wall outlet.
2. Verify that the AC wall outlet is supplying the correct power in one of two
ways: a) Use an AC voltmeter to verify that the AC line voltage is between 100
and 120 VAC (or between 220 and 240 VAC, if applicable) at the AC wall
Page 28
•
• TROUBLESHOOTING THE ELECTRICAL SYSTEM
outlet; or b) Plug in an alternate AC-powered device (a lamp, for example). If
the AC wall outlet is supplying the correct power, proceed to step #3. If the
voltage is outside the range or if the device does not work when plugged into
the AC wall outlet, consult an electrician for further assistance and then
retest the AC wall outlet.
3. Plug the AC power cord into the wall outlet and proceed to the next section.
C. Verify DC power.
1. Make sure that the AC power cord is plugged in and that the AC wall outlet is
delivering the proper voltage.
2. The indicator light should be lit. If it is, proceed to step #3. If the indicator is
not lit, reset the circuit breaker. If the indicator light is still not lit, replace the
power supply and test the new power supply.
3. Disconnect the cable from the DC power connector located on the bottom
•
cover. Use a DC voltmeter to verify 10-16 VDC at the end of the DC cable. Pin
#1 is positive and pin #2 is negative. Proceed to step #5 if the VDC is within
the range. Replace the power supply if the VDC is outside the range and test
the new power supply.
4. Remove the right side cover. Reconnect the DC power cable to the machine.
Locate the relay/resistor circuit board located just inside the frame, midway
between the top and bottom steps (refer to Wiring Diagram 1). There are
three red indicator lights along the bottom edge of the relay assembly circuit
board. They are labeled, from top to bottom: Field, Power, and Relay. Ensure
the black and white wire power connector (labeled J2 on the relay resistor
circuit board) is securely connected to the relay resistor circuit board.
a. The Power light should be lit. If it is, go to step #6. If it is not,

disconnect the power connector from the J2 position on the relay
assembly circuit board (refer to Wiring Diagram 2). Use a DC
voltmeter to measure the VDC at the power connector. Hole #1 (the
white wire) is positive and hole #2 (the black wire) is negative. The
reading should be between 15 and 17 VDC. If you are not getting
power to the connector, replace the power connector assembly and
retest.
b. If you are getting the correct voltage at the power connector,

reconnect it to the J2 position on the relay assembly circuit board.
Page 29
•
• TROUBLESHOOTING THE ELECTRICAL SYSTEM
Disconnect the main cable connector at the J1 position of the relay
assembly circuit board. Check the VDC reading at the silver tabs on
the relay assembly circuit board. Tab #4 (labelled t/WHD is positive
and tab #5 (labelled GND/BLK) is negative (refer to Wiring Diagram
2). You should get a reading between 15 and 17 VDC . If your reading
is not within the range, replace the relay assembly circuit board and
retest.
c. If you are getting the correct voltage at tabs #4 and #5, check the
VDC reading at the connector labelled position J1 on the relay
assembly circuit board. Pin #4 is positive and pin #5 is negative. You
should get a reading between 15 and 17 VDC. If your reading is not
within the range, replace the relay assembly circuit board and
retest.
d. If all of the above power tests produce VDC readings that are within
range and the Power indicator light is still not lit, the Power
indicator light is probably inoperable. Replace the relay assembly
•
circuit board and retest.
5. Ensure that all of the wires you disconnected in steps 5a-5c are securely
reconnected. Remove the console and disconnect the console cable. Use a DC
voltmeter to measure the VDC at pin #9 (positive) and pin #1 (negative) of the
console cable connector. You should get a reading between 15 and 17 VDC. If
the reading is not within the range, replace the cable assembly and retest.
6. If the problem still exists, contact the Customer Service Department at

StairMaster<8l Sports/Medical Products, Inc.
Page 30
•
• CONSOLE DIAGNOSTIC TESTS
The following tests must be performed while the console is in the DIAGNOSTIC mode.
To activate the DIAGNOSTIC mode, press [t ARROW] , [1], [0], [7], [ENTER]. The numbers
will not appear on the display area as you enter them . If the console fails any test, the
console should be replaced or exchanged. To return to the ATTRACT mode, press either
[CLEAR] or [RESET] while in the DIAGNOSTIC mode.
Display Test
Use this test if the console display or text bar exhibits blank spots during use. This test
checks for inoperable Light Emitting Diodes (LEOs) in the console display and the text
bar. If any LED will not light, replace the console.
1. Press [0] to start the test.
2. All LEOs in the console display will flash on and off as a block. The 26 letters
(A-Z) will scroll across the text bar.
3. Press [CLEAR] to end the test.
• Speaker Test
Use this test to make sure the console speaker is fully operational. The speaker will
ascend and then descend through the musical scale.
2. Press [ENTER] to pause the test. Press [CLEAR] to end the test.
Keypad Test
Perform this test if you are having trouble entering data into the console. If you cannot
enter the DIAGNOSTIC mode due to an inoperable keypad, replace the console.
2. The display LEOs will light up in an L-shaped formation, representing the

keypad matrix. Pressing a button on either the exercise program keypad or the
function keypad will light an LED within the outline on the display that
corresponds to that button's position on the console.
3. Firmly press each button. If the LED corresponding to the button you pushed
does not light up, the keypad is bad and the console should be replaced.
Page 31
•
• CONSOLE DIAGNOSTIC TESTS
4. Press [CLEAR] to test the LED and then end the test.
Speed Test
Use this test to verify the electronic speed control routines of the console. You will need
to briefly exercise on the machine for this test.
2. The console will be set at a certain speed. The alternator speed, in RPM, is
displayed on the text bar as "Target" and a single column of lights will light up on
the display.
3. Begin exercising. As the stairs rotate, the text bar will alternately show the
actual RPM and the target RPM.
4. Press [CLEAR] to return to the DIAGNOSTIC mode.
•
Software Revision Level Test
This test allows you to check the version number of the software installed in the console.
2. The software version number will be scrolled across the text bar. The console will
automatically return to the DIAGNOSTIC mode.
3. Contact the Customer Service Department for the most current software revision
update.
Page 32
•
• SPEED CONTROL PROBLEMS
If you have problems with erratic speed control while operating the machine, the cause
may be either electrical or mechanical in nature. You will have to remove the side covers
to conduct most of these tests.
1. Inspect the Poly- Vbelt for proper tension and excessive wear. A loose belt will
cause excessive noise and wear. The machine will run sluggishly if the belt is
too tight.
2. Replace a worn or frayed Poly-V belt. Aqjust the belt so that there is 1/10"
(OJ cm) deflection at a point midway between the alternator and transmission
pulleys with fingertip pressure (refer to Figure 14).
3. Check for proper wire connections on the alternator, relay assembly circuit
board, and load resistor (refer to Wiring Diagram 3).
4. Replace or exchange the console with another console you know is good and
•
retest the machine.
B. Check the relay assembly circuit board while the console is in the ATIRACT mode. You
will need an assistant to complete the test of the relay assembly circuit board.
1. Remove the right side cover. Locate the relay assembly circuit board located
just inside the frame, midway between the top and bottom steps (refer to
Wiring Diagram #1). There are three red indicator lights along the bottom edge
of the circuit board. They are labeled, from top to bottom: Field, Power, and
Relay. Ensure the black and white wire power connector (labeled J2 on the
relay assembly circuit board) is securely connected to the relay assembly circuit
board (refer to Wiring Diagram 2).
2. If the Power light is lit, go to step #3. If it is not, perform the tests as described
in step C-5 of the "Console Fails to Power Up" section.
3. The relay indicator light should be lit. If it is lit, proceed to step #5. If it is not,
use ajumper wire on the relay assembly circuit board. Jump the silver tabs #1
(labeled RLY/RED) and #5 (labeled GND/BLK) (refer to Wiring Diagram 3). The
relay indicator should light up. If it does, go to step #4. If the relay indicator
does not light up, the relay assembly ciruit board must be replaced. Replace the
relay assembly circuit board and retest the machine.
Page 33
•
4. You must check the cable assembly for continuity if the relay indicator lit up
when youjumped tabs #1 and #5.
a. Unplug the main cable from the position labeled J1 on the relay assembly
circuit board. Disconnect the console cable from the back of the console.
Set your multimeter to the continuity check mode; on most meters, this
will be the resistance or ohms setting.
b. Place one lead of the multimeter on pin #1 at the console connector end of
the console cable (refer to Wiring Diagram 1). Place the other lead on pin
#1 at the end of the main cable you disconnected from the relay assembly
circuit board. You will get a reading of near zero ohms if there is
continuity in the cable assembly.
c. Check continuity in both ends of the main cable assembly at pin #5.
d. If there is no continuity in the cable assembly at either pin, replace the

cable assembly and retest. Ifthere is continuity in the cable assembly at
•
both pins and the relay resistor indicator is not lit, the console is inoper-
able and must be replaced .
5. Have your assistant step on the staircase (leave the console in the ATIRACT
mode) while you check the field indicator light. It should be flickering. If it is
and you still have a speed control problem, go to step #6.
If it is not flickering, ensure the following: the console cable is connected to the
console; the console/main cable connection is secure; the connector at position
Jl on the relay assembly circuit board is securely connected; that there is
continuity in the cable assembly. To check for continuity:
a. Unplug the connector at position J1 on the relay assembly circuit board.

Disconnect the console cable from the back of the console. Set your
multimeter to the continuity check mode; on most meters this will be the
resistance or ohms setting.
b. Place one lead of the mi Itimeter on pin #2 at the console connector end of
the console cable (refer to Wiring Diagram 1). Place the other lead on pin
#2 at the end of the main cable you disconnected form the relay assembly
circuit board. You will get a reading of near zero ohms ifthere is continuity
in the cable assembly.
c. If there is no continuity in the cable assembly, replace it and retest. If
Page 34
•
there is continuity in the cable assembly and the field indicator light is
still not flickering, contact the Customer Service Department for further
assistance.
6. If the field indicator was flickering while your assistant was on the machine
and you still have a problem with speed control, you need to test the alternator
(refer to Wiring Diagram 3).
a. Disconnect the white wire (labeled positive output on the alternator) and
the brown wire (labeled "Field " on the alternator). Use ajumper wire to
jump the Field and positive output terminals of the alternator.
b. Have your assistant step onto the staircase. Does the staircase slow
down? If it does not, you need to replace the alternator. If the staircase
does slow down, contact the Customer Service Department for further
assistance.
C. Replace or exchange the alternator with another alternator you know is good and
•
retest the machine.
D. Test the load resistor as outlined in the "Load Resistor Test" section of this Manual.
E. If the speed control problem still exists, contact the Customer Service Department for
further assistance.
Page 35
•
• LOAD RESISTOR TEST
The alternators are heavy-duty models designed to withstand the rigors of commercial
use. One possible reason for repeated failure is an inoperable load resistor. To test the
load resistor:
1. Unplug the AC power cord from the AC wall outlet.
2. Locate the load resistor mounted to the framejust under the staircase.
3. Disconnect one black wire from the resistor (refer to Wiring Diagram 3).
4. Set your multimeter for Rx 1 or the lowest available resistance range. If you have an
analog multimeter, touch the two leads together and acjjust the meter for a zero
reading.
5. Place one lead on Tab A and one lead on Tab 5 of the relay assembly circuit board
(refer to Wiring Diagram 2). You should get a reading of approximately 1.0 ohm or
less.
•
6. Replace the load resistor if the reading is out of range and retest the new load
resistor.
7. Reconnect the AC power cord and reinstall the right side cover.
Page 36
• TROUBLESHOOTING THE DRIVE TRAIN
If you hear a grinding or clicking noise, or experience excessive vibration during exercise,
or if the steps are not functioning properly, you probably have a problem in the drive train.
Attempt to isolate the problem area by performing the following tests in precisely the
order listed below. Refer to the "Parts Removal and Replacement" Section of this Manual
for all disassembly and assembly instructions.
1. Unplug the power supply fromthe AC wall outlet and remove the side covers.
.&WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE THE SIDE
COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS WHILE ANYONE'S
HANDS ARE INSIDE THE MACHINE.
2. Check the condition and the tension level of the Poly-V belt. Replace the belt if it is
excessively worn.
a. Aqjust the tension level so that you can deflect either side of the belt 1/10"
(OJ cm) at the center between the alternator and the transmission pulleys
• b.
(refer to Figure 14). Noise can be generated by a belt that is too tight or too
loose.
If the noise is still present, remove the Poly-V belt and work the revolving
staircase. Note: With the Poly-V belt removed, the staircase will rotate very
quickly.
c. If the noise no longer exists, replace the alternator.
3. Check the condition of the alternator.
a. Remove the Poly-V belt.
b. Spin the alternator pulley with your fingers. It should spin freely and remain
spinning for at least one and one-half revolutions. If is does not spin as it
should, the bearings may be bad and the alternator should be replaced .
c. If the pulley does spin freely, check the alternator for noise, roughness, or the
presence of black powder inside the alternator or near the outside of the case.
If any of these conditions exist, the brushes may be bad and the alternator
should be replaced .
d. Reconnect the Poly-V belt and aqjust the belt tension.
Page 37
•
4. Check the drive chain mechanism. Rotate the stairs and look for chain links that do
not flex as the chain travels over the sprockets. If the links are frozen or sticking,
replace the chain.
5. Check the step chain assemblies.
a. Have your assistant slowly exercise on the machine. Observe the staircase. If
the staircase moves to the left or right during exercise, ensure the set screws
in the bearing aqjusters are tight.
b. Rotate the stairs and look for chain links that do not flex as the chain travels
over the sproCkets. If the links are frozen or sticking, replace the chain.
6. Check the condition of the upper and lower sprocket assemblies. Replace the
sprocket assembly if it is worn excessively, has broken teeth, or if it is bent.
7. Check the aIignment of the upper and the lower sprocket assembl ies. The outside
face of the upper and lower sprockets should be 1-11/16" (4.3 cm) from the outside
•
edge of the left frame rail. Loosen the nuts on the pillow block bearing collars and
tighten or loosen the bearing aqjuster set screws until the distance to both sprockets
is correct. Tighten the pillow block bearing nuts and verify the distance.
8. Check the step assembly.
a. Rotate the steps and check the hinges, step shafts, washers, and bearings
(refer to Figure 16) for wear, corrosion and lack of lubrication. Replace any
worn parts.
b. Ensure the nuts at each step shaft end are tight.
9. Check the transmission.
a. Remove the drive chain and the Poly-V belt. Turn the transmission sprocket.
It should turn freely without binding or releasing. If it does not, replace the
transmission.
b. Check for a 19:1 gear ratio between the two shafts.
Place a mark from the transmission sprocket straight across to the

transmission casing and a mark from the alternator pUlley straight across
to the alternator casing.
Page 38
•
Rotate the transmission sprocket through one full revolution while
observing the alternator pulley. The alternator pUlley should rotate through
19 full revolutions.
Replace the transmission if you detect roughness while rotating the

sprocket or if the alternator pulley does not rotate 19 revolutions.
10. Reinstall all parts, ensuring the Poly-V belt is properly tensioned. Clean and lubricate
the drive and step chains before reinstalling them.
Page 39
•
• PARTS REMOVAL AND REPLACEMENT
COVERS
& WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE THE SIDE
COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS WHILE ANYONE'S
HANDS ARE INSIDE THE MACHINE.
There are five covers on the machine: two side covers, a back cover, a bottom cover, and a
top cover. The side covers overlap the top cover. The side covers must be removed before
the top cover. The side covers must also be removed before the bottom cover can be
removed.
All covers are held in place with reusable plastic fasteners (refer to Figure 12 for
their location). To remove the fasteners, slide either end of the fastener removal tool
under the edge of the pin head (refer to Figure 13). The pin should not be removed. Pull
the cover away from the frame. Do NOT use the fastener removal tool or any other sharp
tool to pry out the fastener base because you may damage the covers.
• To reinstall the fastener, insert the base of the fastener through the cover and into
the frame. When the base is in place, push the pin in all the way to secure the fastener.
Side Covers
1. Remove the 14 fasteners on each side cover.
2. Pull the cover away from the frame.
Top Cover
1. Remove both side covers.
2. Lift the top cover away from the frame.
3. Set the top cover in place. Secure the side covers to complete reinstallation.
Back Cover
1. Remove the 10 fasteners and lift the back cover away from the frame.
Page 40
•
2. Align the holes in the frame and the back cover. Secure the back cover with the 10
fasteners.
Bottom Cover
1. Remove both side covers to gain access to the bottom cover fasteners.
2. Disconnect the DC power cable.
3. Remove the six fasteners and lift the bottom cover away from the frame.
4. Reinstall the bottom cover, then the two side covers. Remember to connect the DC
power cable.
CONSOLE
1. Locate the mounting knobs on the back of the console (refer to Figure 10).
2. Loosen and remove the four mounting knobs.
• 3.
4.
5.
Unscrew the console cable from the back of the console.
To reinstall the console, connect the console cabJe to the back of the console.
Align the four console holes with the four holes on the console mount.
6. Insert and tighten a mounting knob into each hole.
7. There is no need to overtighten the knobs.
POLY-V BELT
AWARNING
THE POLY-V BELT MUST BE ADJUSTED SO THAT THE CENTER OF EITHER SIDE CAN BE
DEFLECTED 1/10" (0.3 CM) FROM ITS CENTER LINE WITH FINGERTIP PRESSURE. A TIGHT
BELT WILL CAUSE SLOW AND SLUGGISH OPERATION; A LOOSE BELT WILL CAUSE
EXCESSIVE NOISE AND BELT WEAR.
1. Remove the left side cover.
2. Loosen the adjustment bolt that mounts the alternator to the slotted alternator
brace.
Page 41
•
3. Pivot the alternator forward to loosen the belt. Remove the Poly-V belt.
4. When reinstalling the POly-V belt, pivot the alternator forward or back as necessary
to allow 1/10" (0.3 em) of play on either side of the belt (refer to Figure 14).
5. Tighten the adjustment bolt and verify the POly-V belt tension.
DRIVE CHAIN
2. Remove the retaining clip and retaining plate from the drive chain master link. Do not
remove the master link from the drive chain yet.
3. Push up on the idler arm with one hand to relieve the tension on the drive chain
(refer to Figure 15). Remove the master link from one end of the drive chain and
remove the drive chain from the sprockets.
4. Reinstall the drive chain by reversing the steps.
• STEP ASSEMBLY
1.
2.
Remove the right and the left side covers.
Rotate the stairs until the step you want to remove is positioned in the middle of the
staircase.
3. Loosen and remove the nut from one end of the step shaft on both the upper and the
lower hinges of that step (refer to Figure 16). You may be required to place another
5/16"-18 nut on the opposite end of the step shaft to remove the nut.
4. Remove the bearing and the washer from each step shaft.
5. Grasp the opposite step retaining nut with pliers or locking pliers. Pull the step shaft
out of the upper and lower step hinges. Be careful to not lose the washer located
between the step and the modified link.
6. Reinstall the step by reversing the procedures.
Page 42
• ,.'
".
.JiJ ';
"fI"
'.... -
STEP CHAIN ASSEMBLY
1. Remove the right and the left side covers.
2. Rotate the stairs to position the step chain master link on the lower span of the chain
3. Remove the master link.
4. Using the old master link, connect the new chain assembly to the lower half of the
old chain assembly.
5. Remove the nut from the step shaft above the master link (refer to Figure 16). You
may be required to place another 5/16"-18 nut on the opposite end of the step shaft
to remove the nut.
6. Remove the bearing, outer step shaft washer and the modified link of the old step
chain assembly from the step shaft.
• 7.
8.
Place the modified link of the new step chain assembly on the step shaft. Reinstall
the outer step shaft washer, bearing and nut.
Rotate the steps until the next step shaft is in approximately the same place as the
previous step shaft.
9. Repeat steps 6-8 until the new chain assembly is installed on the remaining step
shafts.
10. Remove the master link connecting the old chain with the new chain.
11. Connect the new chain assembly together with the master link. It may be necessary
to reduce the chain tension to install the master link. This step is accomplished by:
Count and write down the number of exposed threads on the top bearing
aqjuster set screw for a reference when you reassemble the parts (refer to
Figure 17).
Loosen the nuts on the pillow block bearing housing.
Loosen the bearing aqjustment set screw until the chain tension level is
relieved to a point where the master link may be reconnected.
Page 43
•
Tighten the adjustment screw until the same number of threads are exposed.
Tighten the nuts on the pillow block bearing housing.
12. You should consider replacing the opposite step chain so that both chains will wear
equally.
13. Reassemble the machine in reverse order.
UPPER (AND LOWER) SPROCKET ASSEMBLY
1. Remove the right and left side covers.
2. Remove all of the steps.
3. Remove the drive chain if you are removing the upper sprocket assembly.
4. Remove the right and left step chain assemblies.
• 5.
6.
Count and write down the number of exposed threads on the bearing adjuster set
screws on both sides of the machine for a reference when you reassemble the parts
Loosen the aqjustment screws until the tips of the screws are flush with the inside
face of the bearing aqjusters.
7. Have an assistant support the sprocket assembly. Loosen and remove the nuts on
the pillOW block bearing housing.
8. Remove the sprocket assembly from the frame.
9. Loosen the two set screws on both of the pillow block bearing collars and remove
the pillow block bearings from the sprocket axle.
10. To reinstall the sprocket assembly: .,. ,

Slide the pillow block bearings on both ends of the sprocket axle. Do not
tighten the set screw on the pillow block bearing collars yet.
Place the bearing adjusters and the sprocket assembly onto the frame and start
the pillow block bearing housing nuts onto the frame.
Page 44
•
Slide the sprocket assembly toward the front of the machine while tightening
pillow block bearing housing nuts.
Align the sprocket assembly. The outside face of the left sprocket should be
1-11 /16" (4.3 cm) from the outside edge of the left frame rail. Move the
sprocket axle within the pillow block bearing collar as needed to get the correct
distance.
When the distance is correct, tighten the pillow block bearing collar set screw
on the left and right side of the machine.
Loosen the pillow block bearing housing nuts slightly. Tighten the bearing
adjuster set screws until the exact number of threads are exposed (refer to your
notes taken earlier). Tighten the pillow block bearing housing nuts.
Check the alignment of the other sprocket at this time. If the distance from the
outside edge of the left frame rail to the outside face of the sprocket is not
, -11 /16" (4.3 cm), loosen the set screws on the left and right side pillow block
•
bearing collars and aqjust the axle. Tighten the pillow block bearing collar set
screws on the machine.
11. Complete the reassembly of the machine by performing steps 1-4 in reverse order.
CABLE ASSEMBLY
1. Remove the right side cover.
2. Remove the console and unscrew the console cable from the back of the console.
Unplug the plastic connectors at the console cable: main cablejunction.
3. Hold the console connector and pUll the console cable up and out of the handrails.
4. Reinstall the console cable by pushing the white plastic connector end down through
the handrails. Do not connect the console and the main cables.
5. Remove the main cable from the wire saddles (refer to Wiring Diagram 1).
6. Unplug the white plastic connector labeled J1 on the relay assembly circuit board
(refer to Wiring Diagram 2).
7. Cut the four tyraps on the vertical support.
Page 45
•
8. Remove the main cable from the frame.
9. To reinstall, place the main cable into the wire saddles. Reattach the cable to the
vertical support with four tyraps.
10. Plug the white plastic connector of the main cable into the relay assembly circuit
board at the spot labeled J 1.
11. Screw the console cable into the receptacle in the back of the console. Reattach the
console to the handrail mount. Plug the connectors together at the main cable:
console cablejunction.
12. Reinstall the right side cover. Reconnect the DC power cable.
TRANSMISSION ASSEMBLY
•
2. Remove the step positioned in the middle of the staircase.
3. Remove the drive chain.
4. Remove the Poly-V belt. Inspect the belt for wear. Replace the belt if it is cracked,
worn, torn, or cut.
5. Remove the transmission bracket by loosening and removing the mounting hardware
on the alternator and the transmission (refer to Figure 18).
6. Remove the transmission brace by loosening and removing the mounting hardware
from the transmission and the frame.
7. Support the transmission while loosening and removing the four transmission
mounting bolts. Remove the transmission and rubber pad from the frame.
8. Reinstall the transmission by reversing the removal procedures.
9. Ensure the Poly-V belt is tensioned according to the procedures outlined in the "Poly-
V Belt" section of this Manual.
Page 46
•
ALTERNATOR ASSEMBLY
3. Remove the wiring from the alternator terminals, noting the origin and color of the
wires removed from each terminal.
4. Remove the Poly-V belt. Inspect the belt for wear. Replace the belt if it is cracked,
worn, torn, or cut.
5. Remove the alternator adjustment bolt (refer to Figure 18).
6. Remove the nut, bolt and mounting hardware from the alternator bracket. Remove
the alternator from the frame.
7. Reinstall the alternator by reversing the removal procedures. Be sure to verify the
wiring connections (refer to Wiring Diagram 3).
• 8. Ensure the POly-V belt is tensioned according to the procedures outl ined in the "Poly-
V Belt" section of this Manual.
RELAYIRESISTOR ASSEMBLY
3. Remove the wiring from the alternator terminals, noting the origin and color of the
wires that are removed from each terminal.
4. Unplug the main cable connector from the J1 position on the relay circuit board (refer
to Wiring Diagram 2).
5. Unplug the power connector from the J2 position on the relay circuit board.
6. Loosen and remove the four mounting bolts and remove the relay/resistor assembly
from the frame (refer to Wiring Diagram 1).
7. Reinstall the relay/resistor assembly in the reverse order. Verify the wiring connec-
tions before attaching the side cover (refer to Wiring Diagram 3).
Page 47
•
• GROUNDING INSTRUCTIONS
The machine must be grounded. If it should malfunction or break down, grounding
provides the path of least resistance for the electric current, thereby reducing the risk of
electric shock. This machine is equipped with a cord having an equipment-grounding
conductor and a grounding plug that looks like the plug illustrated in sketch A in Figure 9
below. International machines may vary. It must be plugged into an appropriate outlet that
is properly installed and grounded in accordance with all local codes and ordinances.
&.OANGER
IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING CONNECTOR CAN RESULT
IN THE RISK OF ELECTRIC SHOCK. CHECK WITH A QUALIFIED ELECTRICIAN OR
SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE MACHINE IS PROPERLY
GROUNDED. DO NOT MODIFY THE PLUG PROVIDED WITH THIS MACHINE.
IF IT WILL NOT FIT THE AVAILABLE OUTLET, HAVE A PROPER OUTLET
INSTALLED BY A QUALIFIED ELECTRICIAN.
A temporary adapter that looks like the adapter illustrated in sketches Band C
may be used to connect this plug to a two-pole receptacle as shown in sketch Bif 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 lug extending from the adapter must be connected to a permanent ground such as
a properly grounded outlet box cover. Whenever an adapter is used, it must be held in
place by a metal screw.
3-prong. grounded
outlet box
CAl j ~
Grounding Pin~
91182-A
2/%l/t6 1-4
Figure 9: Grounding System
Page 48
•
• FCC 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 fre-
quency 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 may cause harmful interference in which case the user will be required to
correct the interference at his own expense.
&.WARNING
CHANGES OR MODIFICATIONS TO EQUIPMENT NOT EXPRESSLY APPROVED BY STAIRMASTER®
SPORTS/MEDICAL PRODUCTS, INC. COULD VOID THE USER'S AUTHORITY TO OPERATE THIS
EQUIPMENT.
CANADIAN DOC CLASS ACOMPLIANCE
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.
La present appareil numerique ne depasse pas les limites etablies pour les bruits
radioelectriques applicables aux appareils numeriques de la Class A prescrites dans les
reglements sur Ie brouillage radioelectrique edicte par Ie Ministere des Communications
du Canada .
Page 49
•
• HOW TO ORDER PARTS
If you need assistance, please have both the serial number of your machine and the
date of purchase available when you contact the appropriate StairMaster® Sports/
Medical Products, Inc. office listed below.
OFFICES IN THE UNITED STATES
CORPORATE HEADQUARTERS CUSTOMER SERVICE

12421 Willows Road NE, Suite 100 12421 Willows Road NE, Suite 100
Kirkland, WA 98034 Kirkland, WA 98034
(800) 635-2936 or (206) 823-1825 (800) 331-3578
FAX: (206) 823-9490 FAX: (206) 814-0601
INTERNATIONAL OFFICES AND DISTRIBUTORS
INTERNATIONAL DIVISION CANADA: TRC SPORTS/MEDICAL

(206) 823-1825 PRODUCTS
FAX: (206) 820-7505 (800) 668-4857
•
(905) 712-2719
FAX: (905) 712-3722
EUROPE: HEADQUARTERS JAPAN: SENOH CORPORATION

41-91-827-3801 81-3-5479-6711
FAX: 41-91-827-8902 FAX: 81-3-5479-6703
GERMANY: HEADQUARTERS AUSTRALIA: THE FITNESS

49-2204/610-27 GENERATION PTY LTD
FAX: 49-2204/628-90 61 -3/800-2122
FAX: 61-3/800-2722
U.K.: HEADQUARTERS SWEDEN/NORWAY: NORDIC GYM

44-1908/221-323 PRODUCTION
FAX: 44-1908/223-162 46-278/242-10
FAX: 46-278/159-66
FRANCE/BELGI UM/HOLLAND:
MONDIAL S.P.R.L.
32-82/226775
FAX: 32-82/226854
COUNTRIES NOT LISTED

(206) 823-1825
FAX: (206) 820-7505
Page 50
•
• ... ~ .... . '.:'
FIGURES
.' ... '.
.
Figure 10'. Installation Diagram
• Console
See o.tOl'
Finishing Wosher• .. x
.. x
o Finishing
I
CoP.
e Scr... 2X
15 Nut. 2X
.~
i118.3-A
,..
Page 51
•
• FIGURES
Figure 11: Parts Needing Periodic Lubrication
Bearin g Plate
• Drive Chain
9 11 84-A
4/18/95 1=20
Page 52
•
• FIGURES
Figure 12: Side Cover and Handrail Assemblies
Cover
12 Fastener,
44x
• Side
91185-A
9/06/95 1- 40
Page 53
•
• FIGURES
Figure 13: Cover Fasteners
Cover fastener
Frame
Fastener Removal Tool
•
r Fastener Removal Tool
9 1261-A
9/29/94 1-2
Page 54
•
• FIGURES
Figure 14: Poly-V Belt Tension
. 10" (.25 em)

.10" (.25 Alternator
• Transm iss ion

o
o
o
91186-A
2/02/95 1=4
Page 55
•
• FIGURES
Figure 15: Drive Chain Assembly
17 Drive Cha in
9 11 87-A
4/ 26/95 1= 14
Page 56
•
• FIGURES
Figure 16: Step Assembly
Wave Washer, 10X
•
~Step Shaft
91188-A
4/18/95 1-20
Page 57
•
• FIGURES
Figure 17: Step Chain and Sprocket Assemblies
Bearing Adjuster
/
Flo Washer, 2X 59 Screw
y loc
61 Pillow Block Bearing
/
Upper Sprocket
Assemb ly
Section, 2X
• Plate
4X
ut, 4X
Lower Sprocke
Assemb ly
91189-A
5/01/95 1-20
Page 58
•
• FIGURES
Figure 18: Transmission and Alternator Assemblies
y loc ut
•
Transm iss ion
Flat 44 Transm iss ion

Bracket
Alternator Ad j ustment Bo lt
Screw, 2X 75
Flat Washe
91191-A
9/06/95 1= 16
Page 59
•
• WIRING DIAGRAMS
Wiring Diagram 1
Conso le Cab le
DETAIL Assemb ly
Grom m et
•
Main Cab le
Assemb ly
51 Wire Sadd le. 9X
9 11 92-A
9/06/95 1=20
Page 60
•
• WIRING DIAGRAMS
Wiring Diagram 2
Power Connector Socket Ma in Cab le Socket
(BLACK W-2)l - - - - - --(BROWN W-3)

- - - - (BLUE W-4)
01
o 0
z
c..?
,(WHITE W-5)
I-
---.J
<r:
+
000
•
0 o
0
000
:::0 LJ ~
RES FLD ALT RLY FLD TACH + GRD
o
rrl 0 rrl NO NC C RED BRN BLU WHT BLK GRN
r ~ r \)-4
» rrl 0 Q~
-< :::0 Z-i
-i
(/)
91260-A
4/18/95 1.'
Page 61
•
• WIRING DIAGRAMS
Wiring Diagram 3
W-5 Re lay/Res istor Assemb ly

Pos it ive
Output
Assemb ly
(wh ite)
o
o
o
o
• Ma in Cab le Assemb ly
9 1 193-A
4/ 18/95 1- 12
Page 62
•
• KEY TO FIGURES AND WIRING DIAGRAMS
10 Number Description Part Number
1 Console assembly 24742 -
2 Leq levelers 20017
3 Flat washer, 1/4" 22038
4 Grommet 24663
5 Handrail, riqht 22946-03
Handrail, left 22947-03 .-
6 Back panel 21304

7 Bottom panel 21305 -
9 Top panel 21308 -
10 Screw, #6 x 3/8 24208
11 Internal tooth washer, #8 22109
12 Rivet 22086
13 Screw, #8 - 32 x 3/8 22134
14 Nut, #8 - 32 22110
15 Nut, 3/8 - 16, Low profile 24643
16 Side panel assembly, left (with decal) 24298 -
Side panel assembly, riqht (with decal) 24299 -
•
17 Drive chain, #40 x 41 .5" 23257
18 Idler sorocket 20007
19 Screw, 1/2 - 13 x 2" 22043
20 Nyloc nut, 1/2 - 13 22042
21 Idler arm sprinq 20054
22 Transmission 20001
23 12T sprocket 23427
24 Idler arm 20693
25 #40 Master link 20157
26 Step tread 20541
27 Step assembly 10378-03
28 '- Nut 5/16 - 24 22063
29 Bearinq 23082
30 Flat washer, 5/16" 22128
31 Step shaft 20762
32 Modified link 20548
33 Pushnut 20508
34 Wave washer 20528
35 Alternator assembly 21164
36 Alternator spacer 20114
37 Nvloc nut 1/2 - 13 22092
38 Screw, 1/2 - 13 x 3 3/4" 22090 -
39 Screw 1/4 - 20 x .63" 22028
40 Lock washer, 1/4" 22027
Page 63
•
10 Number Description Part Number
41 Rubber pad 20808
42 Poly-V belt 20202
43 Transmission brace 10059
44 Transmission bracket 10860 -
45 Screw, 5/16 - 18 x1 1/4" 22146
46 Flat washer, 5/16" 22075
47 Screw, 1/4 - 20 x1.0" 22026
48 Nyloc nut, 1/4 - 20 22036
49 Large pulley 20208
50 Set screw 22037
51 Wire saddle 23792
52 7 Main power harness assembly 22957
54 - Console cable assembly 22428
55
56
- Relay assembly
Relay/resistor assembly
23544
23546
-
57 Bearinq adiuster 10037 -
58 Screw, 3/8 - 16 x1" 22039
•
59 Flat washer, 3/8" 22030
60 Nvloc nut 3/8 - 16 22029
61 Pillow block bearinq 20101 -
62 Chain section, #40 x51/2" 20532
63 Chain section, #40 x11 1/2" 20531
64 Lower sprocket assembly 10205-03
65 Upper sprocket assembly 23424-03
66 Bearinq plate 20682
67 Screw, 5/16 - 18 xl " 22071
68 Nyloc nut, 5/16 - 18 22032
69 Screw, 5/16 - 24 x3/8" 22072
70 Finishinq Cap 22323
71 Console mounting knob 24677
72 Finishing washer, 3/8" 22213
73 Screw 3/8 - 16 x3.25 22097
74 Fastener removal tool 23853
75 Screw, 1/4 - 20 x1.25 22164
76 Grommet, 1/4" 10 22435
77 ShouIder washer, .38 10 22191
78 Grommet, 7/8" 15034
79
80
- Main cable assemblv
Tyrap
22956
20473
81 Screw 3/8 - 16 x3.5 22937
Page 64
•
ID Number Description Part Number
82 Screw, 3/8 - 16 x 1.75 24640
Power Supply, PS-7 24683
Power Supply. IPS-3 14072 -
Touch-up kit 21211 -
Page 65
•
STEPMILL 7000
®
OWNER’S MANUAL
®
© 1996, 2001 StairMaster Health & Fitness Products, Inc.
Kirkland, WA 98034
(800) 635-2936
(425) 823-1825
Fax (425) 823-9490
www.stairmaster.com
P/N 22440 - B
© 1996, 2001 StairMaster Health & Fitness Products, Inc. StairMaster and Stepmill are registered trademarks
or trademarks of StairMaster Health & Fitness Products, Inc. in the United States and/or other countries.
All other trademarks are trademarks of their respective companies. StairMaster is a Rutledge Capital company.
Page iii
A FEW REASONS WHY MORE HEALTH AND FITNESS
FACILITIES CHOOSE STAIRMASTER® EQUIPMENT
OUTSTANDING QUALITY
Equipment you can depend upon, week after week, for heavy commercial use –
instead of a sign that says "out of order."
EXCEPTIONAL PERFORMANCE
Generates exceptional customer satisfaction – allowing you to retain existing
club members and attract new ones.
IMMEDIATE CUSTOMER RECOGNITION

An excellent first impression is critical to attracting new club members to your
facility. The StairMaster name on your equipment reinforces your club's reputa-
tion for quality and effectiveness.
NATIONAL SALES SUPPORT
StairMaster is one of the few organizations that maintains its own fully staffed
national sales organization. These individuals will bend over backwards to make
sure you are satisfied.
FACTORY-TRAINED SERVICE NETWORK
The StairMaster service staff is on call to quickly address any product
concerns. Service is just a toll-free call away.
AFFORDABLE LEASING PROGRAM
We help you make the most of your money, with several types of leasing
programs available.
FACILITY PLANNING
Cordless units. Space-efficient designs. Exciting facility layout plans. Our staff
works closely with you to maximize the equipment layout of your club or fitness
area.
MARKETING SUPPORT
Lots of sizzle – with StairMaster product catalogs, posters, promotional kits, and
seasonal promotions.
Page iv
A FULL LINE OF EXCEPTIONAL PRODUCTS
STAIRCLIMBERS ELLIPTICAL STRIDING SYSTEMS
The Best in the Industry The New StairMaster FreeRunner
Our popular FreeClimber® stairclimber Introducing the StairMaster

line now offers you 5 different models FreeRunner™ 5400 ESS – a
to choose from. These models include revolutionary new design that allows
the new fully featured FreeClimber you to vary your stride length from 10'’
4600 PT and the cordless FreeClimber to 40." Not only does this unique VSL
4600 CL, along with the FreeClimber feature accommodate all users, it also
4400 PT and the cordless FreeClimber provides enhanced lower-body
4400 CL with Polar® Heart Rate conditioning – with greater
Monitor, and the cost-efficient involvement of the glutes,
FreeClimber 4200 PT – all designed quadriceps, and hamstrings.
especially for health clubs.
For total-body conditioning, club
Other StairMaster® stairclimbers members will love the fact they can
include the Stepmill® 7000 PT – for the use the handles on the StairMaster
most challenging stairclimbing FreeRunner 5400 for an effective
workout – as well as the legendary upper-body workout. These handles
StairMaster 4000 PT®. can also be easily disengaged to rest
on the side of the machine.
Page v
TREADMILLS STRATUS EXERCISE BIKES
The Highest Quality New Models & Prices
In response to many requests we At last – a cordless line of variable
received from our customers for a high resistance exercise bikes that not only
quality treadmill, StairMaster® has provide the exciting workout programs
selected the Quinton® treadmill as a that StairMaster is famous for, but are
new addition to our product line – with designed with such uncompromising
four different models to choose from – attention to every biomechanical
the ClubTrack® 510, the ClubTrack® 510 detail, they offer you extraordinary
Plus, the ClubTrack® 612 and the safety and comfort.
ClubTrack® 612 Plus. Only Quinton
could match the StairMaster reputa- Introducing Stratus exercise bikes – a
tion for maximum performance, new cordless variable resistance line
durability, and product safety. from StairMaster – that are available
with either an upright or recumbent
seat. Just like StairMaster's legend-
ary stairclimbers, Stratus exercise
bikes are very different from other
models – simply because they feel so
good to use.
Page vi
CROSSROBICS® 1650 LE STAIRMASTER STRENGTH
The Ultimate Exercise Machine SYSTEMS
Feel the Difference
The StairMaster® Crossrobics
product is an innovative machine Club members will feel the difference
that combines aerobic exercise with the first time they use StairMaster®
a weight stack for strength condition- strength equipment – designed to
ing. Available only from StairMaster, work the way your body works.
the Crossrobics machine provides the
ultimate workout. Consisting of the Gravitron® 2000 AT
and the new Arcuate® and Linear™
The Crossrobics 1650 LE features an lines, StairMaster offers you 17
easy-to-operate, first-time user option different strength training products to
and a quick-start feature. choose from. To ensure the highest
quality, all StairMaster strength
equipment is now manufactured at our
own factory in Tulsa, Oklahoma.
Page vii
WARRANTY
This is to certify that the StairMaster® Stepmill® 7000 PT exercise system is
warranted by StairMaster Health & Fitness Products, Inc. to be free of all defects in
materials and workmanship. This warranty does not apply to any defect caused by
negligence, misuse, accident, alteration, improper maintenance, or an “act of God”.
This warranty is non-transferable from the original owner.
Stepmill exercise system should fail to operate properly (except any accessories ), contact
our Customer Service Department to report the problem. When calling, please be
prepared to provide the customer service representative with the following information:
• Your name, customer number, shipping address, and telephone number

• The model and serial number of the inoperable machine
• The date(s) of purchase for the inoperable machine(s)
• Your billing address
been established:
• Please call our Customer Service Department to receive a return

materials authorization prior to shipment.
• StairMaster Health & Fitness Products, Inc. will incur all freight
charges for warranty parts ordered for a machine that is less than 45
days old. The parts will be shipped to you via an overnight courier.*
• You are responsible for freight charges on warranty parts for
machines that are more than 45 days old. You will not be responsible
for the return shipment of the inoperable parts.
• Some inoperable warranty parts must be promptly returned to our
Customer Service Department. We will pay the shipping cost for the
inoperable warranty parts. Detailed instructions are included with
each warranty replacement part.
StairMaster Health & Fitness Products, Inc. neither makes, assumes nor
is void if parts other than those provided by StairMaster Health & Fitness Products, Inc.
are used.
Page viii
PREFACE
The StairMaster® Stepmill® 7000 PT exercise system is a safe, functional, and
effective exercise modality for developing aerobic fitness and increasing the
strength of the major muscle groups of the lower body. It is designed for use by
individuals of all ages and fitness levels. Your purchase of this machine is a
positive affirmation of your commitment to use the best available methods for
enhancing your functional fitness capabilities. In order to derive optimal benefits
from your machine, you should read this manual thoroughly and adhere closely to
the instructions.

Stepmill 7000 PT exercise system works, this manual contains two major
sections. The first section provides an explanation of how the machine should be
used to achieve maximum results. The second section offers instructions and
advice on how to properly maintain your machine. The “Appendix” contains
additional information for the owner.
Throughout this Manual, whenever you are required to enter information into
the console, the console keypad keystrokes are enclosed in [ ]. The names of the
buttons and special console operational modes are shown in capital letters. For
example, your machine is ready for use when the console is in the ATTRACT
mode. You are then required to press the [MANUAL] button to start the MANUAL
exercise program.
The StairMaster Stepmill 7000 PT exercise system is a vertical climbing

machine with a rotating staircase which provides an aerobic workout equivalent
to climbing stairs, without the impact loads and skeletal trauma common to
most aerobic activities. Regular use of the Stepmill 7000 PT exercise system
strengthens and conditions the heart and the following lower body muscle
groups: gluteals, quadriceps, hamstrings, and calf muscles.
Page ix
CONTENTS
SAFETY GUIDELINES ......................................................................................... 1
INSTALLATION INSTRUCTIONS ........................................................................ 3
BASIC OPERATING INSTRUCTIONS ................................................................ 6

General Guidelines for Safe Operation ........................................................... 6
Your First Workout on the StairMaster® Stepmill® 7000 PT
Exercise System ............................................................................................. 6
The ATTRACT Mode ...................................................................................... 6
Basic Instructions for First-Time Users .......................................................... 7
End-of-Workout Summary ............................................................................. 8
POLAR® HEART RATE .......................................................................................... 9
7000 PT CONSOLE .............................................................................................. 10

The Text Bar ................................................................................................... 10
The Display .................................................................................................... 10
The Function Keypad ..................................................................................... 11
The Exercise Program Keypad ....................................................................... 12
The Quick Start Option .................................................................................. 13
The Submaximal Fitness Test ........................................................................ 13
The Stair Climb Test for Fire Fighters ............................................................ 14
Turning the CPAT Stair Climb Test on .................................................... 15
Turning the NYCFD Stair Climb Test on ................................................. 15
Preset Exercise Programs .............................................................................. 16
The Jackpot Option ....................................................................................... 16
Turning the Jackpot Option On and Off ................................................. 17
Customizing Your Exercise Program .............................................................. 17
Programming Your Workout ................................................................... 17
Using a Custom Program ....................................................................... 18
Customizing The Text Bar Scrolling Message ............................................... 18
Editing the Scrolling Message ............................................................... 19
Changing the Console Units and Prompt Language ...................................... 20
Console Codes ............................................................................................... 20
Page x
CONTENTS
MAINTENANCE INSTRUCTIONS ................................................................... 22
Helpful Hints ................................................................................................. 22
Tool List ......................................................................................................... 22
Maintenance Records ................................................................................. 22
Initial Service ................................................................................................ 23
Preventative maintenance ........................................................................... 23
Cleaning and Inspecting ....................................................................... 23
Lubrication ............................................................................................. 24
TROUBLESHOOTING ........................................................................................ 27
General Troubleshooting Guidelines ........................................................... 27
Troubleshooting the Electrical System ....................................................... 27
The Console Fails to Power Up ............................................................ 27
Console Diagnostics Tests ........................................................................... 30
The Display Test .................................................................................... 30
The Speaker Test .................................................................................. 30
The Keypad Test ................................................................................... 31
The Speed Test ..................................................................................... 31
The Software Revision Level Test ....................................................... 31
The Polar® Heart Rate Test ................................................................. 32
Speed Control Problems .............................................................................. 33
Load Resistor Test ........................................................................................ 37
Troubleshooting the Drive Train .................................................................. 38
PARTS REMOVAL AND REPLACEMENT ....................................................... 41

Covers ........................................................................................................... 41
Side Covers ........................................................................................... 41
Top Cover............................................................................................... 41
Back Cover ............................................................................................ 42
Bottom Cover ........................................................................................ 42
Console ......................................................................................................... 42
Poly-V Belt .................................................................................................... 43
Drive Chain ................................................................................................... 43
Step Assembly .............................................................................................. 44
Step Chain Assembly ................................................................................... 45
Upper (and Lower) Sprocket Assembly ....................................................... 47
Cable Assembly ............................................................................................ 49
Page xi
CONTENTS
Transmission Assembly ................................................................................ 50
Alternator Assembly ..................................................................................... 51
Relay/Resistor Assembly ............................................................................. 52
GROUNDING INSTRUCTIONS ......................................................................... 54
FCC COMPLIANCE ............................................................................................. 55
CANADIAN DOC CLASS A COMPLIANCE ..................................................... 55
APPENDICES
Important Phone Numbers ........................................................................... 56
Figures 1 - 7 .................................................................................................. 57
LIST OF TABLES
StairMaster® 7000 PT Exercise System ....................................................... 3
Table 2. Fitness Rating Norms ..................................................................... 14
Table 3. Character Codes for the Scrolling Message ................................ 19
Table 4. Console Codes ............................................................................... 21
Table 5. Recommended Preventive Maintenance Schedule .................... 27
Figure 1: Side Cover and Handrail Assemblies........................................... 57
Figure 2: Cover Fasteners ............................................................................ 58
Figure 3: Step Assembly .............................................................................. 59
Figure 4: Step Chain and Sprocket Assemblies ......................................... 60
Figure 5: Transmission and Alternator Assemblies .................................... 61
Figure 6: Wiring Diagram ............................................................................. 62
Figure 7: Relay Board ................................................................................... 63
Page xii
SAFETY GUIDELINES
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:
! This symbol appearing throughout this manual means

Attention! Be Alert! Your safety is involved.
The following definitions apply to the words “Danger” and “Warning”

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

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

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

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

persons:
1. The external power supply should always be unplugged from the AC

wall outlet before removing or installing parts. Never make adjustments or
repairs while an exercise program is in progress.
2. Close supervision is necessary whenever the machine is used by, on, 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 with the side covers removed.
Page 1
SAFETY GUIDELINES
4. Use this machine only for its intended use as described in this manual. Do
not use attachments or accessories other than those provided by
StairMaster® Health & Fitness Products, Inc.
5. Do not use the external power supply if it has a damaged cord or plug, if it is
not working properly, if it has been dropped or damaged, or dropped into
water. Contact our Customer Service Department at (800) 331-3578 to
replace a damaged part. International customers should contact their
local distributor; refer to the Appendix for the appropriate phone number.
6. Connect the external power supply to a properly grounded AC wall outlet;

refer to the "Grounding Instructions" section of this manual. Keep
all cords away from heated surfaces.
10. To disconnect the external power supply, remove the plug from the AC wall
outlet.
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 should be replaced immediately or the equipment should
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.
SAVE THESE INSTRUCTIONS
Page 2
INSTALLATION INSTRUCTIONS
Before leaving the manufacturing facility in Tulsa, Oklahoma, your
StairMaster® Stepmill® 7000 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.
The dimensions of the machine are listed in Table 1. 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 white function
keypad is located on the right side of the console.

Power Supply Specifications:

The machine requires minor assembly before operation. You will need a pair of
diagonal cutters or a pair of heavy-duty scissors. The Stepmill 7000 PT exercise
system must be placed on a solid, level floor near an AC wall outlet. A minimum
ceiling height of 9 feet (2.8 meters) and a doorway width of 29 inches (74 cm) is
required.
2. Have an assistant tilt the machine forward until the wheels are off the
floor. Make sure the assistant can support the machine so you can remove
the temporary wheels.
Page 3
3. Remove the clevis pin from each wheel (See Drawing Below) and remove
the wheels from the frame.
Rivnut
4 X 21767
Outside of Machine
Clevis Pin Nut
2 X 24439 4 X 22154
Leg Leveler
Cotter Pin 4 X 20017
2 X 20047 Transport Wheel
2 x 20036
4. Help your assistant lower the machine to the floor. Install and adjust the
leg levelers as necessary to level the machine (see Above).
panel.
• Mount both handrails onto the frame as shown in Figure 6.
• Push the console cable assembly through the grommet in the frame
and connect it to the main cable assembly (refer to Figure 6).
• Reinstall the back panel and go to step #6.
6. Unwrap the power supply assembly from the console and connect the DC
power cable from the power supply to the power connector located on the
bottom cover.
7. Place the power supply on the floor near an AC wall outlet. To reduce the
hazard of electrical shock, place the power supply in a location away from
the machine and away from exposure to perspiration. You should not
place your power supply on a carpet because it may overheat.
8. 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® Health & Fitness Products, Inc. before
proceeding any further.
Page 4
! WARNING
PROPERLY GROUNDED.
9. Connect the AC power cord to the AC wall outlet. Refer to the “Grounding
Instructions” section of the Manual if the AC wall outlet does not
10. Watch the console. It should produce an audible sound when plugged
in and then display a simulated EKG signal after the software revision
level scrolling message. If it does not, unplug the power supply and then
plug it back in. If the sound and/or the display are still not present, contact
the Customer Service Department at (800) 331-3578. International
customers should call their local distributor; refer to the Appendix for the
11. When the console displays the simulated EKG signal, your Stepmill®
7000 PT exercise system is in the ATTRACT mode.
12. The console is set at the manufacturing facility to English language

prompts and English units. While the console is in the ATTRACT mode, you
can set the console for foreign language prompts or metric units. To
change the language of the prompts, press [+ INCREASE], [7], [4], [2], [4],
[ENTER]. Press the code number corresponding to the desired language
according to Table 4 and then [ENTER].
To change the console to metric units, press [+ INCREASE], [9], [7], [6],
[0], [ENTER]. Press [1], [ENTER] to set the console to metric units. Press [0],
[ENTER] to set the console to English units.
13. Custom-length DC cables and other accessories are available. Refer to the
Appendix for the phone number of the office nearest you.
Page 5
BASIC OPERATING INSTRUCTIONS
! WARNING
THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE
MACHINE. YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAME GUIDELINES.
YOU SHOULD MAKE THIS MANUAL AVAILABLE TO ALL USERS.
1. Obtain a complete physical examination from your medical doctor and

enlist a health/fitness professional’s aid in developing an exercise
program suitable for your current health status.
2. When working out for the first time, use the MANUAL exercise program at
the lower speeds until you feel comfortable and capable of faster speeds.
3. The speed and duration of your exercise program should always be

subject to how you feel. Never permit peer pressure to exceed your
personal judgment while exercising.
4. Overweight or severely deconditioned individuals should be particularly

5. Although all equipment manufactured by StairMaster Health & Fitness

prior to shipment, proper installation and regular maintenance are
owner.
YOUR FIRST WORKOUT ON THE STAIRMASTER® STEPMILL® 7000 PT

EXERCISE SYSTEM
The ATTRACT Mode
The StairMaster Stepmill 7000 PT exercise system is ready to use when the
console is in the inactive or ATTRACT mode. The ATTRACT mode is denoted by a
Page 6
simulated EKG signal in the display or a scrolling message in the text bar.
You can program your own message to scroll across the text bar. Refer to the
“Customizing the Text Bar Scrolling Message” section of this Manual. A diagram
of the console is shown in Figure 1.
1. Warm up with light calisthenics and easy stretching exercises for at least
five minutes before beginning your exercise program.
! WARNING
IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN,
EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF BREATH,
STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU SHOULD CONSULT
YOUR MEDICAL DOCTOR IMMEDIATELY.
2. Hold onto the handrails and step up onto the staircase. Stand up straight.
The steps will rotate slowly.
3. Select the MANUAL exercise program so you can control the pace of your
first workout and get used to the exercise motion.
4. Press [MANUAL] and then [ENTER]. The console will return to the
ATTRACT mode if you do not press [ENTER] within ten seconds.
5. The console will prompt you to enter your body weight. Enter your weight
in pounds (or kilograms if the console is set up for metric units). Correct
entry errors by pressing [CLEAR] before you press [ENTER].
increments between five and 60 minutes. Press [1], [0], [ENTER] to exercise
for ten minutes.
7. Step up with one foot at a time. Try to stay towards the top of the
staircase. When you begin to exercise, the console will display a single
flashing light in the first interval.
Page 7
8. The flashing column shows which interval is active. Everything to the left
of the active interval indicates completed intervals. As you become
comfortable with the exercise motion, try pressing [+ INCREASE] and
[- DECREASE] to adjust your speed.
9. Relax as much as possible while exercising and maintain an erect posture.

Use the handrails for balance. Don’t lock your elbows or lean on the
console. Supporting your weight will reduce the exercise intensity and the
console will overestimate the number of calories burned.
10. Select a speed (or intensity level) that allows you to step towards the top
of the staircase. Faster is not always better. Exercise at a level that is
consistent with your fitness level.
11. You can stop and rest for up to two minutes at any time during the
workout. To rest, simply stop climbing and step down to the floor or press
[START/STOP] (the stairs will continue to rotate very slowly). To resume
your workout, press [YES] and begin climbing. To return the console to the
ATTRACT mode, press [NO] during the pause. The console returns to the
ATTRACT mode if you rest longer than two minutes or take two rest
breaks.
12. When you have completed the last interval of the workout, the machine
will slow down to the slowest speed. Step off the machine and cool down
by walking or stretching for at least five minutes.
End-of-Workout Summary
1. At the end of your workout, the message “GOAL ATTAINED” will scroll
across the text bar. The total number of Calories you burned during your
workout is then displayed for ten seconds. During this time, you may press
any of the function keypad buttons to receive feedback concerning your
workout. Refer to the “Function Keypad” section of this manual for
details.
2. The summary information is stored in the console memory until the next
person begins an exercise program. Press [WORKOUT STATS] to recall the
summary for the last workout.
Page 8
POLAR® HEART RATE
The StairMaster® Stepmill® 7000 PT features 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 transmitter belt senses your
heart beat and sends a signal to the receiver. Your heart rate, in beats per
minute, is shown on the console text bar.
Before you put the transmitter belt on, wet the two contact 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 transmitter 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. The word "PULSE", your heart rate in beats per minute, and
a pulsing heart icon are displayed in the text bar.
If you display a statistic other than heart rate during your workout, you can
return to heart rate by pressing the white [0] key. Heart rate is part of the
workout stats scrolling display. Average heart rate is shown at the end of your
workout. If you wear a transmitter strap during the Fit Test, the average heart
rate at the end of each stage is automatically used when estimating maximum
aerobic capacity.
Page 9
7000 PT CONSOLE
The StairMaster® Stepmill® 7000 PT exercise system console is divided into four
sections: the text bar, display, the function keypad, and the exercise program
keypad (refer to Drawing below).
THE TEXT BAR
Information regarding workout statistics and data entry is displayed or scrolled

across the text bar. A countdown timer is located directly above the words
"Interval Time". The timer shows the number of seconds remaining in the current
interval.
THE DISPLAY
For all exercise program options except MANUAL, a profile of the selected
program appears in the display. A flashing interval column indicates where on
the profile you are currently exercising (the active interval). The flashing, active
column moves left to right across the display area as you complete each interval.
Page 10
7000 PT CONSOLE
THE FUNCTION KEYPAD
The function keypad is located on the right side of the console. Eight of the
buttons have two pieces of information on them — a number and a workout
statistic. Before the exercise program begins, the numbers are used to enter data
in response to the console prompts. During the exercise program, the buttons are
used to display workout statistics on the text bar.
Time. Displays the elapsed time of your workout, in minutes and

seconds.
Floors. Shows the total number of floors you have climbed. There are
16 eight-inch steps per floor.
Distance. Provides the equivalent horizontal distance you would

have traveled if you used the same amount of energy. There are 48
floors per horizontal mile.
Watts. Displays the power output in watts (746 watts = 1 horse

power). Since power is a rate, watts will not accumulate over time.
During a workout, this key displays the power output at that moment.
Average power is shown for the workout summary.
Intensity Level. Shows the current level between 1 (the easiest) and
20 (the hardest). Shows the number of lights in the MANUAL program
between 1 and 14.
METs. Gives you the relative energy cost of exercise. MET stands for
multiples of the resting metabolic rate. While you are sitting quietly,
your body consumes oxygen at the rate of about 3.5 milliliters per
kilogram of body mass per minute. When you exercise, your body
needs more oxygen in order to function. For example, exercising at 10
METs requires ten times the resting rate of oxygen consumption, or
about 35 milliliters per kilogram per minute. During a workout, this key
shows the current MET level. During the workout summary, the
average MET level is displayed.
Calories. Provides a running total of the number of Calories burned

during a workout.
Page 11
7000 PT CONSOLE
Step Rate. Indicates the climbing speed in steps per minute. It is
based on an average eight-inch step.
Enter. Confirms workout selections and stores the information used

by the console to calculate workout statistics.
Zero. Press this key to see your heart rate during your workout. Press
it during the workout summary to see your average heart rate.
Clear. Erases information from the console memory if pressed before

[ENTER].
[+ INCREASE] / [- DECREASE]. Increases or decreases the

intensity level.
Yes/No. Respond to console prompts.
Start/Stop. If pressed while the console is in the ATTRACT mode, the

console will display the "SELECT A PROGRAM" prompt.
THE EXERCISE PROGRAM KEYPAD
The purple exercise keypad is located below the display and to the left of the
function keypad. While the console is in the ATTRACT mode, press one of the
exercise program keys to preview the desired workout.
The sequence of prompts for the preset exercise programs is slightly

different than the sequence described earlier for the MANUAL program. After
you press one of the exercise program buttons, the exercise program profile is
scrolled across the display.
After the profile is scrolled, the prompts are:
• “PRESS ENTER KEY TO SELECT”

• “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.
Page 12
7000 PT CONSOLE
• “ENTER TIME 5 - 60” -- select the workout duration in one minute
increments from five to 60.
The Quick Start Option
You can quickly start any workout by first pressing one of the purple exercise
program keys and then pressing [ENTER] twice. You do not have to enter any
other information. The length of the workout is set automatically and varies with
the program. Quick starting MANUAL gives you a 15 minute workout. The
preprogrammed workouts last five minutes for every thirty intervals. So, a 60
interval program will last 10 minutes. All workout stats displayed at the end of a
workout are based on a 175 lb. body weight. The Submaximal Fitness Test does
not have a quick start option.
The Submaximal Fitness Test
The Fit Test is a program that estimates your maximal aerobic capacity based on
your heart rate response to submaximal exercise. Start the Fit Test by pressing
[FIT TEST] while the console is in the ATTRACT mode. You will be prompted to
enter your age and gender after a short message is scrolled across the display.
Once you have entered the required information, you will step at the rate of
43 steps per minute for three minutes. At the end of the three minutes, you will
need to enter your heart rate. The console will prompt you to find your pulse; use
the artery below your thumb in your wrist or the artery in the side of your neck.
Start counting the beats when the console prompts you—the first beat you feel
is zero and then one and so on. Enter the number of beats you counted in the ten
seconds. If you are using a heart rate monitor, enter your heart rate directly into
the console.
You will continue to exercise for three minute bouts of increasing intensity
until you reach a point where you have entered two heart rate responses
between 19 and 25 counts (115-150 beats per minute). The test typically lasts
from nine to 15 minutes.
Page 13
7000 PT CONSOLE
At the end of the Fit Test, your results scroll across the display area. Prior to
a three-minute cool down, your estimated aerobic capacity, expressed in
metabolic equivalents (METs) , is shown in the display area. Next, your results
will be compared to normative values for others of your age and gender. These
normative values are based on values developed by the world renowned exercise
physiologist, Dr. Per Olaf Åstrand, and are shown in Table 2. Your results are
stored in the console until the next person starts an exercise program. Press
[WORKOUT STATS] to review your results.
Table 2. Fitness Rating Norms
○
○
○
○
Rating Low Fair Average Above Average Superior
○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
○
○
Gender/Age
○
○
○
○
○
○
○
○
○
Men
○
○
○
○
○
○
○
○
20-29 <10.8 11.1-12.3 12.6-16.0 16.3-19.7 20.0+
○
○
○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
30-39 <9.7 10.0-11.1 11.4-14.6 14.8-18.3 18.6+

○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
○
○
○
40-49 <8.6 8.8-10.0 10.3-13.4 13.7-17.1 17.4+

○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
○
○
50-59 <7.1 7.4-8.8 9.1-12.3 12.6-15.7 16.0+
○
○
○
○
○
○
60-69 <6.0 6.3-7.4 7.7-11.1 11.4-14.0 14.3+

○
○
○
○
○
○
○
○
○
Women
○
○
○
○
○
○
○
20-29 <8.0 8.3-9.7 10.0-13.7 14.0-16.8 17.1+

○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
30-39 <7.7 8.0-9.4 9.7-13.4 13.7-16.6 16.8+

○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
○
○
○
40-49 <7.1 7.4-8.8 9.1-12.8 13.1-16.0 16.3+

○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
○
50-59 <6.0 6.3-7.7 8.0-11.7 12.0-14.0 14.3+

○
○
○
○
○
○
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
○
60-69 <4.8 5.1-6.3 6.6-10.3 10.6-12.6 12.8+

○
○
○
○
○
○
○
○
○
The Stair Climb Test for Fire Fighters
The StairMaster® Stepmill® 7000 PT is routinely used to assess the aerobic

fitness levels of fire fighter candidates in full protective gear carrying heavy
equipment. The Candidate's Physical Ability Test (CPAT), approved by the
International Association of Fire Fighters (IAFF) and reviewed by the U.S. Justice
Department, requires each candidate to step on the 7000 PT at a predetermined
stepping pace for a specific period of time. There are two fire fighter specific
Stair Climb Test programs in the 7000 PT console. 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).
Page 14
7000 PT CONSOLE
CPAT Stair Climb Test: The first phase is a warm-up interval at intensity
level three and lasts twenty-seconds. At the end of the first interval the
time counter will reset to zero. The second phase continues through nine
twenty-second intervals at intensity level four. The CPAT Stair Climb Test
has a total of ten intervals and lasts for three minutes, twenty seconds.
NYCFD Stair Climb Test: The first phase is a warm-up interval at

intensity level three and lasts sixty-seconds. You will then have a sixty-
second rest period. At the end of the rest period the time counter will reset
to zero. The second phase is at intensity level four and lasts for five
minutes, twelve seconds.
Turning on the CPAT Stair Climb Test
1. The console must be in the ATTRACT mode (noted by a simulated EKG

signal in the console display). Press [+INCREASE], [7], [7], [0], [8], [ENTER],
[1], [ENTER] on the console keypad. Make sure to press in the middle of
each key and be aware that the corresponding numbers will not show in
the console display.
2. Start the Stair Climb Test by pressing [FIT TEST] on the console program
key pad.
Note: The steps will start to rotate immediately

after pressing [FIT TEST].
Turning on the NYCFD Stair Climb Test
1. The console must be in the ATTRACT mode (noted by a simulated EKG

signal in the console display). Press [+INCREASE], [7], [7], [0], [8], [ENTER],
[2], [ENTER] on the console keypad. Make sure to press in the middle of
each key and be aware that the corresponding numbers will not show in
the console display.
2. Start the Stair Climb Test by pressing [FIT TEST] on the console program
key pad.
Note: The steps will start to rotate immediately

after pressing [FIT TEST].
Page 15
7000 PT CONSOLE
Preset Exercise Programs
There are seven preset exercise programs. The exercise speed during the
programs varies automatically over 14 increments within each of the 20
different intensity levels. Varying the intensity of an exercise program does
not change the profile shown on the display. Change the intensity level of
your workout by pressing [+ INCREASE] or [- DECREASE]. For each level, the aver-
age energy cost of all programs is about the same.
The FAT BURNER program is a 60 interval workout designed for people

just starting a weight control program.
The FAT BURNER PLUS program is similar but has 90 intervals. It is

meant for the longer workouts you will need as your fitness level
increases.
The STEADY PACE and ROLLING HILLS programs are 30 interval

workouts with gradual speed changes. They are geared for those
who are just starting to exercise or for those who need an easy day of
recovery exercise.
The AEROBIC TRAINING program is a 60 interval workout with

slightly more varied speed changes. It is ideal for those long, slow
workouts to increase your aerobic capacity.
The CROSS COUNTRY and SPEED TRAINING programs are 90

interval workouts with lots of speed changes
THE JACKPOT OPTION
When you finish your workout, a “GOAL ATTAINED” message is normally

displayed in the text bar. This message may be replaced by a Native American
casino style slot machine. When the wheels of the slots stop turning, the console
display will spell out either “YOU WIN” or “THE END”. The odds of winning may
be programmed anywhere from 1-in-1 to 1-in-999. The computer will then
randomly select a winner and display “YOU WIN”, otherwise it will
display “THE END.” Workout statistics are shown, as usual, after the jackpot
message.
Page 16
7000 PT CONSOLE
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.
Laws or ordinances in your area may govern the use of this option.
Turning On and Off the Jackpot Option
1. The console must be in the ATTRACT mode. Press [INCREASE],

[7707], [ENTER].
2. The prompt “ENTER ODDS” will appear in the console display. Enter the
numeric odds you have selected, between 1 and 999.
3. The jackpot results are saved in the console memory until the next
workout is started. Press [WORKOUT STATS] to review the results.
4. Program 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.
CUSTOMIZING YOUR EXERCISE PROGRAM
The StairMaster® Stepmill® 7000 PT exercise system console has enough

memory space for nine exercise programs of your design. Only the exercise
profile is saved, your body weight, the intensity level and the workout time must
be entered each time the custom program is used.
Programming Your Workout
1. The console must be in the ATTRACT mode. Press [+ INCREASE], [1], [6],
[5], [0], [ENTER]. Press the exercise program keypad button that you want
to assign to your custom program.
2. If you select an exercise program keypad button that is already
Page 17
7000 PT CONSOLE
programmed, the profile will appear; it can be modified or completely
rewritten. If the exercise program keypad button was not previously
programmed, you will see a single row of dots along the bottom of the
display.
3. The flashing dot or column indicates which interval can be modified. Press
the [+ INCREASE] or [- DECREASE] to make the column taller or shorter.
Press [ENTER] to move one column to the right and [CLEAR] to move one
column to the left.
4. When all of the intervals are correctly programmed, press [YES] to save
the profile. Press [START/STOP] to abort the programming process without
saving the profile.
Using a Custom Program
1. Press [- DECREASE] and the exercise program keypad button you assigned
to the custom program.
2. Enter your body weight, the intensity level and the workout time in
response to the prompts.
CUSTOMIZING THE TEXT BAR SCROLLING MESSAGE
The message that scrolls across the text bar during the ATTRACT mode can be
replaced with a message of your choice. The console accepts messages up to
128 characters in length, including spaces. To program your message:
1. Encode your message using the character codes listed in Table 3.
2. While the console is in the ATTRACT mode, press [+ INCREASE], [7], [6], [0],
[7], [ENTER].
3. Enter the two-digit code for each letter of your message. The letter
will appear in the text bar as you press the second digit of each code.
Do not press [ENTER] between the code numbers. If you make a mistake
while entering the codes, press [CLEAR] to erase the last character
entered.
Page 18
7000 PT CONSOLE
4. For example, to program the message “EXERCISE IS FUN”, press
[+ INCREASE], [7], [6], [0], [7], [ENTER]. Then press [1], [5], [3], [4], [1], [5], [2],
[8], [1], [3], [1], [9], [2], [9], [1], [5], [1], [0], [1], [9], [2], [9], [1], [0], [1], [6], [3], [1],
[2], [4], [ENTER]. At that point, your message will begin scrolling.
Table 3. Character Codes for the Scrolling Message
Character Code Character Code Character Code
0 00 M 23 Í 46
1 01 N 24 À 47
2 02 O 25 Î 48
3 03 P 26 È 49
4 04 Q 27 Â 50
5 05 R 28 Ç 51
6 06 S 29 Ê 52
7 07 T 30 ¿ 53
8 08 U 31 + 54
9 09 V 32 $ 55
SPACE 10 W 33 . 56
A 11 X 34 , 57
B 12 Y 35 % 58
C 13 Z 36 ? 59
D 14 Ä 37 ´ 60
E 15 Ü 38 ! 61
F 16 Ö 39 - 62
G 17 ß 40 # 63
H 18 Å 41 : 64
I 19 Á 42 ; 65
J 20 Ó 43 ) 66
K 21 É 44 ( 67
L 22 Ñ 45 / 68
Editing the Scrolling Message
1. While the console is in the ATTRACT mode, press [+ INCREASE], [7], [6], [0],
[7], [ENTER] to display the first character of the message onto the text bar.
2. Press [+ INCREASE] or [- DECREASE] to scroll through the message

character-by- character.
Page 19
7000 PT CONSOLE
3. Press [CLEAR] to delete the last character displayed on the text bar. Press
[ENTER] to end the editing process.
4. To edit multiple characters at one time, press [9], [9], [ENTER] to erase all of
the characters to the right of the last character displayed on the text bar.
5. To erase the entire message, press [+ INCREASE], [1], [0], [5], [ENTER] while
in the ATTRACT mode.
6. The edited message will scroll across the text bar. If you have erased the
entire message, the text bar area will be blank during the ATTRACT mode.
7. Press [+ INCREASE], [2], [1], [2], [3], [ENTER] to display the default scrolling
8. Press [+ INCREASE], [2], [1], [2], [1], [ENTER] to display your custom scrolling
CONSOLE CODES
The console codes and the corresponding functions are listed in Table 4.
Press [+ INCREASE] before pressing the code's number keys, and then
press [ENTER]. Some codes, like the one to change the language of the
console prompts, have options that require you to press a number and then
[ENTER] to select that number.
CHANGING THE CONSOLE UNITS AND PROMPT LANGUAGE
The console is set at the manufacturing facility to English language prompts

and English units. While the console is in the ATTRACT mode, you can set the
console for foreign language prompts or metric units.
1. To change the prompt language, press [+ INCREASE], [7], [4], [2], [4],
[ENTER]. Press the code number for the desired language and then press
[ENTER].
2. To change the console to metric units, press [+ INCREASE], [9], [7], [6],
[0], [ENTER] and then [1]. Press [+ INCREASE], [9], [7], [6], [0], [ENTER], [0]
to change back to English units.
Page 20
7000 PT CONSOLE
Table 4. Console Codes
Code Function
105 Clears the custom programmed scrolling message

107 Activates the Diagnostic mode
0 Display test
1 Speaker test
2 Keypad test
3 Speed test
4 Software revision test
108 Heart rate software test
1650 Programs a custom workout
2121 Turns on the custom scrolling message
2123 Turns off the custom scrolling message

7424 Changes the language of the console prompts
7607 Turns on the custom message option
99 Text bar scrolling message editing function
7703 Displays machine usage information
7704 Turns the console speaker on or off
0 Turns the speaker on
1 Turns the speaker off
7705 Turns the Heart Rate feature on or off
0 Turns the Heart Rate feature on
1 Turns the Heart Rate feature off
7708 Changes the Fitness Test options
0 Turns the Submaximal Fitness Test on
1 Turns the CPAT Stair Climb Test on
2 Turns the NYCFD Stair Climb Test on
9760 Change the units displayed by the console
0 Changes the console to English units
1 Changes the console to metric units
9766 Change the software version
0 Changes to 4400 PT software
1 Changes to 7000 PT software
97405 Changes the maximum workout time
52475 Resets time limit to 60 minutes
Page 21
HELPFUL HINTS
Read all maintenance instructions thoroughly before beginning work. In some

cases, an assistant is required to perform the necessary tasks. 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 compo-
nents shall be replaced immediately or the equipment shall be put out of use
until it is repaired.
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. For example, the power supply is
plugged into the connector near the bottom of the right side cover.
TOOL LIST
• Standard screwdriver • Phillips screwdriver

• Combination wrenches (sizes 7/16 - 3/4") • Adjustable wrench
• Combination pliers • External snap ring pliers
• Shop goggles or other eye protection • Wire stripper/crimper tool
• Allen wrench set (sizes 5/64 - 1/4") • Volt-ohm meter (multimeter)
• Socket set or nut driver set • Locking pliers
(sizes 1/4 - 3/4" in 1/16" increments)
MAINTENANCE RECORDS
The console will keep track of the following data on machine usage:
• The number of hours the power supply was turned on.

• The number of hours the machine was in use.
• The total number of floors climbed.
• The number of exercise programs started.
• The hours of MANUAL use.
To display the data, press [+ INCREASE], [7], [7], [0], [3], [ENTER] while the
console is in the ATTRACT mode. The console will display the data in the
sequence listed above. The machine may show a few hours of use due to testing
at the manufacturing facility.
Page 22
INITIAL SERVICE
Upon receiving your machine, use a soft, clean towel to wipe off the dust which
may have accumulated during shipping. Your new machine will require minor
assembly. Refer to the “Installation Instructions” section of this Manual for
details.
The procedures for performing the recommended preventive maintenance

are summarized in Table 5. The schedule is based on normal usage in a commer-
cial health club environment; adjust the schedule to meet actual machine usage.
Refer to the “Parts Removal and Replacement” section of
this Manual for all disassembly and assembly instructions.
! WARNING
1. DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANER

ON THE CONSOLE. Clean the console daily with a water-dampened cloth
and wipe dry after cleaning.
2. Clean the exterior of your Stepmill® 7000 PT exercise system daily with
soap and water.
unpainted surfaces. Repair the damaged area with a rust-inhibitor paint.
Contact our Customer Service Department at (800) 331-3578 to order a
touch-up paint kit.
Page 23
6. Inspect the Poly-V belt for excessive wear during the weekly cleaning.
Adjust the belt tension if necessary.
Lubrication
The StairMaster® Stepmill® 7000 PT exercise system has six components that
require periodic lubrication: the drive chain, the two step chains, the two bearing
plates and the step hinges. These parts are shown in the figure below. You will
need to remove the side covers to lubricate the chains and the bearing plates.
1. Place a protective mat on the floor while you are lubricating your
machine. A rubber floor mat is available from StairMaster Health & Fitness
Products, Inc.
Page 24
2. Lubricate the chains monthly with 30W motor oil. Drip the oil onto the
chain plates and rollers. Let the oil soak in for a few minutes and then
remove any excess oil with a dry rag.
3. Remove the chains every three months to thoroughly clean and lubricate
them. Use a mild degreaser and a stiff brush to remove dirt and corrosion
from the chain. Read the instructions on the degreaser container before
using.
4. Clean each bearing plate and lubricate it with multipurpose grease every
three months. The plate is lubricated to reduce friction when the step
shaft bearings roll over the plate.
5. Once per month, use 30W motor oil or brush light bearing grease into the
step hinges to lubricate the hinges and to prevent corrosion. Wipe off all
excess lubricant.
! WARNING
TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE
THE STEP AREA IS FREE OF GREASE OR OIL. WIPE ANY
EXCESS OIL OFF THE MACHINE SURFACES.
Page 25
RECOMENDED
ACTION
Exterior Soap &

Clean Daily N/A
Surfaces water
Inspect and Weekly or

Poly-V Belt adjust if after 70 hours N/A N/A
necessary of use
Monthly or
30W motor
oil
Assembly Quarterly or
Clean and Mild 30W motor
after 900
lubricate degreaser oil
hours of use
Weekly or
30W motor
Lubricate after 70 hours N/A
oil
of use
Drive Chain
Quarterly or
after 900
hours of use
Monthly or
30W motor
oil
hours of use
Quarterly or
Bearing Clean and Clean, dry Multipurpose
after 900
Plate lubricate rag grease
hours of use
Page 26
TROUBLESHOOTING
This section outlines several tests to systematically identify and isolate the
cause of problems in the electrical system and the drive train. This troubleshoot-
ing section is organized into four basic problem sections: Electrical System,
Console Diagnostics, Speed Control, and the Drive Train. The first step is to
identify the problem. Once you have identified the problem, perform all the tests
in exactly the same order as written. Refer to the “Parts Removal
and Replacement” section of this Manual for all disassembly and assembly
instructions. To order a replacement part, or to get help with the troubleshooting
process, contact our Customer Service Department at (800) 331-3578.
International customers should contact their local distributor or call
(425) 823-1825.
The electrical system consists of: the power supply, main cable, relay board, load
resistor, and the console. In order to identify the component that is causing the
problem, you must systematically test the system. You will need a volt-ohm
meter (multimeter) to conduct portions of the following procedures. The console
and power supply are not serviceable by the owner. If either of these parts are
inoperable, they must be replaced. Opening the console or the power supply will
void the warranty.
2. Is the indicator light lit on the power supply? If it is, proceed to step
#3. If the light is not on, go to step B.
3. Replace or exchange your console with a console you know is good

and retest the machine.
B. Verify AC power.

Page 27
2. Verify that the AC wall outlet is supplying the correct power in one of
two ways: a) Use an AC voltmeter to verify that the AC line voltage is
between 100 and 120 VAC (or between 220 and 240 VAC, if applicable)
at the AC wall outlet; or b) Plug in an alternate AC-powered device (a
lamp, for example). If the AC wall outlet is supplying the correct power,
proceed to step #3. If the voltage is outside the range or if the device
does not work when plugged into the AC wall outlet, consult an
electrician for further assistance and then retest the AC wall outlet.
3. Plug the AC power cord into the wall outlet and proceed to the next
section.
C. Verify DC power.
1. Make sure that the AC power cord is plugged in and that the AC wall
outlet is delivering the proper voltage.
2. The indicator light should be lit. If it is, proceed to step #3. If the
indicator light is still not lit, replace the power supply and test the new
power supply.
3. Disconnect the cable from the DC power connector located on the

bottom cover. Use a DC voltmeter to verify 12-19 VDC at the end of
the DC cable. Pin #1 is positive and pin #2 is negative. Proceed to step
#4 if the VDC is within the range. Replace the power supply if the VDC
is outside the range and test the new power supply.
4. Remove the right side cover. Reconnect the DC power cable to the
machine. Locate the relay/resistor circuit board located just inside the
frame, midway between the top and bottom steps (refer to Wiring
Diagram 1). There are three red indicator lights along the bottom edge
of the relay assembly circuit board. They are labeled, from top to
bottom: Field, Power, and Relay. Ensure the black and white wire
power connector (labeled J2 on the relay resistor circuit board) is
securely connected to the relay resistor circuit board.

Page 28
voltmeter to measure the VDC at the power connector. Hole #1
(the white wire) is positive and hole #2 (the black wire) is
negative. The reading should be between 12 and 19 VDC. If you
are not getting power to the connector, replace the power
connector assembly and retest.

reconnect it to the J2 position on the relay assembly circuit
board. Disconnect the main cable connector at the J1 position of
the relay assembly circuit board. Check the VDC reading at the
silver tabs on the relay assembly circuit board. Tab #4 (labelled +/
WHT) is positive and tab #5 (labelled GND/BLK) is negative (refer
to Wiring Diagram 2). You should get a reading between 12 and
19 VDC. If your reading is not within the range, replace the relay
assembly circuit board and retest.
VDC reading at the connector labeled position J1 on the relay
assembly circuit board. Pin #4 is positive and pin #5 is negative.
You should get a reading between 12 and 19 VDC. If your
reading is not within the range, replace the relay assembly circuit
board and retest.
d. If all of the above power tests produce VDC readings that are
within range and the Power indicator light is still not lit, the
Power indicator light is probably inoperable. Replace the relay
assembly circuit board, reconnect all wires, and retest.
5. Remove the console and disconnect the console cable. Use a DC

voltmeter to measure the VDC at pin #9 (positive) and pin #1 (nega-
tive) of the console cable connector. You should get a reading
between 12 and 19 VDC. If the reading is not within the range,
replace the cable assembly and retest.
6. If your console still does not power up, contact the Customer Service
Department at (800) 331-3578.
Page 29
CONSOLE DIAGNOSTIC TESTS
The following tests must be performed while the console is in the DIAGNOSTIC
mode. To activate the DIAGNOSTIC mode, press [+ INCREASE], [1], [0], [7],
[ENTER]. The numbers will not appear on the display area as you enter them. If
the console fails any test, the console should be replaced or exchanged. To return
to the ATTRACT mode, press either [CLEAR] or [START/STOP] while in the
DIAGNOSTIC mode.
THE DISPLAY TEST
Use this test if the console display or text bar exhibits blank spots during use.
This test checks for inoperable Light Emitting Diodes (LEDs) in the console
display and the text bar. If any LED will not light, replace the console.
2. All LEDs in the console display will flash on and off as a block.
3. Press [CLEAR] to end the test.
THE SPEAKER TEST
Use this test to make sure the console speaker is fully operational. The speaker
will ascend and then descend through the musical scale.
2. Press [ENTER] to pause the test. Press [CLEAR] to end the test.
THE KEYPAD TEST
Perform this test if you are having trouble entering data into the console. If you
cannot enter the DIAGNOSTIC mode due to an inoperable keypad, replace the
console.
2. The display LEDs will light up in an L-shaped formation, representing the

keypad matrix. Pressing a button on either the exercise program keypad or
Page 30
the function keypad will light an LED within the outline on the display that
corresponds to that button's position on the console.
3. Firmly press each button. If the LED corresponding to the button you
pushed does not light up, the keypad is bad and the console should be
replaced.
4. Press [CLEAR] to test the LED and then end the test.
THE SPEED TEST
Use this test to verify the electronic speed control routines of the console. You
will need to briefly exercise on the machine for this test.
2. The console will be set at a certain speed. The alternator speed, in RPM,
is displayed on the text bar as “Target” and a single column of lights will
light up on the display.
3. Begin exercising. As the stairs rotate, the text bar will alternately show the
actual RPM and the target RPM.
4. Press [CLEAR] to return to the DIAGNOSTIC mode.
THE SOFTWARE REVISION LEVEL TEST
This test allows you to check the version number of the software installed in the
console.
2. The software version number will be scrolled across the text bar. The
console will automatically return to the DIAGNOSTIC mode.
3. Contact the Customer Service Department for the most current software
revision update.
Page 31
THE POLAR® HEART RATE TEST
The Polar heart rate system is made up of the console, the heart rate receiver,
and the chest strap (available separately). You can test each component by
performing the following steps:
1. You will need to put a chest strap on in order to test the Polar heart
rate. Before you put the chest strap on, wet the two contact patches.
Secure the chest strap as high under your pectoral muscles (chest) as
is comfortable. The chest strap should fit snugly, comfortably, and
allow normal breathing.
2. While the console is in the ATTRACT mode (noted by a simulated EKG

signal in the console display), or at the “SELECT A WORKOUT” prompt,
press [+INCREASE], [1], [0], [8], [ENTER].
3. A flashing ♥ should be displayed in the console text bar. 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 in the text bar
then you have a problem with either the console, chest strap, or heart
rate receiver.
4. Test your chest strap with a machine that you know is working, or with
a heart rate watch that you know is working.
5. If possible, replace or exchange your console with a console (from

the same type of machine) that you know is working and retest the
machine.
6. 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.

800-331-3578.
Page 32
SPEED CONTROL PROBLEMS
If you have problems with erratic speed control while operating the machine, the
cause may be either electrical or mechanical in nature. You will have to remove
the side covers to conduct most of these tests.
1. Inspect the Poly- V belt for proper tension and excessive wear. A loose
belt will cause excessive noise and wear. The machine will run slug-
gishly if the belt is too tight.
2. Replace a worn or frayed Poly-V belt. Adjust the belt so that there is 1/
10" (0.3 cm) deflection at a point midway between the alternator and
transmission pulleys with fingertip pressure (See Drawing Below).
3. Check for proper wire connections on the alternator, relay assembly

circuit board, and load resistor (See Drawing Below).
Page 33
4. Replace or exchange the console with another console you know is
good and retest the machine.
B. Check the relay assembly circuit board while the console is in the
ATTRACT mode. You will need an assistant to complete the test of the
relay assembly circuit board.
1. Remove the right side cover. Locate the relay assembly circuit board
located just inside the frame, midway between the top and bottom
steps (refer to Wiring Diagram). There are three red indicator lights
along the bottom edge of the circuit board. They are labeled, from top
to bottom: Field, Power, and Relay. Ensure the black and white wire
power connector (labeled J2 on the relay assembly circuit board) is
securely connected to the relay assembly circuit board (refer to Figure
Below).
2. If the Power light is lit, go to step #3. If it is not, perform the tests as
described in step 4b - c of the “Console Fails to Power Up” section.
3. The relay indicator light should be lit. If it is lit, proceed to step #5. If it
is not, use a jumper wire on the relay assembly circuit board. Jump
the silver tabs #1 (labeled RLY/RED) and #5 (labeled GRD/BLK) (refer
Page 34
to Figure on page. 34). The relay indicator should light up. If it does, go
to step #4. If the relay indicator does not light up, the relay assembly
circuit board must be replaced. Replace the relay assembly circuit
board and retest the machine.
4. You must check the cable assembly for continuity if the relay indicator
lit up when you jumped tabs #1 and #5.
a. Unplug the main cable from the position labeled J1 on the relay
assembly circuit board. Disconnect the console cable from the
back of the console. Set your multimeter to the continuity check
mode; on most meters, this will be the resistance or ohms setting.
b. Place one lead of the multimeter on pin #1 at the console

connector end of the console cable (refer to Wiring Diagram).
Place the other lead on pin #1 at the end of the main cable you
disconnected from the relay assembly circuit board. You will get a
reading of near zero ohms if there is continuity in the cable
assembly.
c. Check continuity in both ends of the main cable assembly at pin

#5.
d. If there is no continuity in the cable assembly at either pin,

replace the cable assembly and retest. If there is continuity in the
cable assembly at both pins and the relay resistor indicator is not
lit, the console is inoperable and must be replaced.
5. Have your assistant step on the staircase (leave the console in the
ATTRACT mode) while you check the field indicator light. It should be
flickering. If it is and you still have a speed control problem, go to step
#6.
If it is not flickering, ensure the following: the console cable is

connected to the console; the console/main cable connection is
secure; the connector at position J1 on the relay assembly circuit
board is securely connected; that there is continuity in the cable
assembly. To check for continuity:
Page 35
a. Unplug the connector at position J1 on the relay assembly circuit
board. Disconnect the console cable from the back of the
console. Set your multimeter to the continuity check mode; on
most meters this will be the resistance or ohms setting.

connector end of the console cable. Place the other lead on pin
#2 at the end of the main cable you disconnected from the relay
assembly circuit board. You will get a reading of near zero ohms if
there is continuity in the cable assembly.
c. If there is no continuity in the cable assembly, replace it and

retest. If there is continuity in the cable assembly and the field
indicator light is still not flickering, contact the Customer Service
Department at (800) 331-3578 for further assistance.
6. If the field indicator was flickering while your assistant was on the
machine and you still have a problem with speed control, you need to
test the alternator.
a. Disconnect the white wire (labeled positive output on the

alternator) and the brown wire (labeled “Field” on the alternator).
Use a jumper wire to jump the Field and positive output terminals
of the alternator.
b. Have your assistant step onto the staircase. Does the staircase
slow down? If it does not, you need to replace the alternator. If
the staircase does slow down, contact the Customer Service
Department for further assistance.
c. Replace or exchange the alternator with another alternator you

know is good and retest the machine.
d. Test the load resistor as outlined in the "Load Resistor Test"

section of this Manual. If the speed control problem still exists,
contact the Customer Service Department at (800) 331-3578 for
further assistance.
Page 36
LOAD RESISTOR TEST
The alternators are heavy-duty models designed to withstand the rigors of
commercial use. One possible reason for repeated failure is an inoperable load
resistor. To test the load resistor:
2. Locate the load resistor mounted to the relay board assembly just under
the staircase.
3. Disconnect one black wire from the resistor (See Drawing Below).
4. Set your multimeter for R x 1 or the lowest available resistance range. If

you have an analog multimeter, touch the two leads together and adjust
the meter for a zero reading.
5. Place one lead on Tab A and one lead on Tab 5 of the relay assembly
circuit board (See Drawing Below). You should get a reading of
approximately 1.0 ohm or less.
6. Replace the load resistor if the reading is out of range and retest the new
load resistor.

(800) 331-3578 for further assistance.
Page 37
TROUBLESHOOTING THE DRIVE TRAIN
If you hear a grinding or clicking noise, or experience excessive vibration during
exercise, or if the steps are not functioning properly, you probably have a
problem in the drive train. Attempt to isolate the problem area by performing the
following tests in precisely the order listed below. Refer to the “Parts Removal
and Replacement” Section of this Manual for all disassembly and assembly
instructions.
1. Unplug the power supply from the AC wall outlet and remove the side
covers.
! WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE
WHILE THE SIDE COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS
WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE.
2. Check the condition and the tension level of the Poly-V belt. Replace the
belt if it is excessively worn.
a. Adjust the tension level so that you can deflect either side of the
belt 1/10" (0.3 cm) at the center between the alternator and the
transmis sion pulleys (See Drawing Below). Noise can be generated
by a belt that is too tight or too loose.
b. If the noise is still present, remove the Poly-V belt and rotate the
staircase without standing on it. With the Poly-V belt removed, the
staircase will rotate very quickly.
Page 38
a. Unplug the alternator from the relay board and remove the Poly-V
belt.
b. Spin the alternator pulley with your fingers. It should spin freely and
remain spinning for at least one and one-half revolutions. If it does
not spin as it should, the bearings may be bad and the alternator
should be replaced.
c. If the pulley does spin freely, check the alternator for noise,
roughness, or the presence of black powder inside the alternator or
near the outside of the case. If any of these conditions exist, the
brushes may be bad and the alternator should be replaced.
d. Reconnect the Poly-V belt and adjust the belt tension.
4. Check the drive chain mechanism. Rotate the stairs and look for chain
links that do not flex as the chain travels over the sprockets. If the links are
frozen or sticking, replace the chain.
a. Rotate the steps by hand and listen for the noise.
b. If you hear the noise, remove the drive chain and the Poly-V belt.
Rotate the steps by hand again and listen for the noise. If the noise
has gone away, replace the transmission.
a. Have your assistant slowly exercise on the machine. Observe the

staircase. If the staircase moves to the left or right during exercise,
ensure the set screws in the bearing adjusters are tight.
b. Rotate the stairs and look for chain links that do not flex as the chain
travels over the sprockets. If the links are frozen or sticking, replace
the chain.
Page 39
7. Check the condition of the upper and lower sprocket assemblies. Replace
the sprocket assembly if it is worn excessively, has broken teeth, or if it is
bent.
8. Check the alignment of the upper and the lower sprocket assemblies. The
outside face of the upper and lower sprockets should be 1-11/16" (4.3 cm)
from the outside edge of the left frame rail. Loosen the nuts on the pillow
block bearing collars and tighten or loosen the bearing adjuster set screws
until the distance to both sprockets is correct. Tighten the pillow block
bearing nuts and verify the distance.
9. Check the step assembly. Step Tread
a. Rotate the steps and check the

hinges, step shafts, washers, and Step Hinge
bearings (See Figure to Right) for
2 X Nut
wear, corrosion and lack of
lubrication. Replace any worn
parts.
b. Ensure the nuts at each step

shaft end are tight.
4 X Washer
Step Shaft 2 X Bearing
10. Reinstall all parts. If the problem still exists, contact the Customer Service
Department at (800) 331-3578 for further assistance.
Page 40
PARTS REMOVAL AND REPLACEMENT
COVERS
! WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE
THE SIDE COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS WHILE
ANYONE'S HANDS ARE INSIDE THE MACHINE.
There are five covers on the machine: two side covers, a back cover, a bottom
cover, and a top cover. The side covers overlap the top cover. The side covers
must be removed before the top cover and/or the bottom cover can be removed.
All covers are held in place with reusable plastic fasteners (refer to Figure 5
for their location). To remove the fasteners, slide either end of the fastener
removal tool under the edge of the pin head (refer to Figure 6). The pin should not
be removed. Pull the cover away from the frame. Do NOT use the fastener
removal tool or any other sharp tool to pry out the fastener base because you
may damage the covers - use the fastener removal tool to remove the pin.
To reinstall the fastener, insert the base of the fastener through the cover
and into the frame. When the base is in place, push the pin in all the way to
secure the fastener.
Side Covers
Top Cover
3. Set the top cover in place. Secure the side covers to complete
reinstallation.
Page 41
Back Cover
2. Align the holes in the frame and the back cover. Secure the back cover
with the 8 fasteners.
Bottom Cover
3. Remove the six fasteners and remove the bottom cover from the frame.
4. Reinstall the bottom cover, then the two side covers. Remember to
connect the DC power cable.
CONSOLE
1. Locate the mounting knobs on the back of the console (See cutaway view
Below).
2. Loosen and remove the four mounting knobs and lock washers.
3. Lift up the console and unplug the console cable from the back of the
console. Unplug the Polar® cable from the heart rate receiver.
Console Knob
4 X 24677
4. Remove the console from the frame. Washer
4 X 22027
Console Cable
5. Reinstall the console by reversing 21416
the steps.
Fastener, Hook
22938
Fastener, Loop
Tywrap 22939
25233
Grommet
Polar Cable Assy, 12” 24663
26143
Heart Rate Cap
21765
Receiver, Polar®
Plug-in
Page 42 25165
POLY-V BELT
! WARNING
THE POLY-V BELT MUST BE ADJUSTED SO THAT THE CENTER OF EITHER
SIDE CAN BE DEFLECTED 1/10" (0.3 CM) FROM ITS CENTER LINE WITH FINGER-
TIP PRESSURE. A TIGHT BELT WILL CAUSE SLOW AND SLUGGISH OPERATION; A
LOOSE BELT WILL CAUSE EXCESSIVE NOISE AND BELT WEAR.
2. Loosen the adjustment bolt that mounts the alternator to the slotted
alternator brace then loosen the pivot nut.
4. When reinstalling the Poly-V belt, pivot the alternator forward or back as
necessary to allow 1/10" (0.3 cm) of play on either side of the belt (See
Figure Below).
5. Tighten the adjustment bolt and verify the Poly-V belt tension.
DRIVE CHAIN
2. Remove the retaining clip and retaining plate from the drive chain master
link. Do not remove the master link from the drive chain yet.
Page 43
3. Push up on the idler arm with one hand to relieve the tension on the
drive chain (See Drawing Below). Remove the master link from one end of
the drive chain and remove the drive chain from the sprockets.
4. Install the new drive chain by reversing the steps.
STEP ASSEMBLY
2. Rotate the stairs until the step you want to remove is positioned in the
middle of the staircase.
Step Tread
3. Loosen and remove the nut from one end
of the step shaft on both the upper and
the lower hinges of that step (See
Step Hinge
Figure to Right).
2 X Nut
4. Remove the bearing and the washer

from each step shaft.
5. Grasp the opposite step retaining

nut with pliers or locking pliers.
Pull the step shaft out of the 4 X Washer
upper and lower step hinges. 2 X Bearing
Step Shaft
Page 44
Be careful to not lose the washer located between the step and the
modified link.
Note: Each step assembly weighs approximately 15 lbs. Be aware of finger

placement when removing the step assembly.
STEP CHAIN ASSEMBLY
2. Rotate the stairs to position the step chain master link on the lower span
of the chain. It may be necessary to reduce the chain tension to remove
the master link. Perform the following steps to reduce the chain tension:
• Count and write down the number of exposed threads on the top
bearing adjuster set screw for a reference when you reassemble the
parts (SeeFigure Below).
Page 45
• Loosen the nuts on the pillow block bearing housing.
• Loosen the bearing adjustment set screw until the chain tension level
is relieved to a point where the master link may be disconnected.
4. Using the old master link, connect the new chain assembly to the lower
half of the old chain assembly.
5. Remove the nut from the step shaft above the master link. It may be
necessary to place another 5/16"-18 nut on the opposite end of the step
shaft to gain leverage and remove the nut.
6. Remove the bearing, the outer step shaft washer and the modified link of
the old step chain assembly from the step shaft.
7. Place the modified link of the new step chain assembly on the step shaft.
Reinstall the outer step shaft washer, bearing and nut.
8. Rotate the steps until the next step shaft is in approximately the same
place as the previous step shaft.
9. Repeat steps 6-8 until the new chain assembly is installed on the
remaining step shafts.
11. Connect the new chain assembly together with the master link. Tighten
the bearing adjustment set screw until the same number of threads as in
step 2 are exposed. Tighten the nuts on the pillow block bearing housing.
12. You should consider replacing the opposite step chain so that both chains
will wear equally.
Page 46
4. Count and write down the number of exposed threads on the bearing
adjuster set screws on both sides of the machine for a reference when
you reassemble the parts (See Drawing Below).
6. Loosen the adjustment screws until the tips of the screws are flush with
the inside face of the bearing adjusters.
Page 47
7. Have an assistant support the sprocket assembly. Loosen and remove the
nuts on the pillow block bearing housing.
9. Loosen the two set screws on both of the pillow block bearing collars and
remove the pillow block bearings from the sprocket axle.
10. To reinstall the sprocket assembly:
• Slide the pillow block bearings on both ends of the sprocket axle. Do
not tighten the set screw on the pillow block bearing collars yet.
• Place the bearing adjusters and the sprocket assembly onto the frame
and start the pillow block bearing housing nuts onto the frame.
• Slide the sprocket assembly toward the front of the machine while
tightening the pillow block bearing housing nuts.
• Align the sprocket assembly. The outside face of the left sprocket
should be 1-11/16" (4.3 cm) from the outside edge of the left frame
rail. Move the sprocket axle within the pillow block bearing collar as
needed to get the correct distance.
• When the distance is correct, tighten the pillow block bearing collar
set screw on the left and right sides of the machine.
• Loosen the pillow block bearing housing nuts slightly. Tighten the
bearing adjuster set screws until the exact number of threads are
exposed (refer to your notes taken earlier). Tighten the pillow block
bearing housing nuts.
• Check the alignment of the other sprocket at this time. If the distance
from the outside edge of the left frame rail to the outside face of the
sprocket is not 1-11/16" (4.3 cm), loosen the set screws on the left
and right side pillow block bearing collars and adjust the axle. Tighten
the pillow block bearing collar set screws on the machine and then go
to step 11.
Page 48
11. Complete the reassembly of the machine by performing steps 1- 4 in
reverse order.
CABLE ASSEMBLY
2. Remove the console and unplug the console cable and the Polar® heart
rate cable from the back of the console (See Drawing Below). Unplug the
plastic connectors at the console cable/main cable junction.
Console
Console Cable
21416
Tywrap
25233
Polar Cable Assy, 12”
26143
Receiver, Polar®
Plug-in
25165
Console Cable/
Main Cable Junction
5 X Wire Saddle
Relay Board Main Cable

21769
4 X Tywrap
3. Hold the console connector and pull the console cable up and out of the
handrails.
4. Reinstall the console cable by pushing the white plastic connector end
down through the handrails. Do not connect the console, Polar heart rate,
and the main cables.
5. Remove the main cable from the wire saddles.

Page 49
6. Unplug the white plastic connector labeled J1 on the relay assembly
circuit board.
9. To reinstall, place the main cable into the wire saddles. Reattach the cable
to the vertical support with four tyraps.
10. Plug the white plastic connector of the main cable into the relay assembly
circuit board at the spot labeled J1.
11. Plug the console cable into the back of the console. Reattach the console
to the handrail mount. Plug the connectors together at the main cable/
console cable junction.
1. Remove the left and right side covers.
4. Remove the Poly-V belt. Inspect the belt for wear. Replace the belt if it is
cracked, worn, torn, or cut.
5. Remove the transmission bracket by loosening and removing the

mounting hardware on the alternator and the transmission.
6. Remove the transmission brace by loosening and removing the mounting

hardware from the transmission and the frame.
Page 50
7. Support the transmission while loosening and removing the four
transmission mounting bolts. Remove the transmission and rubber pad
from the frame (See Drawing Below).
9. Ensure the Poly-V belt is tensioned according to the procedures outlined in

the “Poly-V Belt” section of this Manual.
ALTERNATOR ASSEMBLY
3. Remove the wiring from the alternator terminals, noting the origin and color
of the wires removed from each terminal.
Page 51
5. Remove the alternator adjustment bolt (See Drawing on Pg. 51).
6. Remove the nut, bolt and mounting hardware from the alternator bracket.
Remove the alternator from the frame.
7. Reinstall the alternator by reversing the removal procedures. Be sure to

verify the wiring connections.
8. Ensure the Poly-V belt is tensioned correctly (See Drawing Below).
RELAY/RESISTOR ASSEMBLY
of the wires that are removed from each terminal.
4. Unplug the main cable connector from the J1 position on the relay circuit
board.
Page 52
6. Loosen and remove the four mounting bolts and remove the relay/resistor
assembly from the frame.
7. Reinstall the relay/resistor assembly in the reverse order. Verify the wiring
connections before attaching the side cover.
Page 53
GROUNDING INSTRUCTIONS
The machine must be grounded. If it should malfunction or break down, ground-
ing provides the path of least resistance for the electric current, thereby reducing
the risk of electric shock. This machine is equipped with a cord having an
equipment-grounding conductor and a grounding plug that looks like the plug
illustrated in sketch A in the Drawing below. International machines may vary. It
must be plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
! DANGER
IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING
CONNECTOR CAN RESULT IN THE RISK OF ELECTRIC SHOCK. CHECK
WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN
DOUBT AS TO WHETHER THE MACHINE IS PROPERLY GROUNDED. DO
NOT MODIFY THE PLUG PROVIDED WITH THIS MACHINE. IF IT WILL NOT
FIT THE AVAILABLE OUTLET, HAVE A PROPER OUTLET INSTALLED BY A
QUALIFIED ELECTRICIAN.
A temporary adapter that looks like the adapter illustrated in sketches B and
C may be used to connect this plug to a two-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 lug extending from the adapter must be
connected to a permanent ground such as a properly grounded outlet box cover.
Whenever an adapter is used, it must be held in place by a metal screw.
Grounding System
Page 54
FCC 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 communica-
tions. Operation of equipment in a residential area may cause harmful interfer-
ence in which case the user will be required to correct the interference at his
own expense.
! WARNING
CHANGES OR MODIFICATIONS TO EQUIPMENT NOT EXPRESSLY APPROVED BY
STAIRMASTER® HEALTH & FITNESS PRODUCTS, INC. COULD VOID THE USER’S
AUTHORITY TO OPERATE THIS EQUIPMENT.
CANADIAN DOC CLASS A COMPLIANCE
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.
La présent appareil numérique ne dépasse pas les limites etablies pour les bruits
radioélectriques applicables aux appareils numériques de la Class A prescrites
dans les règlements sur le brouillage radioélectrique édicté par le Ministère des
Communications du Canada.
Page 55
IMPORTANT PHONE NUMBERS
If you need assistance, please have both the serial number of your machine and
the date of purchase available when you contact the appropriate
StairMaster® Health & Fitness Products, Inc. office listed below.

(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
For technical assistance and a list of distributors in your area, please call or fax
one of the following numbers.
INTERNATIONAL DIVISION ASIA PACIFIC HEADQUARTERS

(425) 823-1825 Telephone/Fax:+81-45-590-5686
FAX: (425) 820-7505 E-mail: stairintl@aol.com
E-Mail: intlservice@stairmaster.com
EUROPE: HEADQUARTERS
+41-91-827-3801
FAX: +41-91-827-8902
E-Mail: stairmasterch@swissonline.ch
GERMANY: HEADQUARTERS
+49-2204/610-27
FAX: +49-2204/628-90
E-Mail: stairmaster.de@t-online.de
U.K.: HEADQUARTERS
+44-1908/267-345
FAX: 44-1908/267-346
E-mail: stairmasteruk@msn.com
Page 56
Left Handrail
22947-03
Right Handrail
22946-03

Back Panel Top Cover
21304 22555
8 X 22086
Caution Decal
Distribution Decal Right Side Cover
Serial Number Decal 23 X 24757 22547
7 X 24757 Compliance Decal
36 X 22086
Left Side Cover

22544
Bottom Panel Inside Panel
22563
FIGURES
Right - 24638
Page 57
Left - 24639
Transport Wheel Assembly

2 X 10262
FIGURES
Page 58
24 X 21363
Step Assembly (w/Tread)

8 X 21396
Modified Link
Step Tread
8 X 21398 (22063)
(23082)
(22128)
Console
80 X 20528 (22128)

80 X 20508
Modified Link
Detail A
Step Shaft Bearing Step Shaft
16 X 23082 8 X 20762
(22128)
32 X 22128
Step Shaft Nut
16 X 22063
See Detail A
FIGURES
Page 59
Upper Sprocket Assembly
Page 60
FIGURES
(42-Tooth Sprocket)
23424-03
8 X 22071
Bearing Plate (22071)
2 X 20682
(22072)
4 X 10037
(22071)

6 X 22032
(22039)
Pillow Block Bearing
4 X 20012 4 X 22039
8 X 20034 2X 22072
8 X 22030 8 X 22029
Lower Sprocket A
Chain Section, #40 Chain Section, #40 10205-03
5.5” 11.5”
4 X 20532 4 X 20531
Master Link
2 X 25305
(23424-03) See Detail A (10205-03)
Chain Assembly (with Modified Links)

2 X 10195
Detail A
Modified Link
40215
2 X 22191
4 X 22028 22163
4 X 22027 22029
22030

Transmission Pad
20808 2 X 22191
(22191) 22433
20114
Transmission Assembly
23591
(22037) Transmission Assembly Mounting to the Frame

Alternator
Transmission Transmission Pulley 20205
20001 24662
(22036) 20202
22042
20693
20007 4 X 22036
(22036)
22043 (22038) Poly-V Pulley
22983 (22036) 21247
(22036) 4 X 22038
(22038)
23427 Frame Upper Sprocket Assembly
10059 10860 23424-03
(22435) 22075
2 X 22435 Drive Chain
2 X 22037 (22038) 22146 23257 Transmission Assembly
2 X 22164 2 X 22026
20547 (22164) 23591
22139
FIGURES
Page 61
Master Link
25305
Drive Chain Assembly
Page 62
FIGURES
Console
4 X 22213 Console Cable

2 X 24643 21416
2 X 22937
2 X 21363 4 X 22323 Fastener, Hook
22938
10794-03 Fastener, Loop
Tywrap 22939
2 X 22323 25233
Grommet
2 X 22213 Polar Cable Assy, 12” 24663
24643 26143
22097
Figure 6: Wiring Diagram

Heart Rate Cap
21765
Receiver, Polar® Cut-Away View of Polar Receiver
Grommet Plug-in
15034 25165
4 X 22323
4 x 22213 4 X 22028 W-4
4 x 24643 AC Tap
2 X 24640 W-6
5 X 23792 W-5 Ground Relay Board
Positive
4 X 22036 Output W-5 W-2
W-4
(22933) Main Cable W-3 W-6
21769 W-2
W-1
4 X 20473
W-1
B
Relay/Resistor Assembly
W-3 22933
B Field
Power Connector
21768
4 X 22663
22109
22134
22110
Section B-B
FIGURES
Figure 7: Relay Board
Page 63
STEPMILL 7000
®
OWNER’S MANUAL
®
© 2001 StairMaster Health & Fitness Products, Inc.
Kirkland, WA 98034
(800) 635-2936
(425) 823-1825
Fax (425) 823-9490
www.stairmaster.com
P/N 22869 - A
© 2001 StairMaster Health & Fitness Products, Inc. StairMaster and Stepmill are registered trademarks
or trademarks of StairMaster Health & Fitness Products, Inc. in the United States and/or other countries.
All other trademarks are trademarks of their respective companies. StairMaster is a Rutledge Capital company.
Page iii
WARRANTY
This is to certify that the StairMaster® Stepmill® 7000 PT exercise system is
warranted by StairMaster Health & Fitness Products, Inc. to be free of all defects in
materials and workmanship. This warranty does not apply to any defect caused by
negligence, misuse, accident, alteration, improper maintenance, or an “act of God”.
This warranty is non-transferable from the original owner.
Stepmill exercise system should fail to operate properly (except any accessories ), contact
our Customer Service Department to report the problem. When calling, please be
prepared to provide the customer service representative with the following information:
• Your name, customer number, shipping address, and telephone number

• The model and serial number of the inoperable machine
• The date(s) of purchase for the inoperable machine(s)
• Your billing address
been established:
• Please call our Customer Service Department to receive a return

materials authorization prior to shipment.
• StairMaster Health & Fitness Products, Inc. will incur all freight
charges for warranty parts ordered for a machine that is less than 45
days old. The parts will be shipped to you via an overnight courier.*
• You are responsible for freight charges on warranty parts for
machines that are more than 45 days old. You will not be responsible
for the return shipment of the inoperable parts.
• Some inoperable warranty parts must be promptly returned to our
Customer Service Department. We will pay the shipping cost for the
inoperable warranty parts. Detailed instructions are included with
each warranty replacement part.
StairMaster Health & Fitness Products, Inc. neither makes, assumes nor
is void if parts other than those provided by StairMaster Health & Fitness Products, Inc.
are used.
Page iv
PREFACE
The StairMaster® Stepmill® 7000 PT exercise system is a safe, functional, and
effective exercise modality for developing aerobic fitness and increasing the
strength of the major muscle groups of the lower body. It is designed for use by
individuals of all ages and fitness levels. Your purchase of this machine is a
positive affirmation of your commitment to use the best available methods for
enhancing your functional fitness capabilities. In order to derive optimal benefits
from your machine, you should read this manual thoroughly and adhere closely to
the instructions.

Stepmill 7000 PT exercise system works, this manual contains two major
sections. The first section provides an explanation of how the machine should be
used to achieve maximum results. The second section offers instructions and
advice on how to properly maintain your machine. The “Appendix” contains
additional information for the owner.
Throughout this Manual, whenever you are required to enter information into
the console, the console keypad keystrokes are enclosed in [ ]. The names of the
buttons and special console operational modes are shown in capital letters. For
example, your machine is ready for use when the console displays "SELECT
WORKOUT." Press the [MANUAL] button to start the MANUAL exercise
program.
The StairMaster Stepmill 7000 PT exercise system is a vertical climbing

machine with a rotating staircase which provides an aerobic workout equivalent
to climbing stairs, without the impact loads and skeletal trauma common to
most aerobic activities. Regular use of the Stepmill 7000 PT exercise system
strengthens and conditions the heart and the following lower body muscle
groups: gluteals, quadriceps, hamstrings, and calf muscles.
Page v
CONTENTS
SAFETY GUIDELINES ......................................................................................... 1
INSTALLATION INSTRUCTIONS ........................................................................ 3
BASIC OPERATING INSTRUCTIONS ................................................................ 6

General Guidelines for Safe Operation ........................................................... 6
Your First Workout on the StairMaster® Stepmill® 7000 PT
Exercise System ............................................................................................. 7
Basic Instructions for First-Time Users .......................................................... 7
Rest periods .................................................................................................... 8
HEART RATE MONITORING ............................................................................ 10

Locked/Non-Locked Option ......................................................................... 10
Error Messages ............................................................................................ 11
TELEMETRY (POLAR®) HEART RATE ............................................................. 12

Using the Transmitter Belt ........................................................................... 12
Maintaining the Transmitter Belt ................................................................ 13
7000 PT CONSOLE ............................................................................................. 14

The Display Window .................................................................................... 14
The Numeric Keypad.................................................................................... 15
The Entertainment Keypad .......................................................................... 15
The Intensity Level Keys .............................................................................. 15
The Stop Key ................................................................................................ 15
The Workout Statistics ................................................................................ 16
The Exercise Program Keypad..................................................................... 17
The Quick Start Option ............................................................................. 17
The Manual Program ................................................................................ 17
The Fat Burner Program ........................................................................... 18
The Aerobic Training Program ................................................................. 18
The Speed Intervals Program .................................................................. 18
The Constant Heart Rate Program .......................................................... 19
The Fitness Test Programs ........................................................................... 20
Understanding Submaximal Exercise Testing ............................................ 20
Pretest Screening ......................................................................................... 22
The StairMaster Submaximal Fit Test ......................................................... 22
The Firefighter's Stair Climb Tests .............................................................. 25
Page vi
CONTENTS
Turning the CPAT Stair Climb Test on ...................................................... 26
Turning the NYCFD Stair Climb Test on ................................................... 26
Console Codes ............................................................................................. 27
MAINTENANCE INSTRUCTIONS ................................................................... 31

Helpful Hints ................................................................................................. 31
Tool List ......................................................................................................... 31
Maintenance Records ................................................................................. 31
Initial Service ................................................................................................ 32
Preventative maintenance ........................................................................... 32
Cleaning and Inspecting ....................................................................... 32
Lubrication ............................................................................................. 33
TROUBLESHOOTING ........................................................................................ 36
General Troubleshooting Guidelines ........................................................... 36
Troubleshooting the Electrical System ....................................................... 36
The Console Fails to Power Up ............................................................ 36
Console Diagnostics Tests ........................................................................... 39
The Display Test .................................................................................... 39
The Keypad Test ................................................................................... 39
The Serial Port test ............................................................................... 40
The Alternator Test ............................................................................... 40
The Tach Test ........................................................................................ 41
Error Reporting ...................................................................................... 41
The Telemetry (Polar®) Heart Rate Test ............................................... 42
Speed Control Problems .............................................................................. 43
Load Resistor Test ........................................................................................ 47
Troubleshooting the Drive Train .................................................................. 48
PARTS REMOVAL AND REPLACEMENT ....................................................... 51

Covers ........................................................................................................... 51
Side Covers ........................................................................................... 51
Top Cover............................................................................................... 51
Back Cover ............................................................................................ 52
Bottom Cover ........................................................................................ 52
Console ......................................................................................................... 52
Poly-V Belt .................................................................................................... 53
Drive Chain ................................................................................................... 53
Page vii
CONTENTS
Step Assembly .............................................................................................. 54
Step Chain Assembly ................................................................................... 55
Upper (and Lower) Sprocket Assembly ....................................................... 57
Cable Assembly ............................................................................................ 59
Transmission Assembly ................................................................................ 60
Alternator Assembly ..................................................................................... 61
Relay/Resistor Assembly ............................................................................. 62
GROUNDING INSTRUCTIONS ......................................................................... 64
FCC COMPLIANCE ............................................................................................. 65
CANADIAN DOC CLASS A COMPLIANCE ..................................................... 65
APPENDICES
Important Phone Numbers ........................................................................... 66
Figures 6 - 12 ................................................................................................ 67
LIST OF TABLES
StairMaster® 7000 PT Exercise System ................................................ 3
Table 2. Fitness Rating Norms ..................................................................... 14
Table 3. Recommended Preventive Maintenance Schedule .................... 35
Figure 1: Correct Exercise Position ................................................................ 9
Figure 2: Transmitter Belt ............................................................................. 13
Figure 3: The Stepmill 7000 PT Console ..................................................... 14
Figure 4: StairMaster Fitness Protocol ........................................................ 24
Figure 5: Grounding System......................................................................... 64
Figure 6: Side Cover and Handrail Assemblies........................................... 67
Figure 7: Cover Fasteners ............................................................................ 68
Figure 8: Step Assembly .............................................................................. 69
Figure 9: Step Chain and Sprocket Assemblies ......................................... 70
Figure 10: Transmission and Alternator Assemblies .................................. 71
Figure 11: Wiring Diagram ........................................................................... 72
Figure 12: Relay Board ................................................................................. 73
Page viii
SAFETY GUIDELINES
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:
! This symbol appearing throughout this manual means

Attention! Be Alert! Your safety is involved.
The following definitions apply to the words “Danger” and “Warning”

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

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

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

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

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

children, invalids, or disabled persons.
3. Keep your hands away from all moving parts and keep your feet on the
pedals while exercising. Do not operate the machine with the side covers
removed.
Page 1
SAFETY GUIDELINES
4. Use this machine only for its intended use as described in this Manual. Do
not use parts, attachments, or accessories other than those provided by
StairMaster® Health & Fitness Products, Inc.
5. Do not use the external power supply if it has a damaged cord or plug, or if
it is not working properly, if it has been dropped or damaged, or dropped
into water. Contact our Customer Service Department at 1-800-331-
3571 to arrange for the return of damaged parts.
6. Connect the external power supply to a properly grounded AC wall

outlet; refer to the “Grounding Instructions” section. Keep all cords
away from heated surfaces.
7. To disconnect the external power supply, remove the plug from the AC
wall outlet.
10. Always wear insulated gloves when handling batteries.
The safety level given by the design of this equipment can only be
maintained when the equipment is regularly examined for damage and wear. In-
operable 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 oth-
ers) to injury, and reduce the longevity of the machine. Follow all training instruc-
tions listed in the manual and/or on the machine. Physical injury may result from
incorrect or excessive training.
SAVE THESE INSTRUCTIONS
Page 2
Before leaving the manufacturing facility in Tulsa, Oklahoma, your StairMaster®
Stepmill® 7000 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.
The dimensions of the machine are listed in Table 1. 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.

Power Supply Specifications:

The machine requires minor assembly before operation. You will need a pair of
diagonal cutters or a pair of heavy-duty scissors. The Stepmill 7000 PT exercise
system must be placed on a solid, level floor near an AC wall outlet. A minimum
ceiling height of 9 feet (2.8 meters) and a doorway width of 29 inches (74 cm) is
required.
2. Have an assistant tilt the machine forward until the wheels are off the
floor. Make sure the assistant can support the machine so you can remove
the temporary wheels.
Page 3
3. Remove the clevis pin from each wheel (See Drawing Below) and remove
the wheels from the frame.
Rivnut
4 X 21767
Outside of Machine
Clevis Pin Nut
2 X 24439 4 X 22154
Leg Leveler
Cotter Pin 4 X 20017
2 X 20047 Transport Wheel
2 x 20036
4. Help your assistant lower the machine to the floor. Install and adjust the
leg levelers as necessary to level the machine (see Above).
panel.
• Mount both handrails onto the frame as shown in Figure 6.
• Push the console cable assembly through the grommet in the frame
and connect it to the main cable assembly (refer to Figure 6).
• Reinstall the back panel and go to step #6.
6. Unwrap the power supply assembly from the console and connect the DC
power cable from the power supply to the power connector located on the
bottom cover.
7. Place the power supply on the floor near an AC wall outlet. To reduce the
hazard of electrical shock, place the power supply in a location away from
the machine and away from exposure to perspiration. You should not
place your power supply on a carpet because it may overheat.
8. 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® Health & Fitness Products, Inc. before
proceeding any further.
Page 4
! WARNING
PROPERLY GROUNDED.
9. Connect the AC power cord to the AC wall outlet. Refer to the “Grounding
Instructions” section of the Manual if the AC wall outlet does not
10. Watch the console. The console should display a software revision code and
then show “SELECT WORKOUT.” If it does not, unplug the power supply and
then plug it back in. If the sound and/or the display are still not present,
contact the Customer Service Department at 800-331-3578. International
customers should call their local distributor; refer to the Appendix for the
11. When the console displays “SELECT WORKOUT”, your Stepmill®

7000 PT exercise system is ready to use.
12. Custom-length DC cables and other accessories are available. Refer to the
Appendix for the phone number of the office nearest you.
Page 5
! WARNING
THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE
MACHINE. YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAME GUIDELINES.
YOU SHOULD MAKE THIS MANUAL AVAILABLE TO ALL USERS.
1. Obtain a complete physical examination from your medical doctor and

enlist a health/fitness professional’s aid in developing an exercise
program suitable for your current health status.
2. When working out for the first time, use the MANUAL exercise program at
the lower speeds until you feel comfortable and capable of faster speeds.
3. The speed and duration of your exercise program should always be

subject to how you feel. Never permit peer pressure to exceed your
personal judgment while exercising.
4. Overweight or severely deconditioned individuals should be particularly

5. Although all equipment manufactured by StairMaster Health & Fitness

prior to shipment, proper installation and regular maintenance are
owner.
Page 6
YOUR FIRST WORKOUT ON THE STAIRMASTER® STEPMILL® 7000 PT
EXERCISE SYSTEM
1. Warm up with light calisthenics and easy stretching exercises for at least
five minutes before beginning your exercise program.
! WARNING
IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN,
EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF
BREATH, STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU
SHOULD CONSULT YOUR MEDICAL DOCTOR IMMEDIATELY.
2. Hold onto the handrails and step up onto the staircase. Stand up straight.
The steps will rotate slowly.
3. Select the MANUAL exercise program so you can control the pace of your
first workout and get used to the exercise motion.
4. Press [MANUAL] and then [ENTER]. The console will return to the start
screen if you do not press [ENTER] within ten seconds.
5. The console will prompt you to enter your body weight. Enter your weight
in pounds (or kilograms if the console is set up for metric units). Correct
entry errors by pressing [CLEAR] before you press [ENTER].
increments between five and 99 minutes. Press [1], [0], [ENTER] to exercise
for ten minutes.
7. Step up with one foot at a time. Try to stay towards the top of the
staircase. As you become comfortable with exercise motion, press
[LEVEL: ∧] and [LEVEL: ∨] to adjust your climbing speed.
Page 7
8. Relax as much as possible while exercising and maintain an erect posture.
Use the handrails for balance. Don’t lock your elbows or lean on the
console. Supporting your weight will reduce the exercise intensity and the
console will overestimate the number of calories burned.
9. Select a speed (or intensity level) that allows you to step towards the top
of the staircase. Faster is not always better. Exercise at a level that is
consistent with your fitness level.
Rest Periods
10. 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
11. When you are finished with your workout, the machine will slow
down and the message “GOAL ATTAINED” will be displayed. You can
cool down on the machine by continuing to step. The console timer
will continue to count up from the selected time, and the intensity
level will default to level 3. If there is a time limit set on the console,
the timer will last only until the maximum time has been met. For
example, if the time limit was set for 30 minutes and you worked out
for 25 minutes, the cool down period would last for 5 minutes, or until
you stepped off the machine.
12. You can also cool down by getting off the machine walking or
stretching for at least five minutes.
Page 8
Figure 1: Correct Exercise Position
Chest/Shoulders - Keep your

shoulders square and centered
over your hips with your chest
Head - Keep your chin parallel to the
lifted.
floor. Avoid staring at your feet or the
Hands - Rest your computer console. This posture will also
hands lightly on the enhance your breathing.*
side rails or front
handlebars. Back - Although the whole
Excessive leaning on body is in a slightly forward
the side rails can slant, keep your back straight
and avoid bending at the waist.
reduce calorie burn
by up to 20%.
Hips/Torso - Keep your hips
directly under you with the
buttocks slightly contracted.
Elbows - Keep both elbows
Avoid letting your hips rock
slightly bent. If you have
from side to side with each
good balance and want to
step.
burn more calories, you can
pump your arms back and
forth as if you were running. Knees - Keep your knees
aligned with your toes.
Avoid training with your
knees too far past your
Legs - Use a full, pain-free toes and keep your feet
range of motion with each pointing forward. Do not
step, straightening your legs as hyperextend your knees.
far as possible without causing
discomfort or letting your
knees lock out.
Feet - Step squarely in the middle of
each step.
*Please note that in the photo the person has his head turned - keep your head
facing forward as you exercise.
Page 9
HEART RATE MONITORING
HEART RATE INPUT
The 7000 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.
• Telemetry heart rate - after the initial belt signal is detected, the
console will enter a validation phase in which four good heart
beat signals within four seconds are required before
locking on telemetry heart rate signals for the duration of the
workout session. During the validation phase the console will not
recognize contact heart rate signals.
Locked/Non-locked Option
When the “not locked” option is selected the heart rate source signal is not fixed
during the exercise (if the signal is lost either input will be valid). If the “locked”
option is selected then the heart rate source signal is locked on the first detected
signal during the workout. To set a heart rate signal input, or to turn off the heart
rate option all together, perform the following steps:
1. On the console keypad, press [LEVEL: ∧], [3], [2]. At this point the
screen will display “HR INPUTS.” Press [ENTER] to select this
option.
2. There are 4 options to handle heart rate input signals. Only 2 of

those options are appropriate for the 7000 PT; "Both HR Off", and
"Telemetry Only." Press the [SELECT] key to scroll past the other
options until you find either "Both HR Off" or "Telemetry Only."
Press the [ENTER] key to select the desired option.
Page 10
HEART RATE MONITORING
“TELEMETRY ONLY“ - locks out contact heart rate signals
and will only detect telemetry signals. Set your console to this
default.
“BOTH HR OFF“ - turns off the ability to detect any signal at all.
Used in rare situations where there is excessive interference with
the heart rate signals. This option turns off disables the
Constant HR program and the Fitness Test program.
Error Messages
Text line messages are only seen in the Constant Heart Rate and Fitness Test
programs due to the design of the program that necessitates a valid heart rate
signal at all times during the program.
“CHECK HR BELT” - The heart rate signal has been missing for
the last 30 seconds in telemetry signal detection.
“HR BELT NEEDED” - No telemetry belt signal been sensed
during the initial setup time.
“HR MODE DISABLED” - No heart rate signal is allowed due to
the set up option that was chosen. Heart rate monitoring is not
possible.
Page 11
TELEMETRY HEART RATE
The StairMaster® Stepmill® 7000 PT features telemetry (Polar®) heart rate moni-
toring. The system consists of the receiver, located on the stepper, and a trans-
mitter belt (purchased separately) worn across your chest. The monitoring func-
tion 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 micropro-
cessor in the console calculates the heart rate and displays it, in beats per
minute, on the console.
Using the Transmitter Belt
! WARNING
PACEMAKER USERS SHOULD NOT USE THE POLAR
TRANSMITTER BEFORE CONSULTING THEIR DOCTOR.
Before you put the transmitter belt on, wet the two electrode patches
(the grooved rectangles on the reverse side of the belt). Secure the transmitter
belt as high under the pectoral muscles (chest) as is comfortable. The transmitter
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 automati-
cally. Your heart rate in beats per minute and a pulsing heart icon are displayed
on the console.
After the initial belt signal is detected, the console will enter a valida-
tion 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 12
• Tighten the elastic part of the chest belt.
• Adjust the belt higher or lower on your chest.
• Remoisten the electrodes.
• Test your chest strap with a machine that you know is working, or
with a heart rate watch that you know is working.
• If possible, replace or exchange your console with a console
(from the same type of machine) that you know is working and
retest the machine.
• Visually check that the heart rate receiver is positioned correctly
in the neck cover. The heart rate receiver jack should point down.
Ensure that the heart rate receiver is connected to the console,
and that the connection is not loose. If possible, swap the heart
rate receiver with one from another machine.
Figure 2: Transmitter Belt
Maintaining the Transmitter Belt

Clean the chest belt regularly with mild soap and water, then dry thoroughly -
residual sweat and moisture keep the transmitter active and drain the battery in
the transmitter. Do not use abrasives or chemicals such as steel wool or alcohol
for cleaning, as they can damage the electrodes permanently. You can order
replacement belts from StairMaster, Polar Electro, Inc., or your local fitness store:
StairMaster 800-331-3578 P/N 64000
Polar Electro, Inc. 800-227-1314
Page 13
7000 PT CONSOLE
The StairMaster® Stepmill® 7000 PT exercise system console is divided into
seven sections: the display window, the workout options, the numeric keypad,
the entertainment keypad, the workout statistics, the stop key, and the intensity
level keys (see Figure 3).
Display Window
Entertainment Numeric
Keypad Workout Options Keypad
Workout Statistics Stop Intensity Level
Figure 3: The Stepmill 7000 PT Console
THE DISPLAY WINDOW
• Time - The selected workout time is displayed in the

upper left section of the display window. Once the time
is entered, the timer will count down, in minutes and
seconds, until the workout is finished or stopped. If [0]
is entered in the MANUAL or CONSTANT HEART RATE
program, the timer will count up.
• Calories - The real-time amount of calories burned is continually updated and
displayed in the upper right section of the display window.
• Interval Timer - The interval timer is displayed below the Time. The interval
timer counts down time left within each interval.
• Heart Rate - Current heart rate is displayed below the Calories, next to the
heart icon.
• Workout Option Profile - A profile of the selected exercise program appears
in the lower section of the display window during a workout. The taller the col-
umn, 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 dis-
play as you complete each interval.
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7000 PT CONSOLE
THE NUMERIC KEYPAD
The numeric keypad is located on the right side of the console.

Before the exercise program begins, the numbers are used to
enter data in response to the console prompts.
• Enter - Confirms workout selections and stores the informa-
tion used by the console to calculate workout statistics.
• Clear - Erases information from the console memory if
pressed before [ENTER].
THE ENTERTAINMENT KEYPAD
The FreeClimber comes equipped to facilitate the use of com-

mercial entertainment systems. Using any of these keys will
send an output signal through the Communication Specifica-
tion for Fitness Equipment (C.S.A.F.E.) port to a connected
C.S.A.F.E. or compatible system. If a system is not connected,
pressing these keys will have no effect.
• Volume Up/Down - Increases or decreases the volume level of the audio
source.
• Mute - Removes the audio sound from the headphones.
• Channel Up/Down - Changes the channel of the commercial entertainment
system.
THE INTENSITY LEVEL KEYS
The exercise intensity level may be changed at any time during

a workout. Pressing the [ ∨ ] key decreases the intensity and
pressing the [ ∧ ] key increases the intensity.
STOP KEY
Press the [STOP] key any time you want to pause the exercise
program for up to one minute. Press [STOP] a second time, or
[1], and The console will return to the "SELECT WORKOUT"
Prompt.
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7000 PT CONSOLE
THE WORKOUT STATISTICS
During the exercise program, the Stats keys are used to track workout statistics
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.
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 dur-
ing a workout.
• Rate - Displays the current steps per minute.
• Floors - Displays the equivalent number of floors climbed with an 8-inch step.
There are 16 steps per floor, and 48 floors per mile.
• Level - Shows the current intensity level between 1 (the easiest) and 20 (the
hardest).
• Watts - Displays the exercise intensity in watts (746 watts = 1 horsepower).
• METs - Gives you the relative energy cost of exercise. MET stands for mul-
tiples of the resting metabolic rate. While you are sitting quietly, your body con-
sumes oxygen at the rate of about 3.5 milliliters per kilogram of body mass per
minute. When you exercise, your body needs more oxygen in order to function.
For example, exercising at 10 METs requires ten times the resting rate of oxygen
consumption, or about 35 milliliters per kilogram per minute. During a workout,
this key shows the current MET level. During the workout summary, the average
MET level is displayed.
• Target Heart Rate - Available only during the Constant Heart Rate program.
Shows the selected target heart rate.
At the completion of a workout, the statistic averages are calculated

based on the accumulation of data during the workout program, and not including
the cool down period.
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7000 PT CONSOLE
THE 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] with-
out inputting data first will prompt the console to enter these values):
• Weight - 175 lbs.

• Intensity Level - 3
• Workout Time - The default time in the programmed workouts
and Quick Start is 20 minutes. The Manual and Constant Heart
Rate programs do not have a specified default time. In these
programs, the console timer will count up to the maximum time of
99 minutes, and then return to 0.
• Age (Constant Heart Rate program only) - 40 years
Once you have selected a program, the prompts are:
• “ENTER BODY WEIGHT” - type in your body weight in

pounds (or kilograms if your console is set to metric units).
• “ENTER LEVEL 1 - 20” - select your intensity level with
level 1 being the easiest and level 20 the hardest.
• “ENTER TIME 5 - 99” - select the workout duration in one
minute increments from 5 to 99. Press 0 in the MANUAL and
CONSTANT HEART RATE program to workout for an unspecified
amount of time.
The Quick Start Program
Provides an immediate start, without having to enter any user information. This
program uses the standard default settings for derivation of calories burned.
The Manual Program
After pressing the [MANUAL] key, enter user and workout information. Begin
exercising at the selected level. If desired, adjust the workout manually by
using the intensity level arrow keys. The profile in the display window is
divided into 15 equal intervals within the workout time. The profile is based
Page 17
7000 PT CONSOLE
on the selected intensity level, with 2 levels equating to one vertical bar.
The Fat Burner Program
The Fat Burner program is a 60-interval workout designed for people just
starting a weight control program. The relative intensity level is indicated on the
profile and any changes in the intensity level will continue for the remainder of
the program.
The Aerobic Training Program
The Aerobic Training program is a 60-interval workout designed to increase

aerobic capacity. The relative intensity level is indicated on the profile and any
changes in the intensity level will not change the look of the remaining profile.
The Speed Intervals Program
The Speed Intervals program is a workout with 8-rest intervals and 7-exercise
intervals that alternate speed/intensity level changes. You can change the REST
interval speed/level and the EXERCISE interval speed/level independently, using
the level keys. For example, if you decrease the intensity level during a rest in-
terval then subsequent rest intervals will be the same. However, the EXERCISE
interval remains at the same intensity level you started with. To change the
intensity level of the EXERCISE interval, you must change the intensity level
Page 18
7000 PT CONSOLE
during an EXERCISE interval. The intensity level shown during an EXERCISE inter-
val is indicative of your current speed. However, the current speed during a REST
interval is equal to a scaled percentage of the displayed intensity level. Note that
the program profile does not change at any time during the workout session.
Rest Interval Exercise Interval
The Constant Heart Rate Program
The Constant Heart Rate program maintains a chosen target heart rate by
automatically varying the climbing speed during each workout. The default target
heart rate is equal to 70% of your maximum heart rate which is calculated by the
following equation: 220 - (Age) x .70. Choose a different target heart rate (be-
tween 80 and 180 beats per minute) at any time during the workout by using the
numeric keypad to enter the new target heart rate, followed by the [ENTER] key.
The following messages may be shown during a workout:
• “CHECK HR BELT” - The heart rate signal has been missing for
the last 30 seconds in telemetry signal detection.
• “HR BELT NEEDED” - No telemetry belt signal has been sensed
during the initial setup time.
• “HOLD HR SENSORS” - In contact heart rate signal situations
this message will come every 30 seconds to prompt the user to
hold the sensors.
• “HR MODE DISABLED” - No heart rate signal is allowed due to
the set up option that was chosen. Heart rate monitoring is not
possible.
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7000 PT CONSOLE
The Fitness Test Programs
Understanding Submaximal Exercise Testing
Before using the StairMaster FreeClimber for submaximal exercise testing, it

should be noted that all submaximal fitness tests make several assumptions:
• That a steady-state heart rate is obtained for each exercise

workload.
• That a linear relationship exists between heart rate, oxygen up
take and workload.
• That the maximal heart rate for a given age is uniform.
• That the mechanical efficiency of the physical activity performed
(i.e., oxygen uptake at a given workload) is the same for every
one.
It should be kept in mind that any one or all of the above mentioned as-
sumptions may not be met during a submaximal exercise test. If for any
reason one of the assumptions is not met, then errors in predicting VO2 max will
occur.
Unfortunately, it is often quite difficult to meet all of the requirements

for the four listed assumptions. For example, exercising at a given workload for
only a few minutes can involve an insufficient amount of time for many individu-
als 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 exer-
cise at one-minute intervals at the same workload until two successive heart
rates differ by less than five beats per minute.
It is also important that the submaximal heart rates obtained be

between 115 and 150 beats per minute, because it is within this heart rate range
that a linear relationship tends to exist between heart rate and oxygen uptake or
workload for most adults. When the heart rate is less than 115, many external
factors (e.g., talking, laughing, apprehension, etc.) can greatly influence heart
rate. Once the heart rate reaches a level between 115 and
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7000 PT CONSOLE
150, external factors no longer influence heart rate, and a linear relationship ex-
ists. As the heart rate rises above 150, the heart rate-oxygen uptake relationship
becomes curvilinear.
The third assumption involves maximal heart rate. Maximal heart rate is
the greatest heart rate that can be measured when an individual is exercising to
the point of volitional fatigue (i.e., exhaustion) during a graded exercise test. Sev-
eral equations have been developed to estimate the average maximal heart rate
for humans:
• Maximal heart rate = 220 minus age (low estimate)

• Maximal heart rate = 210 minus [0.5 x age] (high estimate)
• Maximal heart rate = 226 minus age (estimate for older
individuals)
Maximal heart rate can, however, vary greatly among different

individuals of the same age. One standard deviation is + 12 bpm, which means
that two-thirds of the population varies an average of plus or minus 12 heart
beats from the average given by a prediction equation. If an individual’s age-pre-
dicted maximal heart rate is higher than that person’s true maximal heart rate,
then his/her estimated VO2 max will be an overestimation of the correct or actual
value.
The final assumption addresses the issue of mechanical efficiency. Be-

cause oxygen uptake at any given work rate can vary by approximately 15% be-
tween different individuals, individuals vary in the amount of oxygen they require
to perform a certain exercise workload. Some individuals are more
efficient at performing a given task than others. As a result, the average
oxygen consumption associated with a given workload may vary significantly
from one person to another. Thus, VO2 max predicted by submaximal exercise tests
tends to be overestimated for those who are mechanically efficient and underes-
timated 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 21
7000 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, irre-
spective of the accuracy of the VO2 max prediction.
Pretest Screening
Prior to any exercise test (maximal or submaximal), participants should complete

a brief health/medical questionnaire, have their resting blood pressure and heart
rate measured, and provide an informed consent form. The Physical Activity
Readiness Questionnaire (PAR-Q) is an example of a valid health/medical
questionnaire for screening individuals prior to submaximal exercise testing.
Canadian health and fitness practitioners have extensively (and quite success-
fully) used the PAR-Q to determine whether individuals should be given an
exercise test. A “yes” answer to any of the seven questions on 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 recommended
only medically supervised physical activity?
2. Do you have chest pain brought on by physical activity?
3. Have you developed chest pain within the past month?
4. Do you tend to lose consciousness or fall over as a result of dizziness?
5. Do you have a bone or joint problem that could be aggravated by the
proposed physical activity?
6. Has a doctor ever recommended medication for your blood pressure or a
heart condition?
7. Are you aware, through your own experience or a doctor’s advice, of any
other physical reason against your exercising without medical supervi-
sion?
The StairMaster Submaximal Fit Test
The StairMaster branching protocol is a series of 3-minute stages of

continuous exercise at increasing intensity. The first stage is a warm-up at ap-
proximately 4 METs. The intensity of the remaining stages is based on the heart
rate response to the warm-up. The test is designed to raise the steady
Page 22
7000 PT CONSOLE
state heart rate of the subject to 110 to 150 beats/min for two consecutive
stages. It is important to remember that two consecutive heart rate measure-
ments must be obtained in the 110 to 150 beats/min range to predict VO2max.
The test typically lasts from 9 to 15 minutes.
In the StairMaster protocol, each work rate is performed for 3

minutes, with heart rates recorded during the final 4 seconds of the second and
third 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 pro-
gram advances to the next 3-minute stage. The program continues for two to four
stages until two steady state heart rates between 110 to 150 beats/min are ob-
tained in two consecutive stages. The line generated from the plotted points is
then extended to the age-predicted maximal heart rate. A corresponding maximal
work rate and VO2max can then be calculated.
At the end of the 3rd minute of each stage, if the heart rates at the end
of the 2 and 3rd minute are not within 5 beats/min of each other, then that work
nd
rate is maintained for an additional minute. At the end of the 4th minute, the
heart rate is compared to the heart rate at the end of the 3rd minute. If the heart
rates are within 5 beats/min, then the heart rate during the 4th minute is plotted
against the work rate. If the heart rate at the end of the 3rd and 4th minute are
not within 5 beats/min, then the work rate is maintained for one more additional
minute. If the heart rate at the end of the 4th and 5th minutes are within 5 beats/
min, then the heart rate at the end of the 5th minute is plotted against the work
rate. If the heart rate at the end of the 4th and 5th minutes are not within 5 beats/
min, then the test failed.
Once two consecutive heart rate measurements are obtained in the 110
to 150 beats/min range, then the test ends successfully and the results are dis-
played. Estimate 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. Press [STATS SCAN] to review the results in
addition to being displayed at the end of the test.
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7000 PT CONSOLE
Figure 4: StairMaster® Fitness Protocol
FIT TEST PROTOCOL

StairMaster CV Products
First Work Level

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

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

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

11 METs 10 METs
Test fails if 2 stages of

at least 115 bpm are not
obtained
Test Complete
- Display Results -
Page 24
7000 PT CONSOLE
Table 2. Fitness Rating Norms (VO2max)
MEN
Age High Good Average Fair Low
20 – 29 >51 51 – 47 47 – 43 42 – 40 <39
30 – 39 >50 50 – 45 45 – 41 41 – 37 <37
40 – 49 >48 48 – 42 42 – 38 38 – 35 <35
50 – 59 >45 45 – 39 38 – 35 35 – 32 <32
60+ >43 42 – 35 35 – 32 32 – 29 <29
WOMEN
Age High Good Average Fair Low
20 – 29 >44 44 – 38 38 – 35 35 – 32 <32
30 – 39 >41 41 – 37 37 – 34 34 – 31 <30
40 – 49 >40 39 – 34 34 – 31 31 – 28 <28
50 – 59 >35 35 – 31 31 – 28 28 – 26 <25
60+ >35 35 – 39 29 – 26 26 – 24 <24
The Firefighter’s Stair Climb Tests
The StairMaster StepMill is routinely used to assess the aerobic fitness

levels of fire fighters in full protective gear carrying heavy equipment. The
Candidate’s Physical Ability Test (CPAT), approved by the International
Association of Fire Fighters (IAFF) and reviewed by the U.S. Justice Department,
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 Depart-
ment (NYCFD).
• CPAT Stair Climb Test – (Fit Test #2) The first phase is a warm-up
interval at intensity of 56 steps/min and lasts twenty-seconds. At
the end of the first interval the time counter will reset to zero.
The second phase continues through nine twenty-second
Page 25
7000 PT CONSOLE
intervals at intensity of 68 steps/min. The CPAT Stair Climb Test
has a total of ten intervals and lasts for three minutes, twenty
seconds (including warm-up).
Turning on the CPAT Stair Climb Test
1. Press [∧], [9], [1], [ENTER], on the console keypad. Make sure to
press in the middle of each key and be aware that the corre-
sponding numbers will not show in the console display.
2. The console will prompt you to “BEGIN FIT TEST.” The test
can be stopped at any time by pressing [STOP].
• NYCFD Stair Climb Test – (Fit Test #3) The first phase is a warm-
up interval at intensity of 56 steps/min and lasts sixty-seconds,
followed by a sixty-second rest period (no stepping). At the end
of the rest period the time counter will reset to zero. The second
phase is at intensity of 68 steps/min and lasts for five minutes,
twelve seconds.
Turning on the NYCFD Stair Climb Test
1. Press [∧], [9], [2], [ENTER], on the console keypad. Make sure to
press in the middle of each key and be aware that the corre-
sponding numbers will not show in the console display.
2. The console will prompt you to “BEGIN FIT TEST.” The test
can be stopped at any time by pressing [STOP].
Page 26
7000 PT CONSOLE
CONSOLE CODES
There are three groups of console codes which are differentiated according to
function. The first group of codes are customization codes and are used to set
defaults such as units, language, heart rate input type, etc. The second group of
codes are machine status codes and are used to track hours and other general
usage patterns for maintenance purposes. The third group of codes are diagnos-
tic codes and are used for troubleshooting. The following key actions are valid in
each group of console codes:
• Pressing [LEVEL ∧], [ 1st # ], [ENTER] displays what group of codes is

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

[ ^ ] [ 3] [ 1 ] change units (MPH or KMH)
[ ^][3][2] choose type of heart rate input and priority (telemetry
or contact)
[ ^][3][3] - N/A -
[ ^][3][4] choose console language
[ ^][3][5] change contrast on console
[ ^][3][6] - N/A -
[ ^][3][7] - N/A -
[ ^][3][8] - N/A -
[ ^][3][9] reset to factory defaults
1. Change the workout time by pressing [LEVEL: ^], [3 , [0]. The console will
display “MAX TIME.” Press [ENTER]. The console will then display the
current time limit. Use the keypad to enter the desired time, then press
[ENTER]. For no time limit, press [0].
Page 27
7000 PT CONSOLE
2. Change the units to either Metric or USA units by pressing [LEVEL: ^], [3],
[1], [ENTER]. The console will display the current units - either “USA
UNITS” or “METRIC UNITS.” Use the [SELECT] key to change option, and
then press [ENTER].
3. Choose the desired heart rate input preference by pressing [LEVEL: ^],
[3], [2]. The console will then display “HR INPUTS.” Press [ENTER]. The
console will then display the current hear rate input selection. Press the
[SELECT] key to scroll through the other options. Press [ENTER] after the
desired option.
4. Change the language by pressing [LEVEL: ^], [3], [4]. The console will
display “LANGUAGE.” Press [ENTER]. The console will then display
the current language. Press the [SELECT] key to scroll through the other
options. Press [ENTER] to change the option.
5. Adjust the contrast on the LCD screen by pressing [LEVEL: ^], [3], [5]. The
console will display “CONTRAST ADJ.” Press [ENTER]. The console will
then display the current contrast number. Press the [LEVEL: ^], and
[LEVEL: ∨] keys to increase or decrease the contrast. The changed value
will remain on exit.
6. Reset the console to factory defaults by pressing [LEVEL: ^], [3], [9]. The
console will display “SET DEFAULTS .“ Press [ENTER]. Then console will
rest itself and then display “DONE.”
Quick Scan Programming
You can quickly access any of the custom menus by pressing [LEVEL: ^],
[3], [ENTER]. The console will then display “CUSTOMIZE.” Scroll through the
following options:
[SELECT] “ MAX TIME” 0

[SELECT] “CHANGE UNITS” 1
[SELECT] “HR INPUTS” 2
[SELECT] “LANGUAGE” 4
[SELECT] “CONTRAST ADJ” 5
Page 28
7000 PT CONSOLE
[SELECT] “CONTRAST ADJ” 5
[SELECT] “MAX SPEED” - N/A- 6
[SELECT] “CLINICAL MODE”-N/A- 7
[SELECT] “SET DEFAULTS “ 9
Machine Status Codes
[ ^ ] [ 4 ] [ 0 ] display machine run time in hours

[ ^ ] [ 4 ] [ 1 ] display number of workouts
[ ^ ] [ 4 ] [ 2 ] display distance traveled
[ ^ ] [ 4 ] [ 3 ] display software rev
[ ^ ] [ 4 ] [ 4 ] display machine type
[ ^ ] [ 4 ] [ 5 ] -N/A-
[ ^ ] [ 4 ] [ 6 ] display machine run time in hours since last cleared
(used for maintenance)
1. Display the machine run time by pressing [LEVEL: ^], [4], [0]. The console
will display “RUN HOURS XXXXX”.
2. Display the number of workouts by pressing [LEVEL: ^], [4], [1]. The console
will display “WORKOUTS XXXX.”
3. Display the total distance covered up to date by pressing [LEVEL: ^], [4], [2].
The console will then display “DISTANCE XXXX.”
4. Display the console software revision number by pressing [LEVEL: ^], [4],
[3]. The console will display “CONS 92111-XXX.”
5. Display the machine type by pressing [LEVEL: ^], [4], [4]. The console will
display “STEPPER (or other machine type).”
6. Display the machine run time since last cleared by pressing [LEVEL: ^], [4],
[6]. The console will display “MAINT HOURS XXXX.”
Page 29
7000 PT CONSOLE
Quick Scan Programming
You can quickly access any of the custom menus by pressing [LEVEL: ^],
[4], [ENTER]. The console will then display “MACHINE STATUS.” Scroll through
the following options:
[ SELECT ] “ RUN HOURS XXXX” 0

[ SELECT ] “ WORKOUTS XXXX” 1
[ SELECT ] “ DISTANCE XXXX” 2
[ SELECT ] “ CONS 90211- XXX ” 3
[ SELECT ] “ STEPMILL” 4
[ SELECT ] -N/A-
[ SELECT ] “ MAINT HOURS xxxx” 6
Resetting the Maintenance Hour Counter
For ease of maintenance records, the Stepmill® console has a maintenance timer
that will clock the number of hours, workouts, and time between last servicing.
After each maintenance period reset the counter.
[ ^ ] [ 7 ] [ 1 ] Reset Service
1. Reset the maintenance hour counter by pressing [LEVEL: ^], [7], [1]. The
console will dusplay “RESET SERVICE.” Press [ENTER]. The console will
display “DONE.” Press [CLEAR] to return to the starting screen.
Configuration Code
The Stepmill console supports other StairMaster® exercise systems. It is

important to verify that the machine configuration code matches the type of
machine you have. Speed control problems, along with other problems, can occur
if the console is not set up correctly.
[ ^ ] [ 8 ] [ 0 ] Change Machine
1. Change the machine type by pressing [LEVEL: ^], [8], [0]. The console will
display “CHANGE MACHINE.” Press [ENTER]. The console will then display
the current machine type. Use the [SELECT] key to toggle between
options. Press [ENTER] for the desired option.
Page 30
HELPFUL HINTS
Read all maintenance instructions thoroughly before beginning work. In some

cases, an assistant is required to perform the necessary tasks. The safety level
given by the design of this equipment can only be maintained when the equip-
ment 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. 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
• Standard screwdriver • Phillips screwdriver

• Combination wrenches (sizes 7/16 - 3/4") • Adjustable wrench
• Combination pliers • External snap ring pliers
• Shop goggles or other eye protection • Wire stripper/crimper tool
• Allen wrench set (sizes 5/64 - 1/4") • Volt-ohm meter (multimeter)
• Socket set or nut driver set • Locking pliers
(sizes 1/4 - 3/4" in 1/16" increments)
MAINTENANCE RECORDS
For ease of maintenance the 4400/4600 PT/CL console will keep track of hours,
number of workouts, time between last servicing, etc. You can quickly access any
of the custom menus by pressing [LEVEL: ^], [4], [ENTER]. The console will then
display “MACHINE STATUS”. Scroll through the following options:
[ SELECT ] “ RUN HOURS XXXX”* 0

[ SELECT ] “ WORKOUTS XXXX” 1
[ SELECT ] “ DISTANCE XXXX” 2
[ SELECT ] “ CONS 90211- XXX ” 3
[ SELECT ] “ STEPMILL” 4
[ SELECT ] -N/A-
[ SELECT ] “ MAINT HOURS xxxx” 6
*The machine may show a few hours of use due to testing at the
manufacturing facility.
Page 31
INITIAL SERVICE
Upon receiving your machine, use a soft, clean towel to wipe off the dust which
may have accumulated during shipping. Your new machine will require minor
assembly. Refer to the “Installation Instructions” section of this Manual for
details.
The procedures for performing the recommended preventive maintenance

are summarized in Table 3. The schedule is based on normal usage in a commer-
cial health club environment; adjust the schedule to meet actual machine usage.
Refer to the “Parts Removal and Replacement” section of this Manual for all
disassembly and assembly instructions.
! WARNING
1. DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANER

ON THE CONSOLE. Clean the console daily with a water-dampened cloth
and wipe dry after cleaning.
2. Clean the exterior of your Stepmill® 7000 PT exercise system daily with
soap and water.
unpainted surfaces. Repair the damaged area with a rust-inhibitor paint.
Contact our Customer Service Department at 800-331-3578 to order a
touch-up paint kit.
Page 32
6. Inspect the Poly-V belt for excessive wear during the weekly cleaning.
Adjust the belt tension if necessary.
Lubrication
The StairMaster® Stepmill® 7000 PT exercise system has six components that
require periodic lubrication: the drive chain, the two step chains, the two bearing
plates and the step hinges. These parts are shown in the figure below. You will
need to remove the side covers to lubricate the chains and the bearing plates.
1. Place a protective mat on the floor while you are lubricating your
machine. A rubber floor mat is available from StairMaster Health & Fitness
Products, Inc.
Page 33
2. Lubricate the chains monthly with 30W motor oil. Drip the oil onto the
chain plates and rollers. Let the oil soak in for a few minutes and then
remove any excess oil with a dry rag.
3. Remove the chains every three months to thoroughly clean and lubricate
them. Use a mild degreaser and a stiff brush to remove dirt and corrosion
from the chain. Read the instructions on the degreaser container before
using.
4. Clean each bearing plate and lubricate it with multipurpose grease every
three months. The plate is lubricated to reduce friction when the step
shaft bearings roll over the plate.
5. Once per month, use 30W motor oil or brush light bearing grease into the
step hinges to lubricate the hinges and to prevent corrosion. Wipe off all
excess lubricant.
! WARNING
TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE
THE STEP AREA IS FREE OF GREASE OR OIL. WIPE ANY
EXCESS OIL OFF THE MACHINE SURFACES.
Page 34
RECOMENDED
ACTION
Exterior Soap &

Clean Daily N/A
Surfaces water
Inspect and Weekly or

Poly-V Belt adjust if after 70 hours N/A N/A
necessary of use
Monthly or
30W motor
oil
Assembly Quarterly or
after 900
hours of use
Weekly or
30W motor
Lubricate after 70 hours N/A
oil
of use
Drive Chain
Quarterly or
after 900
hours of use
Monthly or
30W motor
oil
hours of use
Quarterly or
Bearing Clean and Clean, dry Multipurpose
after 900
Plate lubricate rag grease
hours of use
Page 35
TROUBLESHOOTING
This section outlines several tests to systematically identify and isolate the
cause of problems in the electrical system and the drive train. This troubleshoot-
ing section is organized into four basic problem sections: Electrical System,
Console Diagnostics, Speed Control, and the Drive Train. The first step is to
identify the problem. Once you have identified the problem, perform all the tests
in exactly the same order as written. Refer to the “Parts Removal and Replace-
ment” section of this Manual for all disassembly and assembly instructions. To
order a replacement part, or to get help with the troubleshooting process,
contact our Customer Service Department at 800-331-3578. International
customers should contact their local distributor or call 425-823-1825.
The electrical system consists of: the power supply, main cable, relay board, load
resistor, and the console. In order to identify the component that is causing the
problem, you must systematically test the system. You will need a volt-ohm
meter (multimeter) to conduct portions of the following procedures. The console
and power supply are not serviceable by the owner. If either of these parts are
inoperable, they must be replaced. Opening the console or the power supply will
void the warranty.
2. Is the indicator light lit on the power supply? If it is, proceed to step
#3. If the light is not on, go to step B.
3. Replace or exchange your console with a console you know is good

and retest the machine.
B. Verify AC power.
Page 36
2. Verify that the AC wall outlet is supplying the correct power in one of
two ways: a) Use a voltmeter to verify that the AC line voltage is
between 108 and 130 VAC (or between 208 and 240 VAC, if applicable)
at the AC wall outlet; or b) Plug in an alternate AC-powered device (a
lamp, for example). If the AC wall outlet is supplying the correct power,
proceed to step #3. If the voltage is outside the range or if the device
does not work when plugged into the AC wall outlet, consult an
electrician for further assistance and then retest the AC wall outlet.
3. Plug the AC power cord into the wall outlet and proceed to the next
section.
C. Verify DC power.
1. Make sure that the AC power cord is plugged in and that the AC wall
outlet is delivering the proper voltage.
2. The indicator light should be lit. If it is, proceed to step #3. If the
indicator light is still not lit, replace the power supply and test the new
power supply.
3. Disconnect the cable from the DC power connector located on the

bottom cover. Use a DC voltmeter to verify 12-19 VDC at the end of
the DC cable. Pin #1 is negative and pin #2 is positive. Proceed to step
#4 if the VDC is within the range. Replace the power supply if the VDC
is outside the range and test the new power supply.
4. Remove the right side cover. Reconnect the DC power cable to the
machine. Locate the relay/resistor circuit board located just inside the
frame, midway between the top and bottom steps (refer to Wiring
Diagram 1). There are three red indicator lights along the bottom edge
of the relay assembly circuit board. They are labeled, from top to
bottom: Field, Power, and Relay. Ensure the black and white wire
power connector (labeled J2 on the relay resistor circuit board) is
securely connected to the relay resistor circuit board.

Page 37
voltmeter to measure the VDC at the power connector. Pin #1
is negative and Pin#10 is positive. The reading should be between
12 and 19 VDC. If you are not getting power to the connector,
replace the power connector assembly and retest.

reconnect it to the J2 position on the relay assembly circuit
board. Disconnect the main cable connector at the J1 position of
the relay assembly circuit board. Check the VDC reading at the
silver tabs on the relay assembly circuit board. Tab #4 (labelled +/
WHT) is positive and tab #5 (labelled GND/BLK) is negative (refer
to Wiring Diagram 2). You should get a reading between 12 and
19 VDC. If your reading is not within the range, replace the relay
assembly circuit board and retest.
VDC reading at the connector labeled position J1 on the relay
assembly circuit board. Pin #4 is positive and pin #5 is negative.
You should get a reading between 12 and 19 VDC. If your
reading is not within the range, replace the relay assembly circuit
board and retest.
d. If all of the above power tests produce VDC readings that are
within range and the Power indicator light is still not lit, the
Power indicator light is probably inoperable. Replace the relay
assembly circuit board, reconnect all wires, and retest.
5. Remove the console and disconnect the console cable. Use a DC

voltmeter to measure the VDC at pin #1 (negative) and pin #10 (positive)
of the console cable connector. You should get a reading between 12
and 19 VDC. If the reading is not within the range, replace the cable
assembly and retest.
Page 38
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
[START/STOP] while in the DIAGNOSTIC mode. Please note that there may be
addition verbiage on the display other than is listed in this manual. The Stepmill®
7000 PT console is used on other StairMaster® equipment.
Diagnostic Codes
[^][6][0] Test display

[^][6][1] Test keyboard
[^][6][2] Test serial port
[^][6][3] Test alternator
[^][6][4] -N/A-
[^][6][5] -N/A-
[^][6][6] Test Tach
[^][6][7] - [ 6 ] [ 9 ] -N/A-
The Display Test
During the display test, the console screen alternates between all LCD segments
turned on, and 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.
The Keypad Test
Perform this test if you are having trouble entering data into the console.
During the test, pressing any key displays that key name on the message line.
Press [CLEAR] to exit.
1. Press [ LEVEL: ^ ], [ 6 ], [ 1 ], [ENTER] to start the test.
Page 39
2. Firmly press each button except [CLEAR]. The name of the key will be
shown in the display window. Press [CLEAR] to end the test.
The Serial Port Test
This test verifies that the RS 232 port used for linking to commercial entertain-
ment systems is working. You must have the loop-back cable assembly, pn
040051-001 to perform this test.
1. Insert the loop-back cable assembly into the RS 232 port on the back
of the console.
2. Press [ LEVEL: ^ ], [ 6 ], [ 2 ], [ENTER], to start the test.
3. The console will run a diagnostic test and then display either “PASS”
or “FAIL”. Replace the console if it fails this test.
The Alternator Test
Use this test to verify the alternator field routines of the console. You will need
to briefly exercise on the machine for this test.
1. Press [ LEVEL: ^ ], [ 6 ], [ 3 ], [ENTER], to start the test.
2. For “Field on” press [ LEVEL: ^]. Step on the machine for
approximately 10 to 15 seconds. If full resistance is achieved during
this time, your console has correct current flow. If no resistance is
achieved, either the console or the alternator is bad. See the
electrical troubleshooting portion of this manual to isolate and test
the alternator. Replace the console if the alternator is good.
3. For ‘Field off” press [ LEVEL: V]. Step on the machine for
approximately 10 to 15 seconds. You should not get resistance with
the field turned off. Press [CLEAR] to end the test.
Page 40
The Tach Test
If you do not have resistance, perform the tach test. The tach test will tell you the
tach signal, in revolutions per minute (RPMs), picked up by the console.
1. Press [ LEVEL: ^ ], [ 6 ], [ 6 ], [ENTER]. The console will display

“TAR TACH ACT”. The target tach speed of 2000 RPMs will be shown
in the upper left corner of the display window. The actual tach picked
up by the console will be shown in the upper right corner of the
display window.
2. Start stepping on the steps. The number in the right hand corner of
the console should increase to 2000 RPMs (+/- 200). If the tach signal
picked up by the console is less then 1900 RPMs then there is a
problem in the AC tach circuit - either with the console software,
alternator (check the AC tach wire, the field wire, the diode, and the
terminal posts), or the main cable.
Error Reporting
The console will display various error messages in the display window. The total
amount of errors will be displayed in the upper right numeric window. Note that
only the highest priority reported error will be displayed. Errors are handled in
two ways. One as a non-fatal “WARNING” which will display the text message
but continue system operation until the user presses the [CLEAR] key. The sec-
ond way is as a fatal “ERROR” which will stop the exercise and return the system
to an idle intensity state. The console will display the error text and not let the
user restart the programs unless power has been turned off and then back on.
The following microprocessor errors require a console replacement;

ALU ERROR, TIMER ERROR, and STATIC RAM ERROR.
Resetting the power may clear the following microprocessor errors;

EEPROM ERROR, and PROGRAM ERROR. If resetting the power doesn’t work, the
console may need to be replaced.
Page 41
The Telemetry (Polar®) Heart Rate Test
The telemetry heart rate system is made up of the console, the heart rate re-
ceiver, and the chest strap (available separately). You can test each component
by performing the following steps:
1. You will need to put a chest strap on in order to test the telemetry
heart rate. Before you put on the chest strap, wet the two contact
patches. Secure the chest strap as high under your pectoral muscles
(chest) as is comfortable. The chest strap should fit snugly,
comfortably, and allow normal breathing.
2. A flashing ♥ should be displayed on the console. Your heart rate, in

beats per minute, will show next to the heart icon. If the heart icon
does not show, or if your heart rate is not displayed on the console
then you have a problem with either the console, chest strap, or
heart rate receiver.
3. Verify that the console software has been set up to receive telemetry
(see the heart rate monitoring section of this manual). Note that
holding the contact heart rate sensors (if enabled) can inhibit the
telemetry heart rate input from working.
4. Test your chest strap with a machine that you know is working, or
with a heart rate watch that you know is working.
5. If possible, replace or exchange your console with a machine that you

know is working and retest the machine.
6. Excess false heart rate detection: the telemetry receiver located in the
console is susceptible to mechanical vibration as well as external elec-
trical interference. Hitting the console or the frame may momentarily
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 ma-
chine into a different outlet, or moving it to a new location.
Page 42
If you have problems with erratic speed control while operating the machine, the
cause may be either electrical or mechanical in nature. You will have to remove
the side covers to conduct most of these tests.
1. Inspect the Poly- V belt for proper tension and excessive wear. A loose
belt will cause excessive noise and wear. The machine will run slug-
gishly if the belt is too tight.
2. Replace a worn or frayed Poly-V belt. Adjust the belt so that there is 1/
10" (0.3 cm) deflection at a point midway between the alternator and
transmission pulleys with fingertip pressure (See Drawing Below).
3. Check for proper wire connections on the alternator, relay assembly

circuit board, and load resistor (See Drawing Below).
Page 43
4. Replace or exchange the console with another console you know is
good and retest the machine.
B. Check the relay assembly circuit board while the console displays "SELECT
WORKOUT." You will need an assistant to complete the test of the
relay assembly circuit board.
1. Remove the right side cover. Locate the relay assembly circuit board
located just inside the frame, midway between the top and bottom
steps (refer to Wiring Diagram). There are three red indicator lights
along the bottom edge of the circuit board. They are labeled, from top
to bottom: Field, Power, and Relay. Ensure the black and white wire
power connector (labeled J2 on the relay assembly circuit board) is
securely connected to the relay assembly circuit board (refer to Figure
Below).
2. If the Power light is lit, go to step #3. If it is not, perform the tests as
described in step 4b - c of the “Console Fails to Power Up” section.
3. The relay indicator light should be lit. If it is lit, proceed to step #5. If it
is not, use a jumper wire on the relay assembly circuit board. Jump
the silver tabs #1 (labeled RLY/RED) and #5 (labeled GRD/BLK) (refer
Page 44
to Figure on page. 34). The relay indicator should light up. If it does, go
to step #4. If the relay indicator does not light up, the relay assembly
circuit board must be replaced. Replace the relay assembly circuit
board and retest the machine.
4. You must check the cable assembly for continuity if the relay indicator
lit up when you jumped tabs #1 and #5.
a. Unplug the main cable from the position labeled J1 on the relay
assembly circuit board. Disconnect the console cable from the
back of the console. Set your multimeter to the continuity check
mode; on most meters, this will be the resistance or ohms setting.

connector end of the console cable (refer to Wiring Diagram).
Place the other lead on pin #1 at the end of the main cable you
disconnected from the relay assembly circuit board. You will get a
reading of near zero ohms if there is continuity in the cable
assembly.
c. Check continuity in both ends of the main cable assembly at pin

#5.
d. If there is no continuity in the cable assembly at either pin,

replace the cable assembly and retest. If there is continuity in the
cable assembly at both pins and the relay resistor indicator is not
lit, the console is inoperable and must be replaced.
5. Have your assistant step on the staircase (leave the console in the
ATTRACT mode) while you check the field indicator light. It should be
flickering. If it is and you still have a speed control problem, go to step
#6.
If it is not flickering, ensure the following: the console cable is

connected to the console; the console/main cable connection is
secure; the connector at position J1 on the relay assembly circuit
board is securely connected; that there is continuity in the cable
assembly. To check for continuity:
Page 45
a. Unplug the connector at position J1 on the relay assembly circuit
board. Disconnect the console cable from the back of the
console. Set your multimeter to the continuity check mode; on
most meters this will be the resistance or ohms setting.

connector end of the console cable. Place the other lead on pin
#2 at the end of the main cable you disconnected from the relay
assembly circuit board. You will get a reading of near zero ohms if
there is continuity in the cable assembly.
c. If there is no continuity in the cable assembly, replace it and

retest. If there is continuity in the cable assembly and the field
indicator light is still not flickering, contact the Customer Service
Department at 800-331-3578 for further assistance.
6. If the field indicator was flickering while your assistant was on the
machine and you still have a problem with speed control, you need to
test the alternator.
a. Disconnect the white wire (labeled positive output on the

alternator) and the brown wire (labeled “Field” on the alternator).
Use a jumper wire to jump the Field and positive output terminals
of the alternator.
b. Have your assistant step onto the staircase. Does the staircase
slow down? If it does not, you need to replace the alternator. If
the staircase does slow down, contact the Customer Service
Department for further assistance.
c. Replace or exchange the alternator with another alternator you

know is good and retest the machine.
d. Test the load resistor as outlined in the "Load Resistor Test"

section of this Manual. If the speed control problem still exists,
contact the Customer Service Department at (800) 331-3578 for
further assistance.
Page 46
LOAD RESISTOR TEST
The alternators are heavy-duty models designed to withstand the rigors of
commercial use. One possible reason for repeated failure is an inoperable load
resistor. To test the load resistor:
2. Locate the load resistor mounted to the relay board assembly just under
the staircase.
3. Disconnect one black wire from the resistor (See Drawing Below).
4. Set your multimeter for R x 1 or the lowest available resistance range. If

you have an analog multimeter, touch the two leads together and adjust
the meter for a zero reading.
5. Place one lead on Tab A and one lead on Tab 5 of the relay assembly
circuit board (See Drawing Below). You should get a reading of
approximately 1.0 ohm or less.
6. Replace the load resistor if the reading is out of range and retest the new
load resistor.

(800) 331-3578 for further assistance.
Page 47
If you hear a grinding or clicking noise, or experience excessive vibration during
exercise, or if the steps are not functioning properly, you probably have a
problem in the drive train. Attempt to isolate the problem area by performing the
following tests in precisely the order listed below. Refer to the “Parts Removal
and Replacement” Section of this Manual for all disassembly and assembly
instructions.
1. Unplug the power supply from the AC wall outlet and remove the side
covers.
! WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE
WHILE THE SIDE COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS
WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE.
2. Check the condition and the tension level of the Poly-V belt. Replace the
belt if it is excessively worn.
a. Adjust the tension level so that you can deflect either side of the
belt 1/10" (0.3 cm) at the center between the alternator and the
transmis sion pulleys (See Drawing Below). Noise can be generated
by a belt that is too tight or too loose.
b. If the noise is still present, remove the Poly-V belt and rotate the
staircase without standing on it. With the Poly-V belt removed, the
staircase will rotate very quickly.
Page 48
a. Unplug the alternator from the relay board and remove the Poly-V
belt.
b. Spin the alternator pulley with your fingers. It should spin freely and
remain spinning for at least one and one-half revolutions. If it does
not spin as it should, the bearings may be bad and the alternator
should be replaced.
c. If the pulley does spin freely, check the alternator for noise,
roughness, or the presence of black powder inside the alternator or
near the outside of the case. If any of these conditions exist, the
brushes may be bad and the alternator should be replaced.
d. Reconnect the Poly-V belt and adjust the belt tension.
4. Check the drive chain mechanism. Rotate the stairs and look for chain
links that do not flex as the chain travels over the sprockets. If the links are
frozen or sticking, replace the chain.
a. Rotate the steps by hand and listen for the noise.
b. If you hear the noise, remove the drive chain and the Poly-V belt.
Rotate the steps by hand again and listen for the noise. If the noise
has gone away, replace the transmission.
a. Have your assistant slowly exercise on the machine. Observe the

staircase. If the staircase moves to the left or right during exercise,
ensure the set screws in the bearing adjusters are tight.
b. Rotate the stairs and look for chain links that do not flex as the chain
travels over the sprockets. If the links are frozen or sticking, replace
the chain.
Page 49
7. Check the condition of the upper and lower sprocket assemblies. Replace
the sprocket assembly if it is worn excessively, has broken teeth, or if it is
bent.
8. Check the alignment of the upper and the lower sprocket assemblies. The
outside face of the upper and lower sprockets should be 1-11/16" (4.3 cm)
from the outside edge of the left frame rail. Loosen the nuts on the pillow
block bearing collars and tighten or loosen the bearing adjuster set screws
until the distance to both sprockets is correct. Tighten the pillow block
bearing nuts and verify the distance.
9. Check the step assembly. Step Tread
a. Rotate the steps and check the

hinges, step shafts, washers, and Step Hinge
bearings (See Figure to Right) for
2 X Nut
wear, corrosion and lack of
lubrication. Replace any worn
parts.
b. Ensure the nuts at each step

shaft end are tight.
4 X Washer
Step Shaft 2 X Bearing
10. Reinstall all parts. If the problem still exists, contact the Customer Service
Department at 800-331-3578 for further assistance.
Page 50
COVERS
! WARNING
TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE
THE SIDE COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS WHILE
ANYONE'S HANDS ARE INSIDE THE MACHINE.
There are five covers on the machine: two side covers, a back cover, a bottom
cover, and a top cover. The side covers overlap the top cover. The side covers
must be removed before the top cover and/or the bottom cover can be removed.
All covers are held in place with reusable plastic fasteners (refer to Figure 5
for their location). To remove the fasteners, slide either end of the fastener
removal tool under the edge of the pin head (refer to Figure 6). The pin should not
be removed. Pull the cover away from the frame. Do NOT use the fastener
removal tool or any other sharp tool to pry out the fastener base because you
may damage the covers - use the fastener removal tool to remove the pin.
To reinstall the fastener, insert the base of the fastener through the cover
and into the frame. When the base is in place, push the pin in all the way to
secure the fastener.
Side Covers
Top Cover
3. Set the top cover in place. Secure the side covers to complete
reinstallation.
Page 51
Back Cover
2. Align the holes in the frame and the back cover. Secure the back cover
with the 8 fasteners.
Bottom Cover
3. Remove the six fasteners and remove the bottom cover from the frame.
4. Reinstall the bottom cover, then the two side covers. Remember to
connect the DC power cable.
CONSOLE
1. Locate the mounting knobs on the back of the console (See cutaway view
Below).
2. Loosen and remove the four mounting knobs and lock washers.
3. Lift up the console and unplug the console cable from the back of the
console.
4. Remove the console from the frame.
5. Reinstall the console by reversing

the steps.
Page 52
POLY-V BELT
! WARNING
THE POLY-V BELT MUST BE ADJUSTED SO THAT THE CENTER OF EITHER
SIDE CAN BE DEFLECTED 1/10" (0.3 CM) FROM ITS CENTER LINE WITH FINGER-
TIP PRESSURE. A TIGHT BELT WILL CAUSE SLOW AND SLUGGISH OPERATION; A
LOOSE BELT WILL CAUSE EXCESSIVE NOISE AND BELT WEAR.
2. Loosen the adjustment bolt that mounts the alternator to the slotted
alternator brace then loosen the pivot nut.
4. When reinstalling the Poly-V belt, pivot the alternator forward or back as
necessary to allow 1/10" (0.3 cm) of play on either side of the belt (See
Figure Below).
5. Tighten the adjustment bolt and verify the Poly-V belt tension.
DRIVE CHAIN
2. Remove the retaining clip and retaining plate from the drive chain master
link. Do not remove the master link from the drive chain yet.
Page 53
3. Push up on the idler arm with one hand to relieve the tension on the
drive chain (See Drawing Below). Remove the master link from one end of
the drive chain and remove the drive chain from the sprockets.
4. Install the new drive chain by reversing the steps.
STEP ASSEMBLY
2. Rotate the stairs until the step you want to remove is positioned in the
middle of the staircase.
Step Tread
3. Loosen and remove the nut from one end
of the step shaft on both the upper and
the lower hinges of that step (See
Step Hinge
Figure to Right).
2 X Nut
4. Remove the bearing and the washer

from each step shaft.
5. Grasp the opposite step retaining

nut with pliers or locking pliers.
Pull the step shaft out of the 4 X Washer
upper and lower step hinges. 2 X Bearing
Step Shaft
Page 54
Be careful to not lose the washer located between the step and the
modified link.
Note: Each step assembly weighs approximately 15 lbs. Be aware of finger

placement when removing the step assembly.
STEP CHAIN ASSEMBLY
2. Rotate the stairs to position the step chain master link on the lower span
of the chain. It may be necessary to reduce the chain tension to remove
the master link. Perform the following steps to reduce the chain tension:
• Count and write down the number of exposed threads on the top
bearing adjuster set screw for a reference when you reassemble the
parts (SeeFigure Below).
Page 55
• Loosen the nuts on the pillow block bearing housing.
• Loosen the bearing adjustment set screw until the chain tension level
is relieved to a point where the master link may be disconnected.
4. Using the old master link, connect the new chain assembly to the lower
half of the old chain assembly.
5. Remove the nut from the step shaft above the master link. It may be
necessary to place another 5/16"-18 nut on the opposite end of the step
shaft to gain leverage and remove the nut.
6. Remove the bearing, the outer step shaft washer and the modified link of
the old step chain assembly from the step shaft.
7. Place the modified link of the new step chain assembly on the step shaft.
Reinstall the outer step shaft washer, bearing and nut.
8. Rotate the steps until the next step shaft is in approximately the same
place as the previous step shaft.
9. Repeat steps 6-8 until the new chain assembly is installed on the
remaining step shafts.
11. Connect the new chain assembly together with the master link. Tighten
the bearing adjustment set screw until the same number of threads as in
step 2 are exposed. Tighten the nuts on the pillow block bearing housing.
12. You should consider replacing the opposite step chain so that both chains
will wear equally.
Page 56
4. Count and write down the number of exposed threads on the bearing
adjuster set screws on both sides of the machine for a reference when
you reassemble the parts (See Drawing Below).
6. Loosen the adjustment screws until the tips of the screws are flush with
the inside face of the bearing adjusters.
Page 57
7. Have an assistant support the sprocket assembly. Loosen and remove the
nuts on the pillow block bearing housing.
9. Loosen the two set screws on both of the pillow block bearing collars and
remove the pillow block bearings from the sprocket axle.
10. To reinstall the sprocket assembly:
• Slide the pillow block bearings on both ends of the sprocket axle. Do
not tighten the set screw on the pillow block bearing collars yet.
• Place the bearing adjusters and the sprocket assembly onto the frame
and start the pillow block bearing housing nuts onto the frame.
• Slide the sprocket assembly toward the front of the machine while
tightening the pillow block bearing housing nuts.
• Align the sprocket assembly. The outside face of the left sprocket
should be 1-11/16" (4.3 cm) from the outside edge of the left frame
rail. Move the sprocket axle within the pillow block bearing collar as
needed to get the correct distance.
• When the distance is correct, tighten the pillow block bearing collar
set screw on the left and right sides of the machine.
• Loosen the pillow block bearing housing nuts slightly. Tighten the
bearing adjuster set screws until the exact number of threads are
exposed (refer to your notes taken earlier). Tighten the pillow block
bearing housing nuts.
• Check the alignment of the other sprocket at this time. If the distance
from the outside edge of the left frame rail to the outside face of the
sprocket is not 1-11/16" (4.3 cm), loosen the set screws on the left
and right side pillow block bearing collars and adjust the axle. Tighten
the pillow block bearing collar set screws on the machine and then go
to step 11.
Page 58
11. Complete the reassembly of the machine by performing steps 1- 4 in
reverse order.
CABLE ASSEMBLY
2. Remove the console and unplug the console cable from the back of the
console (See Drawing Below). Unplug the plastic connectors at the console
cable/main cable junction.
3. Hold the console connector and pull the console cable up and out of the
handrails.
4. Reinstall the console cable by pushing the white plastic connector end
down through the handrails. Do not connect the console, and the main
cables.
5. Remove the main cable from the wire saddles.
Page 59
6. Unplug the white plastic connector labeled J1 on the relay assembly
circuit board.
9. To reinstall, place the main cable into the wire saddles. Reattach the cable
to the vertical support with four tyraps.
10. Plug the white plastic connector of the main cable into the relay assembly
circuit board at the spot labeled J1.
11. Plug the console cable into the back of the console. Reattach the console
to the handrail mount. Plug the connectors together at the main cable/
console cable junction.
1. Remove the left and right side covers.
5. Remove the transmission bracket by loosening and removing the

mounting hardware on the alternator and the transmission.
6. Remove the transmission brace by loosening and removing the mounting

hardware from the transmission and the frame.
Page 60
7. Support the transmission while loosening and removing the four
transmission mounting bolts. Remove the transmission and rubber pad
from the frame (See Drawing Below).
9. Ensure the Poly-V belt is tensioned according to the procedures outlined in

the “Poly-V Belt” section of this Manual.
ALTERNATOR ASSEMBLY
of the wires removed from each terminal.
Page 61
5. Remove the alternator adjustment bolt (See Drawing on Pg. 51).
6. Remove the nut, bolt and mounting hardware from the alternator bracket.
Remove the alternator from the frame.
7. Reinstall the alternator by reversing the removal procedures. Be sure to

verify the wiring connections.
8. Ensure the Poly-V belt is tensioned correctly (See Drawing Below).
RELAY/RESISTOR ASSEMBLY
of the wires that are removed from each terminal.
4. Unplug the main cable connector from the J1 position on the relay circuit
board.
Page 62
6. Loosen and remove the four mounting bolts and remove the relay/resistor
assembly from the frame.
7. Reinstall the relay/resistor assembly in the reverse order. Verify the wiring
connections before attaching the side cover.
Page 63
GROUNDING INSTRUCTIONS
The machine must be grounded. If it should malfunction or break down, ground-
ing provides the path of least resistance for the electric current, thereby reducing
the risk of electric shock. This machine is equipped with a cord having an
equipment-grounding conductor and a grounding plug that looks like the plug
illustrated in sketch A in the Drawing below. International machines may vary. It
must be plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
! DANGER
IMPROPER CONNECTION OF THE EQUIPMENT-GROUNDING
CONNECTOR CAN RESULT IN THE RISK OF ELECTRIC SHOCK. CHECK
WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN
DOUBT AS TO WHETHER THE MACHINE IS PROPERLY GROUNDED. DO
NOT MODIFY THE PLUG PROVIDED WITH THIS MACHINE. IF IT WILL NOT
FIT THE AVAILABLE OUTLET, HAVE A PROPER OUTLET INSTALLED BY A
QUALIFIED ELECTRICIAN.
A temporary adapter that looks like the adapter illustrated in sketches B and
C may be used to connect this plug to a two-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 lug extending from the adapter must be
connected to a permanent ground such as a properly grounded outlet box cover.
Whenever an adapter is used, it must be held in place by a metal screw.
Figure 5: Grounding System
Page 64
FCC 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 communica-
tions. Operation of equipment in a residential area may cause harmful interfer-
ence in which case the user will be required to correct the interference at his
own expense.
! WARNING
CHANGES OR MODIFICATIONS TO EQUIPMENT NOT EXPRESSLY APPROVED BY
STAIRMASTER® HEALTH & FITNESS PRODUCTS, INC. COULD VOID THE USER’S
AUTHORITY TO OPERATE THIS EQUIPMENT.
CANADIAN DOC CLASS A COMPLIANCE
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.
La présent appareil numérique ne dépasse pas les limites etablies pour les bruits
radioélectriques applicables aux appareils numériques de la Class A prescrites
dans les règlements sur le brouillage radioélectrique édicté par le Ministère des
Communications du Canada.
Page 65
IMPORTANT PHONE NUMBERS
If you need assistance, please have both the serial number of your machine and
the date of purchase available when you contact the appropriate
StairMaster® Health & Fitness Products, Inc. office listed below.

(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
For technical assistance and a list of distributors in your area, please call or fax
one of the following numbers.
INTERNATIONAL DIVISION ASIA PACIFIC HEADQUARTERS

(425) 823-1825 Telephone/Fax:+81-45-590-5686
FAX: (425) 820-7505 E-mail: stairintl@aol.com
E-Mail: intlservice@stairmaster.com
EUROPE: HEADQUARTERS
+41-91-827-3801
FAX: +41-91-827-8902
E-Mail: stairmasterch@swissonline.ch
GERMANY: HEADQUARTERS
+49-2204/610-27
FAX: +49-2204/628-90
E-Mail: stairmaster.de@t-online.de
U.K.: HEADQUARTERS
+44-1908/267-345
FAX: 44-1908/267-346
E-mail: stairmasteruk@msn.com
Page 66
Left Handrail
22947-03
Right Handrail
22946-03

Back Panel Top Cover
21304 22555
8 X 22086
Caution Decal
Distribution Decal Right Side Cover
Serial Number Decal 23 X 24757 22547
7 X 24757 Compliance Decal
36 X 22086
Left Side Cover

22544 Bottom Panel
22563 Inside Panel
FIGURES
Right - 24638
Page 67
Left - 24639
Transport Wheel Assembly

2 X 10262
FIGURES
Page 68
24 X 21363
Step Assembly (w/Tread)

8 X 21396
Step Tread Modified Link
8 X 21398 (22063)
(23082)
(22128)
Console
80 X 20528 (22128)

80 X 20508
Modified Link
Detail A
Step Shaft Bearing Step Shaft
16 X 23082 8 X 20762
(22128)
32 X 22128
Step Shaft Nut
16 X 22063
See Detail A
FIGURES
Page 69
Upper Sprocket Assembly
Page 70
(42-Tooth Sprocket)
FIGURES
23424-03
8 X 22071
Bearing Plate (22071)
2 X 20682
(22072)
4 X 10037
(22071)

6 X 22032
(22039)
Pillow Block Bearing
4 X 20012 4 X 22039
8 X 20034 2X 22072
8 X 22030 8 X 22029
Lower Sprocket Assembly

Chain Section, #40 Chain Section, #40 10205-03
5.5” 11.5”
4 X 20532 4 X 20531
Master Link
2 X 25305
(23424-03) See Detail A (10205-03)

Chain Assembly (with Modified Links)
2 X 10195
Detail A
Modified Link
40215
2 X 22191
4 X 22028 22163
4 X 22027 22029

22030
Transmission Pad
20808 2 X 22191
(22191) 22433
20114
23591
(22037) Transmission Assembly Mounting to the Frame

Alternator
Transmission Transmission Pulley 20205
20001 24662
(22036) 20202
22042
20693
20007 4 X 22036
(22036)
22043 (22038) Poly-V Pulley
22983 (22036)
(22036) 21247
4 X 22038
(22038)
23427 Frame Upper Sprocket Assembly
10059 10860 23424-03
(22435) 22075
2 X 22435 Drive Chain
2 X 22037 (22038) 22146 23257 Transmission Assembly
2 X 22164 2 X 22026
20547 (22164) 23591
22139
FIGURES
Page 71
Master Link
25305
Drive Chain Assembly
Page 72
FIGURES
Console
4 X 22213 Console Cable

2 X 24643 21416
2 X 22937
2 X 21363 4 X 22323 Fastener, Hook
22938
10794-03 Fastener, Loop
Tywrap 22939
2 X 22323 25233
Grommet
2 X 22213 Polar Cable Assy, 12” 24663
24643 26143
22097
Figure 11: Wiring Diagram

Heart Rate Cap
21765
Receiver, Polar® Cut-Away View of Polar Receiver
Grommet Plug-in
15034 25165
4 X 22323
4 x 22213 4 X 22028 W-4
4 x 24643 AC Tap
2 X 24640 W-6
5 X 23792 W-5 Ground Relay Board
Positive
4 X 22036 Output W-5 W-2
W-4
(22933) Main Cable W-3 W-6
21769 W-2
W-1
4 X 20473
W-1
B
Relay/Resistor Assembly
W-3 22933
B Field
Power Connector
21768
4 X 22663
22109
22134
22110
Section B-B
FIGURES
Figure 12: Relay Board
Page 73

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STEPMILL 7000 PT

PART NUMBER 27698 1

2. REMOVE TOP COVER FROM CARTON,

3. REMOVE PLASTIC BAG FROM

4. USE KNIFE TO REMOVE PLASTIC

5. REMOVE STEPMILL FROM PALLET:

6. REMOVE BUBBLE PACK AND CARTON

7. REMOVE CONSOLE FROM BUBBLE

8. USE A KNIFE TO OPEN CARTON.

9. THE CARTON CONTAINS OWNER’S

10. THE HARDWARE PLASTIC BAG

11. TWO WHEELS ARE USED TO MOVE

12. USE KNIFE TO REMOVE STRETCH

13. THE POWER SUPPLY CARTON

14. USE TWO 9/16” WRENCHES AND

15. GET CONSOLE BRACKET FROM

16. GET FOUR PLASTIC COVERS AND SNAP

17. USE A 5/32” ALLEN WRENCH TO

18. GET MAGAZINE RACK AND POSITION

19. GET FOUR CONSOLE SCREWS AND

20. GET TWO WHEELS, TWO AXLES, AND

21. INSTALL CLIP INTO HOLE IN AXLE TO

23. REMOVE ALL PACKING MATERIALS

25. SEE OWNER’S MANUAL FOR SET UP

© 1996 StairMaster Sports/Medical Products, Inc.. StairMaster and Stepmill are

• Your name, shipping address, and telephone number;

StairMaster Sports/Medical Products, Inc. neither makes, assumes nor

* Note: Aerosol products cannot be transported via air.

WHAT IS IN THIS MANUAL?

Following the information on installation and a brief explanation of how the

WHAT IS THE STAIRMASTER STEPMILL 7000 PT EXERCISE SYSTEM?

The StairMaster Stepmill7000 PT exercise system is avertical climbing machine with a

BASIC OPERATING INSTRUCTIONS 6

PARTS REMOVAL AND REPLACEMENT 40

IMPORTANT SAFETY INSTRUCTIONS

Read all instructions before using the machine.

• To reduce the risk of burns, electric shock, or injury to persons:

1. The external power supply should always be unplugged from the AC

2. Close supervision is necessary whenever the machine is used by. on,

8. Do not use the machine outdoors.

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

I SAVE THESE INSTRUCTIONS I

Table 1. Dimensions and Specifications for the

Power Supply Specifications, PS 7:

1. Roll the machine to its desired location on its temporary wheels.

5. A<!just the leg levelers as necessary to level the machine.

7. Unwrap the power supply assembly from the console.

• 4. Overweight or severely deconditioned individuals should be particularly

5. Although all equipment manufactured by StairMaster Sports/Medical

YOUR FIRST WORKOUT ON THE STAIRMASTER~ STEPMILL ~ 7000 PT

The ATIRACT Mode

• Figure 1: Console Diagram

3. DISTANCE provides a cumulative total of the equivalent distance, in miles (or

7. CALORIES provides a running total of the Calories burned during a workout.

11. The + and • ARROWS increase or decrease, respectively, the workout

Pressing [WORKOUT STATS] while the console is in the ATIRACT

EXERCISE PROGRAM KEYPAD

"PRESS ENTER KEY TO SELECT"