Testing for Continuity of the Gray Cable on a Stairmaster 4000PT

1. First disconnect the grey cable from the back of the console and UNPLUG YOUR MACHINE from the wall.
2. If your cable has a 6-pin round connector, you will need to check pin sockets #5 (black wire), #3 (blue wire), #2 (brown wire) and #4 (white wire) with your ohmmeter for continuity in each pin. Should get continuity from all if cable is good.

If your cable is a 9-pin cable, you will need to check pin sockets #5 (blue wire), #3 (black wire), #2 (brown wire) and #4 (white wire) with your ohmmeter for continuity in each pin. Should get continuity from all if cable is good.

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Stairmaster Stepper 4000PT Alternator Belt Replacement WARNING: The belts must be properly tensioned. A belt that is too loose will cause slow and sluggish operation. A belt that is too tight will cause excessive noise and belt wear.

1. Remove side covers.
2. Loosen the adjustment screw that mounts the alternator to the alternator brace and the pivot adjusting bolt that mounts the alternator to the frame.
3. Pivot the alternator down and remove the belt.
4. Make sure the is centered on the pulleys during installation.
5. Pivot the alternator up or down as necessary to allow 1/4" (0.6 cm) of belt deflection with fingertop pressure at the midpoint between the two pulleys.
6. Tighten the alternator adjustment bolt. Verify 1/4" (0.6) deflection in the belt.
7. Reinstall the covers

How to Replace Alternator Belt on Stairmaster 4000PT Stepper

Preform this test if you are having trouble entering data into the console. If you cannot enter the DIAGNOSTIC code due to an inoperable keypad, replace the console.

1. Press [2] to start the test.
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 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 10 seconds later.

How to Perform Keypad Test on Stairmaster 4000PT

Stairmaster Stepper 4000PT Spring Pulley Replacement

1. Remove the bottom cover.
2. Unhook the pedal arm return spring from the spring hanger.
3. Remove the snap ring from th pulley shaft. WARNING: To reduce the risk of eye injury, wear eye protection when removing snap rings.
   
4. Slide pulley and washer off the shaft.
5. Before reinstalling the pulley, clean the pulley shaft thoroughly with a clean, dry cloth. Apply a thin coat of multipurpose grease to the pulley shaft.
6. Slide the pulley and washer onto the shaft. Install the snap ring.
7. Route the spring under the spring pulley.
8. Hook the end of the spring over the spring hanger. WARNING: Do not twist the spring during installation. It will wear excessively and reduce the life of the spring.
   
9. Reinstall the cover.

How To Replace Spring Pulley on Stairmaster 4000PT

Replacing a Pedal Arm Return Spring on the Stairmaster 4000PT Stepper

How To Replace a Spring on Stairmaster 4000PT

1. Remove bottom cover.
2. Unhook the pedal arm return spring from the spring hanger.
3. Detach the spring from the step chain by removing the master link. The spring-chain connector is in good condition if it has an hour glass shape. Replace a worn spring-chain connector.
4. Check to ensure that the spring pulley turns freely and is not worn excessively. Refer to the "Spring Pulley" section if you have to replace the pulley.
5. To reinstall th spring, connect it to the end of the step chain using the master link.
6. Route the spring under the spring pulley.
7. Hook the end of the pedal arm return spring onto the spring hanger. WARNING: Do not twist the spring during installation. It will wear excessively and reduce the life of the spring.
   

How to Replace Pedal Arm Return Spring on Stairmaster 4000PT