Stairmaster CORE HEALTH & FITNESS 4G User manual

ASSEMBLY
MANUAL
CORE HEALTH & FITNESS
4G
To access the full Owner’s Manual for this product scan or visit:
QR.COREHANDF.COM/OM4G

Page 2
Before using this product, it is essential to read the ENTIRE Owner’s Manual and ALL installation instructions. The
Owner’s Manual describes equipment operation and instructs members on how to use correctly and safely.
Read all warnings posted on the machine.
Health related injuries may result from incorrect or excessive use of exercise equipment. Core Health & Fitness
strongly recommends you to encourage your members to discuss their health program or fitness regimen with
a health care professional, especially if you or they have not exercised for several years, are over 35, or have
known health conditions.
WARNING!
DANGER: to reduce the risk of electrical shock:
1. Always unplug the machine from the electrical outlet before
cleaning or servicing.
2. This product is factory-equipped with a specific DC Power
Supply to permit connection to the proper electric circuit.
Make sure that the product is connected to a dedicated
power line having an outlet with the same configuration as
that of the plug.
3. Improper connection of the equipment-grounding conductor
can result in a risk of electric shock. Check with a qualified
electrician or serviceman if you are in doubt as to whether
the product is properly grounded. Do not modify the plug
provided with the product. NO adapter should be used with
this product. If the product must be reconnected for use on
a different type of electric circuit, the reconnection should
be made by qualified service personnel in order to avoid a
hazard.
4. This machine is not intended to be serviced by the end user,
refer servicing to qualified personnel only.
5. If the power supply cord is damaged, it must be replaced
by the manufacturer, its service agent, or similarly qualified
persons in order to avoid hazard.
6. Keep the cord away from heated surfaces. Unplug
power cord when the machine is unattended and before
performing any preventative maintenance such as cleaning
or replacing a worn part.
7. Do not operate unit in damp or wet locations.
WARNING: to reduce the risk of serious injury to persons
using this equipment, read and follow all of these warnings:
24 in (0.6 m)
48 in (1.25 m)
Fig. 1 Required Clearance
1. Assemble and operate the machine on a solid level surface.
Position the machine with a minimum of 48 inches (1.25
meters) of clearance to allow for ease of mounting and
dismounting. Allow for 24 inches (0.6 meters) of clearance
behind the machine. A ceiling height of 10’ (3.0 meters)
is recommended to accommodate most users. These
dimensions are the recommended minimum distances.
The actual area for access and passage shall be the
responsibility of the facility and should take into account
this training envelope, Americans with Disabilities Act
Accessibility Guidelines (ADAAG) requirements and any
required local codes or regulations
(www.access-board.gov/ada).
The clear safety area recommendations are accurate as of
the time of this manual publication, Core Health & Fitness
strongly recommends that you review the latest applicable
standards from:
IMPORTANT SAFETY INSTRUCTIONS

Page 3
ASTM standards for Stationary Training Equipment (https://
www.astm.org/)
and ISO standards for Stationary Training Equipment
(https://www.iso.org)
2. This equipment is designed for use in a commercial
gymnasium or health club. To ensure the proper use of the
equipment in a safe manner, all users of the equipment
should read this manual before using the machine. This
machine should be made a part of your club training
program in order that the equipment is used by your
members in a safe manner as intended. In addition to
instructing the club members in the proper use of the
equipment, the club member should obtain a complete
physical examination from their health care provider before
beginning any exercise program.
3. The safety and integrity of this machine can only be
maintained when the equipment is regularly examined for
damage and wear and repaired. It is the sole responsibility
of the owner of this equipment to ensure that regular
maintenance is performed. Worn or damaged parts must
be replaced immediately or the equipment removed from
service until the repair is made.
4. Do not exceed the maximum allowable user weight limit of:
• 350 lbs. (159 kg.)
5. It is the purchaser’s sole responsibility to properly instruct
its end users and supervising personnel as to the proper
operating procedures of all Stairmaster equipment.
6. This machine is not intended to be used by children. It is
not intended to be used by persons with reduced physical,
sensory, or mental capabilities or lack of experience
and knowledge, unless given instruction and under the
personal supervision concerning use of the machine by a
person responsible for their safety. Do not leave children
unsupervised around the machine.
7. Wear proper exercise clothing and athletic shoes during a
workout. Avoid wearing loose clothing. Tie back long hair
and keep towels away from the moving parts. Face forward
at all times and never attempt to turn around while the
machine is moving.
8. Obtain a medical exam before beginning any exercise
program. If at any time during exercise you feel faint, dizzy,
or experience pain, stop and consult your physician. Use the
value calculated or measured by the console for reference
purposes only.
9. Inspect equipment before each use. Replace all parts at the
first sign of wear or damage. If in doubt about a certain part,
DO NOT use the equipment until the part is replaced.
Failure to replace worn or damaged parts may result in
serious injury or even death.
10. Replace any “Caution”, “Warning”, or “Danger” labels that
are illegible or damaged.
11. Use only replacement components supplied by StairMaster.
Substitutes are forbidden and will void all warranties.
12. This equipment should only be used in a supervised
environment.
13. Familiarize yourself with the location of the STOP buttons on
the console and right handrail.
• Pushing the STOP button will bring the machine to a complete
stop and signals machine to go into pause mode.
• Pushing the STOP button twice will bring the machine to a
complete stop and end your workout.
14. Always wear closed toe shoes when operating this machine.
15. Serious injury is possible if caution is not used while
exercising on this machine.
16. Use the handrails to mount or dismount the machine. Do not
step off of the machine while it is moving. Press the STOP
button and wait for the machine to come to a complete stop
before dismounting.
17. Do not operate the machine if the shrouds are removed or
if the power cord is damaged in any manner. Keep all air
openings free from dirt or any material that would block the
flow of air to the motor.
18. Do not over exert yourself during exercise. Stop exercising
if you feel pain or tightness in your chest, become short
of breath or feel faint. If you feel pain or experience any
abnormal symptoms, stop exercising and consult your
health care provider.
19. WARNING: Heart rate monitoring systems may be
inaccurate. Over-exercising may result in serious injury or
death. If you feel faint stop exercising immediately
20. Noise emission under load is higher than without load.
SAVE THESE INSTRUCTIONS

Page 4
The pages in this section show examples of the warning labels and communication stickers placed on the equipment as part of the manufacturing process. It is
critical that owners maintain the integrity and placement of these stickers. If you find any stickers missing or damaged the replacement numbers are shown on
the support site. For console warnings, see the console Owner’s Manual for details. See Support and Service to order replacements. NOTE: STICKERS AND
LABELS ARE NOT SHOWN TO SCALE
Serial Label
050-5711
Console Warning
Fig. 2 Shown with 19” OpenHub
SKU: 9-3415 Description: 4G
Unit Weight1Width Length Height Max User Weight
348 lbs
158 kg
29 in
74 cm
54 in
137 cm
64 in
163 cm
80 - 350 lbs
36 - 159 kg
1 Shipping Weight (Boxed): 434 lbs (197kg)
Shipping Dimensions: 49in x 30in x 43in (125cm x 76cm x 109cm)
PRODUCT SPECIFICATIONS

Page 5
WHAT’S IN THE BOX
D
J
B
A
H
N
E
G
L
F
I
MO
K
C
Fig. 2
# PN Description
A 020-8110-XX ASSY, SHROUD, PLASTIC, SIDE, TOP, RADIAL, R, W/ CLIP, 4G
B 020-8111-XX ASSY, SHROUD, PLASTIC, SIDE, TOP, RADIAL, L, W/ CLIP, 4G
C 020-8113-XX ASSY, SHROUD, PLASTIC, CENTER, FRONT, W/ CLIP, 4G
D 020-8119-XX ASSEMBLY, NECK SHROUDS, 4G
E 020-8146-XX CLAMP, R25, M8 C-BORE HOLE, SM
F 020-8147-XX CLAMP, R25, M8 THREAD HOLE, SM
G 050-5885 ASSEM., CRATE, PACKAGING, 4G SM
H 711-4036-XX ASSY, BASE W/ COMPONENTS, 4G
# PN Description
I 711-4046-XX ASSEM., HANRAIL BASE, W/RING, 4G
J 711-4136-XX ASSEM., NECK, W/WIRING & LABELS, 4G
K 711-4137 ASSEM., FULL HANDRAIL, R, 4G SM
L 711-4138 ASSEM., FULL HANDRAIL, L, 4G SM
M 711-4154 KIT, SM, POWER INPUT ACCESORIES
N 711-4155 KIT, HARDWARE PACK, 4G SM
O 711-4156 KIT, DOCUMENTATION, 4G SM
REQUIRED TOOLS
• 6mm Allen Key
• 13mm Socket
• Ratchet Wrench
• 13mm Open-Ended Wrench
• #2 Phillips Head Screwdriver
ASSEMBLY
To watch the installation video of this unit scan or visit:
QR.COREHANDF.COM/4GINSTALL

Page 6
HARDWARE CARD
G
A
CF
E
B
D
# Part Number Qty Description
A 110-3402 4 SCREW, #8-18, 3/4", HI-LOW, PHT, PH, CS, BO
B 110-3568 4 SCREW, M8x1.25, 25mm, SHC, HK, AS, BEC, NP, Gr 12.9
C 110-4180 4 SCREW, M8x1.25, 65mm, SHC, HK, AS, BEC, NP, GR 10.9
D 110-4197 8 SCREW, M8X1.25, 25mm, FLANGED, HEX, ZP, Cl 10.9
E 110-4229 12 SCREW, M5x0.8x30, PHM, PH, CS, BZ, DP
F 110-4329 6 SCREW, M5x0.8x20, PHM, PH, CS, BZ, DP
G 110-4364 8 NUT, M8x1.25, AS, NP, FLANGE, SERRATED

Page 7
ASSEMBLY PROCEDURE
1. Remove outer cardboard
container (not shown).
2. Pry off two wooden supports
from the bottom of the pallet then
remove.
CAUTION: Staples from the
pallet may be sharp
3. Remove all packaging material.
Set aside hardware card 711-4155
for use.
Fig. 3
4. Pry off wooden plank at rear of
machine securing machine to
pallet.
Fig. 4
5. Roll unit off pallet to final install
location.
Fig. 5

Page 8
6. Install the leveling feet 140-3485.
140-3485-KT
Fig. 6
Fig. 7
7. Thread the cable bundle up through and out of the top of the mast 711-4135-XX while installing the mast
onto the frame.

Page 9
8. Use a ratchet wrench with a 13mm
socket and a 13mm open-ended
wrench to secure - DO NOT
FULLY TIGHTEN - the mast 711-
4135-XX to the frame using four
(4) pieces each of the M8 x 25mm
flange bolt 110-4197 and M8
flange nut 110-4364.
110-4197
110-4364
711-4135-XX
Fig. 8
9. Install the right side upright
handrail grommet 020-8120
onto one (1) piece of the upright
handrail 711-4046-XX, then slide
the handrail onto the right side
frame post.
10. Repeat Step 2 for the left side
grommet 020-8121 and upright.
020-8121
020-8120
711-4046-XX
Fig. 9

Page 10
12. Use a 6mm allen key to secure -
DO NOT FULLY TIGHTEN - the
right side upright handrail 711-
4046-XX to the frame using two
(2) of the M8x65mm socket head
cap screws 110-4180 and one (1)
piece each of the large handrail
clamp 020-8146-XX and large
threaded handrail clamp 020-
8147-XX.
13. Repeat Step 12 for the left side
upright handrail.
110-4180
020-8146-XX
020-8147-XX
711-4046-XX
Fig. 10
14. Install the left handrail assembly
711-4138 and right handrail
assembly 711-4137 into the
upright handrails and mast.
711-4135-XX
711-4138
711-4137
711-4046-XX
Fig. 11

Page 11
15. Use a ratchet wrench with a 13mm
socket and a 13mm open-ended
wrench to secure - DO NOT
FULLY TIGHTEN - the left and
right handrails to the mast 711-
4135-XX using (4) pieces each of
the M8 x 25mm flange bolt 110-
4197 and M8 flange nut 110-4364.
110-4197
110-4364
Fig. 12
16. Use a 6mm allen key to secure -
DO NOT FULLY TIGHTEN - the
right side handrail to the right
side upright handrail using two (2)
pieces of M8x35mm socket head
cap screws 110-3568 and one (1)
piece of the small handrail clamps
020-8146-XX.
17. Repeat Step 16 for the left side
handrail.
110-3568
020-8146-XX
711-4046-XX
Fig. 13

Page 12
18. Connect the heart rate cables
711-4139 and Speed keypad
cable 711-4140 coming from the
left handrail to the receiving cables
coming from the hole in the rear of
the mast 711-4135-XX.
19. Connect the heart rate cables
711-4139 and Stop keypad cable
711-4141 coming from the right
handrail to the receiving cables
coming from the hole in the rear of
the mast 711-4135-XX.
20. Fully tighten all hardware from
Steps 12, 13, 8, 15, 16 and 17.
Heart Rate from
Right Handrail
Stop Button from
Right Handrail
Speed +/- from
Left Handrail
Heart Rate from
Left Handrail
Speed +/-
From Mast
Stop Button
from Mast
Left Heart Rate
from Mast
Right Heart Rate
from Mast
Fig. 14
21. Use a #2 phillips head screwdriver
to secure the front shroud to the
frame using two (2) pieces of the
M5x30mm pan head machine
screw 110-4229.
110-4229 020-8112-XX
Fig. 15

Page 13
22. Use a #2 phillips head screwdriver
to secure the top shroud to the
frame using two (2) pieces of the
M5x20mm pan head machine
screw 110-4329.
020-8113-XX
110-4329
Fig. 16
23. Use a #2 phillips head screwdriver
to finish securing the top shroud to
the frame using two (2) pieces of
the M5x20mm pan head machine
screw 110-4329.
110-4329
Fig. 17

Page 14
24. Use a #2 phillips head screwdriver
to secure the neck cover to the
frame using two (2) pieces of the
M5x20mm pan head machine
screw 110-4329.
020-8161-XX
110-4329
Fig. 18
25. Install the mast 711-4135-XX
grommet into the top shroud.
020-8113-XX
020-8162
Fig. 19

Page 15
26. Use a #2 phillips screwdriver to
secure the mast 711-4135-XX
shroud around the mast 711-
4135-XX and handrails using four
(4) pieces of the #8-18, 3/4” pan
head machine screw.
FRONT MAST
SHROUDS
110-3402
REAR MAST
SHROUDS
Fig. 20
27. Use a #2 phillips screwdriver to
secure the upper right side shroud
020-8110-XX to the frame using
five (5) pieces of the M5 x 30mm
pan head machine screw 110-
4229.
28. Repeat for the upper left side
shroud 020-8111-XX.
020-8110-XX
110-4229
Fig. 21

Page 16
Console installation instructions are for the LCD console 700-0538-XX only.
For other consoles, refer to their owner’s manual for installation instructions on a G/FC Frame.
29. Unpackage console from box,
then separate rear shroud from
console.
30. Use a #2 phillips screwdriver to
remove the rear console panel
from the rear console shroud, then
install the rear console shroud to
the mast 711-4135-XX.
020-7923-XX
020-7927-XX
731-0584
Fig. 22
31. Use a #2 phillips screwdriver to
secure the rear console panel to
the rear console shroud using the
screws 731-0584 removed in Step
30.
731-0584
020-7927-XX
Fig. 23

Page 17
32. Use a #2 phillips screwdriver to
secure the rear console shroud to
the mast 711-4135-XX using eight
(8) pieces of the #8-18, 3/4” screw
110-3402 and eight washers 120-
3307.
701-0454-XX
711-4135-XX
120-3307
110-3402
Fig. 24
33. Install the Power cable 701-0246
and CSAFE cable 701-0245 from
the console into the corresponding
connections in the rear console
shroud.
CSAFE from
Console
Power from
Console
Fig. 25

Page 18
34. Connect the following cables as
shown:
Data Cable 411-4119
Heart Rate cable 411-4139
Keypad Cable 220-0328
Grounding Cable 701-0357
220-0328
711-4119
711-4139
701-0357
711-4118
Fig. 26
35. Use a #2 phillips screwdriver to
secure the front of the console to
the rear console shroud using six
(6) pieces of the #8-18, 3/4” screw
110-3402.
36. Install the console grommet
020-8149.
37. Installation is complete.
701-0325-XX
020-8149
701-0454-XX
110-3402
Fig. 27

Page 19
SUPPORT & SERVICE
PREVENTATIVE MAINTENANCE
Protect your product & assure it always runs like new with a Core Advantage Preventative Maintenance or Extended
Warranty Package. Contact your service manager for more information: [email protected]
To help us support you, please provide the following information when requesting assistance with your equipment:
Facility Name & Address Product Serial Number Description of Issue
Our goal is to provide fast, reliable support to all your product support requests. We strive to answer all support
requests under an average hold time of 3 minutes, all support emails within 1 business day and all field service
requests within 48 hours.
For Technical Support, Service, Parts Orders or any Customer Service needs, please contact us by phone, email,
or through our 24 hour support site:
PHONE & EMAIL SUPPORT AVAILABLE: MONDAY - FRIDAY 6AM - 5PM PST
4400 NE 77th Avenue, Suite 250 Vancouver, WA 98662
Tel: [phone] • [phone] • [email protected]
Warranty information: https://corehandf.com/warranty
To request access scan or visit:
CONNECT.COREHANDF.COM
• General Inquiries
• Warranty Registration
• Preventative Maintenance
• Service Requests
• Parts Orders
• Automated partner payment
• Product technical library
• Transparency on service performance
• 24-Hour Automated Assistant
• Live Chat
OFFERS 24-HOUR SELF SERVICE ACCESS TO:
Core Connect is your portal to all things service! Whether you need to
order parts or register your warranty, Core Connect is the most effective
way to get what you need fast and keep your facility operating smoothly.
CORE CONNECT
Core Connect is accessible through our app on mobile devices

© 2023 CORE HEALTH & FITNESS LLC PART NUMBER 620-8997, REV A
All rights reserved. Star Trac, the Star Trac logo and StairMaster are registered trademarks of Core Health & Fitness, LLC. Schwinn and Nautilus are registered
trademarks of Nautilus Inc. used under license to Core Health & Fitness LLC. Throwdown is a registered trademark of Throwdown Industries, LLC.