Stairmaster HIITMill Reference guide

Technical Procedure
Page 1
620-8590 Rev. A
Latest Rev.
Required Tools:
• 2.5mm Allen Key
• 3mm Allen Key
• 4mm Allen Key
• 5mm Allen Key
• 6mm Allen Key
• 10mm Wrench
• 10mm Socket
• Ratchet
• Needle Nose Pliers
1. Remove the three (3) socket head cap screws se-
curing the brake covers to the unit using a 4mm
allen key
2. Loosen the screw securing the brake cable to
the brake, then use a 10mm wrench to remove
the M6 nut securing the brake cable to the cable
bracket.
3. Pull the entire cable from the back of the brake
cable bracket.
HIITMill (X) Push/Pull Brake Cable Install
Applies to: HIITMill and HIITMill X

Technical Procedure
Page 2
620-8590 Rev. A
4. Remove the brake spring with a pair of needle
nose pliers and discard.
5. Use a 4mm allen key to remove the two (2) M8 x
20mm screws from the user left side handrail.
6. Use a 2.5mm allen key to remove the M4 x 8mm
screw located in front of the M8 screws removed
in Step 5.
7. Repeat Steps 5 + 6 for the user right side hand-
rail.
8. Once all the screws securing the handlebar to the
frame have been removed, remove the handle-
bar.

Technical Procedure
Page 3
620-8590 Rev. A
9. Use a 3mm allen key to remove the two (2) M5 x
16mm screws securing resistance lever covers to
the user left handrail.
10. Carefully pull up on the resistance lever to re-
move both the resistance lever assembly and the
brake cable.
NOTE: The brake cable may need to be fed up
through the frame while the level assembly is pulled
from the top.
11. Use a 5mm allen key to remove the two (2) M8 x
25mm screws securing the ywheel guard to the
frame.
12. Remove the three (3) M10 x 25mm screws secur-
ing the user left side handrail to the frame.
13. Carefully separate the user left side handrail from
the unit and lay the handrail on the deck.
WARNING: Please be aware of any additional cables
running from the console to the brake. Ensure these
are not damaged or stretched during the removal of
the handrail.

Technical Procedure
Page 4
620-8590 Rev. A
14. Feed one end of the new push/pull brake cable
up through the bottom of the frame where
indicated.
NOTE: Some early production units may have a circu-
lar opening rather than rectanguar as shown right.
15. Pull the push/pull brake cable up through and
out of the hole in the frame.
TECH TIP: Use the supplied hook tool to grab the
push/pull brake cable and pull it up through the hole
while feeing the brake cable from the bottom.
16. Feed the new brake cable up through the user
left side handrail ensuring that the cable routes
BEHIND the weight horn and swing arm as
shown.
17. Reinstall the user left side handrail using the
screws removed in Steps 11 + 12.

Technical Procedure
Page 5
620-8590 Rev. A
18. After the new cable is routed out of the top of
the handrail, attach the cable end tting to the
cable, thread the tting about 3/4 down the
cable. thread one of the cable tting ends onto
the top of the cable.
19. Set the bottom 7/16” nut on the cable to about
1/2 way up the threaded portion of the cable
sleeve then slide the resistance lever assembly
onto the cable, securing with the 2nd 7/16”nut
and 7/16” toothed lock washer.
NOTE: The amount of cable that is threaded into the
tting may need to be adjusted in order to attach the
new resistance lever assembly. See Step 19.
20. Secure the cable tting end to the resistance
lever using the supplied clevis and cotter pin.
21. Push the resistance lever assembly with attached
cable back into the user left handrail, be sure to
pull any slack cable out of the bottom of the unit.
22. Using a 6mm allen key, remove and discard the
two (2) M8 x 35mm screws from the user left
side belt roller guide then install the new cable
bracket over the top of the belt roller guide using
the provided M8 x 40mm screws.

Technical Procedure
Page 6
620-8590 Rev. A
23. Ensure that the bottom nut located on the cable
is threaded all the way down then secure the
bottom end of the new brake cable into the new
cable bracket.
24. Use a 5mm allen key and a 10mm wrench to re-
move and replace the brake screw with the screw
supplied.
25. Set the resistance to Level 6 then thread a cable
tting end onto the bottom of the cable and
connect it to the left side of the brake via the
screw installed in Step 24. Ensure that the brake
is pushed up against the ywheel while attach-
ing the tting to the brake screw.
26. Using a 10mm wrench and a 5mm allen key,
tighten the M6 nut onto the screw replaced in
Step 24.
27. Install the supplied e-clip onto the new brake
screw.
28. Remove ONE of the screws securing the brake
assembly to the brake using a 6mm allen key,
then use a 10mm socket to install one of the
supplied hex head screws. DO NOT REMOVE ALL
THREE SCREWS AT THE SAME TIME.
29. Repeat Step 28 for the remaining two screws. All
three screws should be replaced.

Technical Procedure
Page 7
620-8590 Rev. A
30. Install the new resistance lever covers using a
3mm allen key. Ensure that the STOP icon is fac-
ing the rear of the machine.
31. Test the tension on the new cable by pulling the
lever all the way back to the STOP position, the
belt should not be moving while standing on the
unit while the lever is in this postion. If the belt
does move, refer to Step 25 as some adjustment
may be needed.
32. Install the new outer brake cover using a 4mm
allen key and the three (3) screws removed in
Step 1.