Stairmaster StepMill SM5 User manual

Assembly Manual
StepMill SM5
®
150005-06132012C

Table of Contents
Model SM5 Specifications..................................................................................................................................................... 2
Safety Warnings .......................................................................................................................................................................3
Safety Caution and Warning Labels.................................................................................................................................. 4
Before You Start........................................................................................................................................................................5
Hardware ....................................................................................................................................................................................6
..........................................................................................
........................stnetnoCxoB ........................................................... 7
Assembly.....................................................................................................................................................................................9
Contact Information...............................................................................................................................................................15
Product Spec cations
Model SM 5
Unit Weight: 343 lbs ( 156
kg)
Shipping Package Weight:
438 lbs ( 199 kg)
Workout Area:
72" W x 93" L ( 182 cm x 236 cm)
Power Supply: Use only with Power Supply Model No. FY1206000
Max user weight: 350 lbs (159 kg)
Assembly Manual
2
Dimensions: 34.3”W x 59.5” L x 88.6” H
(87 cm x 151 cm 225 cm)
Please see owner’s manual for all regulatory information
2004/108EC, Electromagnetic Compatibility
2001/95/EC, General Product Safety Directives
2006/95/EC, Electrical Equipment Low Voltage Safety
Safety: EN957-1, EN957-8, & EN60335-1
Conducted & Radiated Emissions: EN55014-1, EN55014-2, EN55013 & CISPR 13 & 14.1
Harmonics: EN61000-3-2
Flicker: EN61000-3-3
Immunity: EN55020

Important Safety Instructions
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Before using this equipment, obey the following warnings:
Read and understand the complete Assembly Manual.
Read and understand all Warnings on this machine.
If this machine is being used in a commercial setting, end users may not have access to this Assembly Manual.
It is the responsibility of the facility to instruct users as to the proper usage of the equipment, as well as
making them aware of potential hazards.
Keep children away from this machine. Watch them closely when near the machine. Moving parts that
appear dangerous to adults may not appear so to children.
Consult a physician before starting an exercise program. Stop exercising if you feel pain or tightness in your
chest, become short of breath, or feel faint. Contact your doctor before using the machine again.
Examine this machine for loose parts or signs of wear. Pay special attention to the steps. Contact
StairMaster® Customer Service for repair information. Use only genuine StairMaster® replacement parts.
Set up and operate your StepMill® on a hard, level surface.
Do not wear loose clothing or jewelry while exercising.
Maximum user weight limit: 350 lb. (136 kg). Do not use if you are over this weight.
Keep at least 19 inches (50 cm) clear area around the machine. This is the recommended safe distance for
access and passage around and emergency dismounts from the machine.
Warn bystanders to keep a safe distance, at least 3 feet (1 m). Do not allow anyone to touch the operator
while the machine is in motion.
Do not over exert yourself during exercise. Do not try to exercise with more resistance than you can physically
handle.
When you use an electrical appliance, basic precautions must always be followed, including the following:
DANGER – To decrease the risk of electric shock always unplug this appliance from the electrical outlet
immediately after use and before cleaning.
To decrease the risk of burns, fire, electric shock, or injury to persons:
An appliance must not be left unattended when plugged in. Unplug from outlet when not in operation, and
before you put on or remove parts.
Close supervision is necessary when this appliance is used by, on, or near children, invalids, or disabled persons.
Use this appliance only for its intended use as described in this manual. Do not use attachments that are not
recommended by the manufacturer.
Do not operate this appliance if it has a damaged cord or plug, if it is not working correctly, if it has been
dropped or damaged, or fallen into water. Return the appliance to a service center for examination and repair.
Keep the cord away from heated surfaces.
Do not drop or put any object into any opening.
Do not use outdoors.
T
KEEP THESE INSTRUCTIONS
Assembly Manual
3

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Before You Start
Locate the area where you will assemble and use your StairMaster
®
Commercial Series StepMill
®
SM 5.
We recommend you install it on a hard, level surface. Allow an assembly area of at least 36” (0.91 m)
on each side and behind the machine. You can put the rear of the machine closer to the wall during use.
Basic Assembly
Follow these basic assembly tips when putting together your machine:
1. Collect all the pieces needed for each assembly step.
2. Read through and understand the instructions.
3. Turn all bolts and locknuts to the right to tighten, and the left to loosen.
4. Lightly and carefully lift pieces when attaching. Look through the bolt holes to help guide bolt
placement.
5. Two people are recommended to assemble this machine.
Assembly Manual
5

Hardware
Item # Description Qty
1
5/16 " - 18 *1 3/4” Button Head Screw 4
2
3/8 " - 16 * 1" Button Head Screw 8
3
1/4 " - 20 * 3/4" Phillips Head Screw 4
4 5/16” - 18 * 3/4” Button Head Screw 4
5
3/8” -16 * 2 1/2” Button Head Screw 4
Hardware
Hardware not to scale
12
13
7
Assembly Manual
6
45
6 3/8” - 16 * 3 5/8” Button Head Screw 2
7 3/8” - 16 Nylon Hex Nut 14
8
5/16” - 18 Nylon Hex Nut 4
9
3/8” - 18 Nut Cap 8
10 3/4”OD * 5/16” ID Flat Washer 4
11
3/4”OD * 3/8” ID Flat Washer 12
6
10
911
12
12
1” OD * 3/8”ID Flat Washer 8
13
8
Clevis Pins 2
14
15
2
2
14
15
Cotter Pins
Transport Wheels
3

Box Contents
18 19
20
Assembly Manual
21`
23
16
17
22
Item # Description Qty
16 Assembly Manual 1
17 Owner’s Manual Kit 1
18 Rivet Puller 1
19 Rivet 30
20 Levelers 4
21 Hardware Card #1 1
22 Hardware Card #2 1
Top Cover 1
24 Power Supply & Power Cord Kit 1
25 Cover Handrail Left 1
26 Cover Handrail Right 1
7
24
25
26
23
26

Box Contents
Item # Descritpion Qty
27 Console Mast 1
28 Touchscreen or LCD Console 1
28
27
Assembly Manual
28
Console Options
29
30
31
32 33
29 Upper Handrail Assembly 1
30 Water Bottle Holder 1
31 Lower Handrails 2
32 Rubber Sleeve (Console Mast) 1
33 Rubber Sleeve (Handrails) 2
34 Wheel Panel Left 1
35 Wheel Panel Right 1
35
34
36 Wheel Plate 2
36
36
37
8
37 Bracket Mast Mount 1
38
38 End Cap 1

Assembly
The following instructions provide direction to assemble the StairMaster
®
StepMill
®
SM 5. All instructions
in the manual are given with the orientation of standing on a level surface and facing the machine.
Figure 1
Assembly Manual
9
(See Figure 1)
Step 1: Unpacking the StepMill SM5
Tools:
Box Knife
Hammer or Pry Bar
1-1 Remove the outer cardboard box using the
hammer to remove staples along the bottom of
the box.
1-2 Remove all boxes resting on steps and then remove
handrails.
1-3 Remove the wheel panels and misc packaging from
underneath.
1-3 With a hammer or pry bar, remove the wood
securing the back of the machine to the
pallet.
1-4 Remove remaining box from base of steps.
(See Figure 2)
Step 2: Remove from pallet
Tools:
Hammer or Pry Bar
2-1 With a hammer or pry bar, remove the wood
securing the front of the machine to the
pallet.
2-2 With the assistance of another person, remove
StepMill machine from the pallet
Use a second person when performing
assembly steps requiring heavy lifting or
awkward movements.
Figure 2
.
.
.

Assembly
Step 3: Attach Handrail
Assembly Manual
10
Figure
3A
Figure
3C
3-1 Secure item #37(Bracket Mast Mount) to frame
3-2 Slide item #33(Rubber Sleeves Handrail) below
the bolt holes on item #31(Lower Handr
3-3 Attach item #31(Lower Handrails) to mounting
frame brackets using hardware items #2, #11,
3-4 Standing at the front of the SM5, attach item
#29(Upper Handrail Assembly) to items #31 using
hardware it
Figure
3D
Figure
3B
using hardware items #1, #10, and #8 (gure 3A)
and 7. (gure 3B).
4

Assembly
Assembly Manual
11
Figure 4C
Figure 4B
Step 4: Attach Mast
4-1 Slide item #27(Console Mast) through the handrail
assembly, through item #32(Rubber Sleeve), and through
4-2 Route console wires and coax cable up through item #27
routing console wires and coax cable.
4-3 Secure item #27(Console Mast) to item #37(Bracket Mount)
4-4 Secure item #29(Upper Handrail Assembly) to item #27
(Console Mast) by using hardware items #5, #12, #9, and
4-5 Fasten all bolts, slide item #23(Top Cover) and item #32
(Rubber Sleeve) into position. Use item #19(Rivet) to fasten
item #23(Top Cover) into place.
Figure 4A
3
by using hardware items #6, #11, and #7. (gure 4B)
#7. (gure 4C)

Assembly
Figure 6A
Figure
6B
Assembly Manual
12
Figure
5A
Step 5: Attach Water Bottle Holder
5-1 Attach item #30(Water Bottle Holder) on top of mast
plate using hardware items #2, #12, #7, and #9.
5-2 Secure item #38(Mast Cap) onto top of mast
Step 6: Install Console
6-2 Connect the wiring and power harness to their
respective locations in the back of the console.
Note: Make sure cables and harnesses are not crimped or
pinched while attaching the console to the mast.
6-1 Fasten green ground wire from back of console
to Mast tab. (gure 6C)
3
Figure
6C

Assembly
Figure 8A
Figure
7A
Assembly Manual
13
Step 7: Attach Lower Platics
7-1 Attach items #34(Wheel Panel Left) and #35
(Wheel Panel Right) to main frame using hardware
7-2 Attach items #25(Cover Handrail Left) and #26
(Cover Handrail Right) to main frame using hardware
Note: Ensure items #34 mates with #25 and #35 mates with
#26. Fit for item #33(Rubber Sleeves) must be secure
within perspective plastics.
Step 8: Install Levelers and Transport Wheels
8-1 With the assistance of another person, tilt the SM5
to one side and insert hardware item #13(Clevis Pin)
from the outside of the frame, slide item #15(Wheel)
8-2 While tilted to one side, insert hardware item #20
(Levelers) in the front and back of the SM5.
8-3 Repeat the Wheel and Leveler process for the
opposite side.
Use a second person when performing assembly
steps requiring heavy lifting or awkward movements.
19
19
43

Step 9: Remove Transport Wheels
Use a second person when performing assembly
steps requiring heavy lifting or awkward
movements.
9-1Roll the StepMill
® machine to the workout location.
9-2With the assistance of another person, tilt the
StepMill® machine to one side and remove the Cotter
Pin, the Clevis pin and the Wheel (Figure 9 ). Repeat
for the opposite side.
NOTE: Retain the Cotter pins, Clevis pins and Wheels for
moving the machine in the future.
9-3Adjust the Levelers as needed.
Assembly
Figure 9
Assembly Manual
14

Step 10: Connecting Power Supply
10-1 Connect the DC Power Cable from the Power Supply
to the power connector located on the bottom cover
(Figure 10).
10-2 Place the Power Supply on the floor near an AC wall
outlet.
10-3 Check that the Input AC Power Rating marked on
the Power Supply matches the available power.
To reduce the risk of electrical shock, 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.
Step 11: Final Check
Failure to visually check and test assembly before
use can cause damage to the equipment. It can
also cause serious injury to users and bystanders.
11-1 Tighten all hardware.
11-2 Refer to the Owner’s Manual for Operating and
Maintenance Information.
Figure 10
Assembly
Assembly Manual
15

2
12
7
9
5
12
7
9
611
11 7
16
Assembly Manual
Mast hardware detail
Item #’s listed in balloons
37
1
10
8

Assembly Manual
17
Handrail Hardware detail
Item #’s listed in balloons
29
4
31
2
7
11

Contacts
Please supply the serial number of your machine and the date of
purchase when you call StairMaster. Use the space in the boxes below
to write down this information. To d the serial number on your
machine, refer to the Safety Warning Label information page.
CUSTOMER SERVICE
Tel: [phone]
Parts e-mail: [email protected]
Service e-mail: [email protected]
STAIRMASTER
StairMaster
4400 NE 77th Ave, Suite 300
Vancouver, Washington 98662
USA
1-888-678-2476 | www.stairmaster.com
Serial Number
Date of Purchase
Assembly Manual
18

© 2011 Core Fitness, LLC, dba StairMaster. All rights reserved. StairMaster and the StairMaster logo are either registered trademarks or trademarks of Core Fitness, LLC. All other
trademarks are owned by their respective companies.
StairMaster, 4400 NE 77th Ave, Suite 300, Vancouver, WA 98662
1-888-678-2476 | www.stairmaster.com
Assembly Manual
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