Stairmaster HIITMill 9-4590 Operating instructions

Stairmaster
Brand
Stairmaster
Model
HIITMill 9-4590
Type
Operating instructions

This manual is also suitable for

Page 1
620-8545 Rev. B
Rev. B
These instructions will walk the reader through the rebuilding the HIITMill (X)
brake lever.
Tools Required:
• 3mm Allen Key
• 4mm Allen Key
• 8mm Combination Wrench (x2)
• 10mm Combination Wrench (x2)
• 8mm Socket
• Torque Wrench
• Needle Nose Pliers
• 715-4073-KT “HIITMill Brake Lever Rebuild Kit
1. Using a 3mm allen key, remove the two (2)
screws securing the lever covers to the frame
then remove the lever covers.
2. Carefully pull the brake lever assembly out of the
frame.
HIITMill (X) Brake Lever Rebuild Instructions
Applies to: HIITMill (9-4590) + HIITMill X (9-4640)
Page 2
620-8545 Rev. B
3. Use the 10mm wrenches to loosen the two hex
nuts on the brake cable.
4. Disconnect the brake cable from the lever assem-
bly by rst rotating the level assembly forward
until it is perpendicular to the brake cable.
5. After rotating the level assembly, slide the lever
assembly back so that the brake cable pin comes
loose from the lever assembly.
Page 3
620-8545 Rev. B
6. With the level assembly free, use the 8mm
wrenches to remove ONE of the 5mm hex head
screws then slide the other screw and attached
lever axle out from the other side. Discard the
loose hex head screw and washer. If both screws
begin to come free from the lever axle, remove
and discard both screws.
NOTE: DO NOT discard the lever axle as this will be
reused at a later step.
7. Remove the lever from the lever housing.
8. Remove the two (2) polymer IGUS bushings and
replace with the IGUS bushings contained in
715-4073.
Page 4
620-8545 Rev. B
9. Remove the two (2) Belville (OLD) or Delrin
(NEW) thrust washers and replace with the Delrin
washers contained in 715-4073.
10. Reinsert the lever into the lever housing then
insert the screw and lever axle so that is passes
through the IGUS bushings replaced in Step 8
and the Delrin washers replaced in Step 9. Finally,
apply a drop of Loctite #243 to the new hex head
screw from 715-4073 and secure the screw into
the other side of the lever axle using a torque
wrench, torque to 45 in-lb (5.1 NM).
NOTE: If both screws came loose from the lever axle
in Step 6, they will both need to have Loctite applied
and torque values applied as described above.
11. Once the lever assembly has been reassembled,
follow Steps 1-5 in reverse to reinstall the lever
assembly into the frame. Ensure that the lever
assembly cutouts face the front of the machine
and that the red stop portion of the lever shroud
decals is facing the rear of the machine.
Page 5
620-8545 Rev. B
12. Remove the three (3) screws securing the brake
shrouds to the frame then remove the brake
shrouds.
13. Pull the resistance lever towards the rear of unit
so that maximum resistance is applied then
check to ensure that the rubber brake pad is
contacting the edge of the ywheel. If the rub-
ber pad is resting on the edge of the ywheel,
replace the shrouds that were removed in Step
12, this will conclude the instructions, otherwise
proceed to the next Step 14.
14. Use a 4mm allen key to loosen the brake wire
tension screw then use a pair of needle nose
pliers to pull the brake wire so that it is under
tension. Finally tighten the wire tension screw
while continuing to provide tension on the brake
wire.
NOTE: The belt has been removed to show clarity.
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Stairmaster HIITMill 9-4590 Operating instructions

Stairmaster
Brand
Stairmaster
Model
HIITMill 9-4590
Type
Operating instructions
This manual is also suitable for
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