Stairmaster Steppers C40 Console Repair
C40 Console Repair Video Demonstrating Replacement of the PCB and PCBA for Stairmaster Steppers
- This video demonstrates the steps necessary when replacing the PCB and/or PCBA in order to repair a C40 console used on Stairmaster steppers
- This procedure applies to the following models:
- 7000PT Stepmill
- 4400PT
- 4400CL
- 4600PT
- 4600CL
- To begin changing the console boards on your machine you must first remove the console from the machine. You will need to disconnect the main cable harness and remove the four screws that hold the console to the frame
- Once you have removed the console from the machine you need to remove the six screws from the back of the console. After the screws are removed you can carefully separate the two pieces a bit and see the two cables that connect the two panels as shown in the video. These two cables must be disconnected before you can separate the back panel from the front
- The ribbon cable that connects the two boards must be removed by separating the connector as shown in the video and then carefully lifting the ribbon off the connector. Once you have successfully removed the cable that connects the two boards (PCB and PCBA), you can flip the panel up slowly as shown in the video enough to see where the keypad ribbon connects to the PCB. Carefully remove the keypad ribbon from the connector on the PCB. Now you can fully separate the two panels
- At this point you can access the boards to replace the one giving you issues. For instance if you have diagnosed the console as having a bad PCBA you can now replace that board by removing the four screws that attach it to the panel. Then carefully remove the board
- To install the new one carefully line up the holes and replace the screws as seen in the video
- If you have determined the PCB as the problem you will remove the five screws attaching it to the panel and then carefully remove the board as shown in the video
- Before installing the new PCB to the panel you will want to make sure that the interconnect cable is connected fully and connected to the proper connector as shown in the video. If they cable is connected to the wrong connector it will not power up or work at all. This is a common mistake when replacing the board/s
- Now replace the board and screws
- Then you can re-assemble the console, but be sure to connect the cable and ribbon fully and to the correct connector. It may help to stand one panel up next to the end where the keypad ribbon goes from the keypad to the PCB. Then plug in the interconnect cable that connects the PCB to the PCBA as seen in the video
- Place the 2 panels together and replace the screws. The Longer screws go in the bottom portion of the console and the 2 shorter screws go in the top part of the console. Once the screws are replaced you can install the console to the machine
- Be sure to connect the main cable assembly to the back of the console and be certain the cable is fully connected with the tabs in the locked position as shown in the video
- This concludes our example of how to replace a PCB or PCBA when repairing a C40 console found on steppers by Stairmaster
Keeping your Treadmills Clean
In most gyms, the equipment that sees the most use are usually the cardio machines, in particular, the treadmills. These machines are expensive, and require some regular basic maintenance and cleaning to keep running properly. Treadmills, more than almost any other piece of equipment, absorb a LOT of wear and tear. Just a bit of caution and common sense will keep your machine in top form (while it keeps you in top form!), and prevent you from having to buy expensive replacement parts, or even worse, a new treadmill.
Whether your treadmill is in a gym or at the home, your best friend is going to be the operation manual. Whether in booklet form or on-line, make sure to read it thoroughly and see what the manufacturer recommends for regular maintenance and cleaning. If in doubt, either visit the company's website or give them a call for further information.
The cleaning supplies you'll need are simple. Some soft rags, a cleaning solution of some kind (mild, non-acid soap is best), some Isopropyl alcohol, and a vacuum with a hose attachment. That's pretty much it. Remember to observe proper safety. Turn off and unplug the machine before doing ANY cleaning to it.
Give your machine a wipe down after each workout. This keeps your body oils and sweat off the machine, which can corrode certain parts. A clean rag or equipment wipes will do the trick. Once a week, give it a more thorough cleaning, especially if it's in a gym environment. Take a mild soap and water solution and apply to a rag. Give it a once over, paying attention to the areas that are touched the most, such as the hand rails, the heart monitor grips, and the control console. Be sure the rag is damp, not dripping wet.
Dirt and dust are also a big issue with treadmills. The deck that the belt runs over needs a smooth surface to run correctly, and even small particles of dust collecting underneath the belt can cause big damage to the deck. To prevent this, all you need is a simple vacuum cleaner. If equipped, periodically raise the elevation, pop on the hose attachment and vacuum underneath the machine. Hand dust any places the hose won't reach. Also, lift the motor cover and vacuum the exposed area. If the treadmill is in a gym, make sure that your patrons don't wear the shoes they came in off the street with on the treadmill. Proper workout shoes will keep the grime and dirt off the treadmill and decrease your maintenance issues.
The deck is one of the most expensive parts of any treadmill, and you want to keep it in good working order. Some decks require waxing. Depending on the machine, the wax is either applied automatically from an internal reservoir or the deck needs to be waxed by the user. Either way, make sure you do this! Keep the reservoir full, and make sure you have wax on hand if you have to do it yourself. Keep the surfaces of the deck clean from grime, and give it a good wipe down with a soft cloth once a week.
Cleaning the heart monitor grips is important, too, especially in a gym. Many people rely on these to check their heart rates during workouts, and since the grips are touched by many, many different hands, they can get dirty very fast. Combat this with a little Isopropyl alcohol or use a disinfecting wipe. Apply Isopropyl alcohol to rag and wipe down. Even if it doesn't look dirty, it probably is. Cleaning these grips once a week will keep them working like new.
Belt slippage is a common problem with most treadmills, but it's an easy one to fix if you know how. If you notice that the belt on your machine looks or feels slippery, it probably needs to be tightened. At the rear part of the machine, there will be two large adjustment bolts. Find where these are using your manual. After getting the proper sized socket and wrench (something you should have in case of maintenance issues anyway), give them a quarter turn clockwise, then get on the treadmill and check if it still feels the same. Keep turning the bolts a quarter turn then checking until it no longer slips.
A treadmill is like any other machine. It needs a little TLC from time to time. Keeping it clean and maintained will make sure that it lasts you a long time.
Fitness Equipment Repair Videos
You may not know it, but for several years now, SPORTSMITH has been producing instructional videos. Our resident tech gurus put in some long hours to bring our customers no-nonsense, how-to videos, on a variety of subjects. These videos are professional quality and made using the latest filming and editing equipment. We also host videos produced by the tech wizards at a variety of other equipment manufacturers, such as Schwinn and StarTrac.
What kind of videos are on the Sportsmith site? Well, we currently host about 100 different videos (with more to come!) and they cover a variety of technical and how-to subjects. Want to revive an old felt brake pad on your spin bike? We can show you how. Our tech videos range from simple, such as how to install a ramp sleeve on a Precor elliptical machine, to the complicated, such as replacing the running belt on a treadmill.
As always, we at SPORTSMITH strive to diversify and bring you, our customer, a full suite of services. We want you to get the most out of our service and your purchases. What better way to do that than show you how to repair and extend the life of those purchases. Just click on the “Need Help Click Here” button found on the top of the Sportsmith.net website. All videos are embedded, so you won’t have to leave the site to see any of them. We also have our own YouTube channel, so be sure to check out all fitness repair videos there as well!
What tech support videos would you like to see? Click here to tell us.
LifeFitness 95Xi Crosstrainer Battery Replacement
Battery Replacement Video for LifeFitness 95Xi Crosstrainer
- The video shows how to replace the battery on a LifeFitness 95Xi Crosstrainer.
- Tools required:
- Phillips Screwdriver
- T25 Torx Driver
- Begin with the Phillips screwdriver and remove the main shroud as seen in our main shroud removal video.
- Disconnect the red and black wires from the battery.
- Remove the (2) Torx screws that are securing the battery to the drive module.
- Install the new battery in reverse order.
- Click link for more information and parts for the LifeFitness 95Xi Crosstrainer.
How to Remove a Crank Arm Using a Crank Arm Puller Tool
Video of How to Use a Crank Arm Puller Tool
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In our video we show you how to use a crank puller tool
- Tools Needed:
- Cotterless Crank Puller Tool
- 7/8" Wrench
- Be sure and remove the crank arm bolt before installing the crank arm puller
- Now that you have removed your crank arm bolt, to get the crank arm off you will need a crank arm puller tool
- The tool used in the video is a Park Tool marked CCP-22
- To see our complete listing of crank pullers, click here.
- Begin by threading the tool into the crank arm as far as possible by hand
- Then, using a 7/8 inch wrench turn the crank puller as far into the crank arm as possible
- If you only finger tighten the tool into the arm your risk damaging the crank arm, the tool or both
- Once the tool is fully threaded into the crank arm turn the handle of the crank arm puller clockwise to press the arm off of the bottom bracket spindle
For more info about this video and tools used click here.
How to install a Ramp Sleeve on the Precor Elliptical
Installing a Ramp Sleeve onto a Precor Elliptical
- In this video we demonstrate how to install a ramp sleeve onto a Precor elliptical
- Tools required:
- Bungee or Piece of String
- Wet Soapy Cloth* or Paper Towel*
- Clean Dry Cloth
*(non-citrus based cleaning agent - Precor approved cleaner is 30:1 solution of water and Simple Green®)
For more information about this video click here.
Star Trac NXT Crank Bolt Torque
How to get Proper Torque of a Crank Arm Bolt for a StarTrac NXT
- In this video we are showing how to properly torque your crank arm bolt using an adjustable or "click" style torque wrench.
- Tools needed:
- Adjustable Torque Wrench
- Flat Tip Screwdriver
- You will begin by removing the crank arm bolt cap with a flat tip screwdriver.
- Once it's removed make sure your torque wrench is set to 30 foot pounds for the StarTrac NXT.
- It's a good idea to tighten the brake assembly to aid in holding the crank arm still as seen in the video.
- Place the wrench in position and tighten until you hear the click of the torque wrench, as shown in the video.
- The click lets you know you have achieved the preset torque with this type of torque wrench.
- Don't forget to release the brake assembly tension and re-install the crank arm bolt cap.
For more information click here.
How To Install a Ramp Sleeve onto a Precor Elliptical
About This Video
Installing a Ramp Sleeve onto a Precor Elliptical
- In this video we demonstrate how to install a ramp sleeve onto a Precor elliptical.
- Tools required:
- Bungee or Piece of String
- Wet Soapy Cloth* or Paper Towel*
- Clean Dry Cloth
- Use a wet soapy cloth* or paper towel* to clean the surface of the ramp, making sure it is free of all dirt and debris
- Ramp surface needs to be completely dry before applying the ramp sleeve
- This is a very cost effective way to get more life out of your ramp assembly
- Once the ramp assembly is clean and dry, remove the paper from the two sided tape on the ramp sleeve and place the sleeve onto the ramp assembly by holding the sleeve at an up angle and aligning the bottom edge before pressing the ramp sleeve into the ramp assembly as shown in the video
- Press firmly all over the sleeve to ensure it is completely fitted to the ramp assembly
- Now you can remove the protective cover from the top of the ramp sleeve and let the pedal arm back down into position for use
- Repeat steps to install other ramp sleeve
*(non-citrus based cleaning agent - Precor approved cleaner is 30:1 solution of water and Simple Green®)
For more information about this video click here.
How to Unpack and Assemble a StarTrac NXT Spinner
About This Video
Unpacking and Assembly Video of the StarTrac NXT Spinner® :
- This video presentation will aid in properly unpacking and assembling your StarTrac NXT cycle.
- Tools needed for this procedure will be:
- Ratchet Handle
- 4MM Allen Socket
- 5MM Allen Socket
- 13MM Wrench
- 15MM Wrench
- 21MM Wrench
- Adjustable Torque Wrench
- For more information about this video and detailed instructions click here.
No Resistance on the Stairmaster Stepmill 916
About This Video
This video covers the electronic troubleshooting for a complaint of No Resistance on the Stairmaster Stepmill 916.
Tools Needed: Multi Meter, Assistant for Testing Purposes
For more information about this video,a step by step guide, and parts click here.

