HIITMill (X) Push/Pull Brake Cable Install Applies to: HIITMill and HIITMill X 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 securing the brake covers to the unit using a 4mm allen key Latest Rev. 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. Page 1
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 handrail. 8. Once all the screws securing the handlebar to the frame have been removed, remove the handlebar. Page 2
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 remove 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 flywheel guard to the frame. 12. Remove the three (3) M10 x 25mm screws securing 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. Page 3
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 circular 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. Page 4
18. After the new cable is routed out of the top of the handrail, attach the cable end fitting to the cable, thread the fitting about 3/4 down the cable. thread one of the cable fitting 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 fitting may need to be adjusted in order to attach the new resistance lever assembly. See Step 19. 20. Secure the cable fitting 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. Page 5
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 remove and replace the brake screw with the screw supplied. 25. Set the resistance to Level 6 then thread a cable fitting 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 flywheel while attaching the fitting 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. Page 6
30. Install the new resistance lever covers using a 3mm allen key. Ensure that the STOP icon is facing 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. Page 7