Stairmaster Steppers 4400CL Cover Removal and Replacement

Feb 08, 2023

There are three covers on the 4400 PT/CL and the 4200 PT: the top cover, the mid-cover and the bottom cover. The top and bottom covers are made of a right and left section. Do not separate the right and left sections of either the top or bottom covers to perform most maintenance tasks. Access to the interior of the machine takes three steps: remove the mid cover, slide the top cover upward, and remove the bottom cover.

The 4600 PT/CL has an additional shield over the handles. Access to the interior of the machine takes four steps: remove the mid cover, remove the shield, separate the top covers, and remove the bottom cover.

Mid Cover

1. Use the fastener removal tool to remove each of the four fastener pins on the mid cover.
2. Stand on the pedasls and keep them on the floor.
3. Slide the mid cover down and away from the machine. Remove the cover from the frame tube. Carefully let both pedals return to the upper stops.

Top Cover

1. 4400 PT/CL, 4200PT: Remove the mid cover and the console.
2. Release the pins along the middle seam of the top cover. Use a small phillips screwdriver or similar tool to push the fastener center pin in at least halfway. Use your fingers to remove the fastener base from the cover and then separate the top covers.
3. 4600 PT/CL: Use the fastener removal tool to release the cover fasteners and separate the top covers.
4. To reinstall the 4400 PT/CL and 4200 PT fasteners, remove the pin completely from the base. Insert the base into the hole in the covers. Insert the pin into the base until in is flush with the base. 

Shield(4600 PT/CL)

1. Remove the two mounting screws from the bottom shield.
2. Seperate the top shield from the bottom shield and remove the upper and lower shield from the handrail.

Bottom Cover

1. Remove the mid cover.
2. 4600/4200/4400 PT: Disconnect the DC power cable from the connector located on the bottom side of the left bottom cover.
3. Remove the fastener located on each side of the lower edge of the bottom cover.
4. 4400/PT/CL, 4200 PT: Kneel in front of the machine, facing the cover seam. Push in and hold both sides of the lower cover to disengage the locking tabs at the joint between the upper and lower covers. Use your hands to push up the top cover and separate the top cover from the bottom cover. Pull out and forward on the lower cover to remove it from the frame.

4600 PT/CL: Remove the cover fasteners and seperate the left and right top cover from each other. Pull out and forward on the lower cover to remove it from the frame.