DUAL ADJUSTABLE PULLEY IP-D9302 INSTALLATION INSTRUCTIONS
Copyright 2010. Star Trac by Core Industries, Inc. All rights reserved, including those to reproduce this book or parts thereof in any form without first obtaining written permission from Star Trac. Every effort has been made to keep this information current; however, periodically, changes are made to the information herein, and these changes will be incorporated into new editions of this publication. All product names and logos are trademarks of their respective owners. Printed in the USA. Page 2
REQUIRED TOOLS: INSTALLATION INSTRUCTIONS 5MM HEX KEY SOCKET 1 TORQUE WRENCH 1 GENERAL NOTES: Unless otherwise noted Loctite 242/243 or equivalent thread locker must be used on all threaded fasteners. (Do not use thread locker when a Nyloc nut is used.) All Star Trac Strength equipment MUST be secured to the floor using either 10mm or 3/8in. (grade 5 minimum) bolts. To accommodate this there are mounting holes located on every foot. This Installation Instructions Manual must be used in conjunction with the equipment s Owner s Manual. The Owner s manual describes equipment setup and instructs members on how to use it correctly and safely. THREAD LOCKER APPLICATION: Clean all threads and holes, apply no more than 3-4 drops per bolt. Thru Holes Blind Holes Metric Steel Bolts Torque Specifications Bolt Size Thread Pitch Torque, N-m (lbs-ft) 6mm 1.25 10-13.5 (8-10) 8mm 1.25 25.5-28.5 (19-21) 10mm 1.75 55.5-58 (45-48) 12mm 1.25 61-65 (45-48) Torque all hardware to values as specified above, unless noted otherwise. See Page 9 of this manual for fastener sizing information; for reference only. Note: All torque values are in N-m unless otherwise stated. Should any component not be present or if you have any operational questions, please refer to your owner s manual or on the web @ www.startrac.com. Specifically refer to your Inspiration serial number and model number labeled on your equipment. PACKAGING REMOVAL: Carefully remove all packaging materials that wrap the equipment. DO NOT USE A KNIFE OR BOX CUTTER AS YOU MAY DAMAGE THE EQUIPMENT. At this time remove any sub-components from the box and set aside for later assembly. Page 3
TOWER ASSEMBLY: 1. Stand one of the DAP towers upright and slide the dip bar assembly onto its mounting sleeve. Now slide the other DAP tower into place using the dip bar assembly as a guide. 2. Locate and install the six (M8,25mm,Button Head Bolts) and six (M8,Flat Washers) as shown. Do not tighten bolts at this time. 3. Install the two rear DAP tower supports using sixteen (M8,25mm,Button Head Bolts) and sixteen (M8,Flat Washers). 4. After all bolts are installed use an M5 Hex key socket and torque wrench to tighten all M8 bolts from step one through step three. WEIGHT PLATE INSTALLATION:. 1. Use a M5 hex key to loosen the four M10 set screws located on the guide rod collars. Page 4
2. Slide the guide rods down into the DAP tower frame then tilt the guide gods towards the inside of the DAP as shown. 3. Slide the rubber bumpers up and off of the guide rods and set aside for re installation later. 4. With the top plate still attached to the DAP via the cable, slide top plate up and off of the guide rods. Set the top plate behind the DAP with the cable still attached. Note: the guide rods and collars will remain in the DAP tower, tilted as shown. 5. One weight plate at a time slide 18 weight plates onto the guide rods. Note: the weight plates must be loaded with the Lock N Load switches closest to the rear of the DAP. The plates in the right tower will mirror those in the left tower. 6. After all the weight plates have been installed slide the top plate back onto the guide rods. 7. Slide the rubber stops back onto the guide rods as shown. 8. Set the black plastic centering caps on top of each guide rod then tilt the guide rods back into the DAP tower. Holding the guide rods push them upward until the black plastic centering caps push into the DAP tower frame. 9. While holding the guide rods in place have another person tighten the four set screws located in the shaft collars, that were loosened in step one. Black cap fully inserted Page 5
6. Ensure that the cables did not get twisted when the top plate was removed. The cable should follow the arrows as shown. SHROUD INSTALLATION:. 1. Use the provided plastic push-in rivets to Install the Outside shroud and inside shrouds. There are four rivets per shroud as shown below. Before operation of this unit go through the entire machine and ensure that all bolts and fasteners are tight. Also verify that all moving components operate smoothly and freely. Page 6
HARDWARE GUIDE WARNING! Before using this product, it is essential to read the ENTIRE operations manual and ALL installation Instructions. The Owner s manual describes equipment setup and instructs members on how to use it correctly and safely. Health related injuries may result from incorrect or excessive use of exercise equipment. Star Trac strongly recommends you to encourage you and your members to discuss their health program or fitness regimen with a health care professional, especially if you or they have not exercised for several years, are over 35, or have known health conditions. Page 7
STAR TRAC 14410 Myford Road Irvine, California 92606 Telephone: (800) 228-6635, (714) 669-1660 Fax: (714) 508-3303 www.startrac.com Part No. 620-8050, Rev A., 26 OCT 10