Unpacking; Assembly; Siting Requirements; Parts And Materials - Star Trac Leg Curl Owner's Manual

A S
ETUP - L
SSEMBLY AND

PARTS AND MATERIALS

The following parts are included with the STAR TRAC INSTINCT LEG EXTENSION:
1 Frame, Weight Stack
2 Frame, Main
3 Crossbeam, Lower
4 Crossbeam, Upper
5 Handgrips
6 Post, Seat
7 Support, Back Cushion
8 Support, Seat Cushion
9 Actuator, Leverage Arm
10 Leverage Arm
11 Cushion, Seat
15 Belt
16 Cushion, Leg
17 Selector Pin
18 Shaft, Actuator, Leverage Arm
21 Cushion, Back
22 Shaft, Leverage Arm
24 End Cap
28 Collar, Large
29 Collar
32 Shroud, Lower, Rear
33 Shroud, Lower, Front
34 Shroud, Upper
T R
OOLS EQUIRED
Most STAR TRAC INSTINCT machines can be assembled using the following tools:
Metric Hex Key Wrenches - 2.5mm, 5mm, 6mm, 8mm, 10mm
Metric Open-End Wrenches - 10mm, 15mm, 17mm
Metric Ratchet Socket Wrench Set (including 17mm socket)
Torque Wrench
Your INSTINCT LEG EXTENSION includes a hex key set and combination open-end wrench.

SITING REQUIREMENTS

Your INSTINCT LEG EXTENSION requires approximately 32 square feet of floor space to ensure safe operation of the unit.

UNPACKING

Your INSTINCT LEG EXTENSION is shipped in one or more shipping cartons. Each carton will generally contain one sub-
assembly of the entire unit. To unpack:
Remove the shipping straps from the outside of each shipping carton.
Open the top of each carton and fold back all four flaps.
Remove the packing materials, foam inserts, and ALL parts from each shipping carton. Keep the contents of each carton in
a separate area to facilitate assembly. To ensure personal safety during assembly, place all packing materials outside the
assembly area.
Verify that all parts listed above are included in your shipment.
Take time now to enter your INSTINCT LEG EXTENSION serial number in the space below. If parts are missing, or if you have
any operational questions, please call Star Trac's Service department at (800) 503-1221; have your serial number ready.
Serial No. __________________________________________
14
E
EG XTENSION
1 36 Retainer, Belt
1 39 Support, Weight Stack
1 40 Cap, Rubber
1 41 Guide Post, Weight Stack
1 42 Plate, Top, Weight Stack
1 43 Weight, 10lb
1 45 Nut, Tapped Hole
1 48 Setscrew
1 51 Screw,
1 52 Screw, Flat Head Socket, 10X25M
1 53 Screw, Button Head Socket Cap, 8X20M
1 54 Screw, Button Head Socket Cap, 10X30M
1 55 Screw, Button Head Socket Cap, 10X35M
1 56 Screw, Button Head Socket Cap, 10X63M
1 57 Screw, Button Head Socket Cap, 10X80M
1 59 Screw, Button Head Socket Cap, 10X125M
1 60 Screw, Button Head Socket Cap, 10X130M
4 63 Lock Nut, Nylon Insert, 10M
2 65 Washer, 9M
1 66 Washer, 11M
1 67 Washer, Spring, 10M
1 68 Weight, 5lb
2 69 Weight, 15lb
Channel Lock Pliers
Vice Grip Pliers
Rubber Mallet
Phillips Head Screwdriver - #2
STAR TRAC INSTINCT LEG MACHINES O
Continue to slide the leverage arm shaft (32) into the rear support bearing in the weight stack frame (1).
Secure the leverage arm shaft (32) to the weight stack frame (1) using two screws (72) and end caps (35). Tighten the
screws securely.
Tighten the two setscrews (67) in each leverage arm shaft support bearing in the weight stack frame (1).
NOTE: Two people are required to install the leverage arm actuator; one to hold the actuator in position, and one to install
the actuator shaft.
2
Hold the leverage arm actuator (10) in place on the leverage arm (14) with the mounting flanges of the actuator posi-
2
tioned around the shaft guide on the leverage arm.
2
Insert the leverage arm actuator shaft (28) through the leverage arm and both actuator mounting flanges.
2
1
Secure the leverage arm actuator shaft (28) to the leverage arm (14) using two screws (72) and end caps (35). Tighten the
6
screws securely.
6
Slide the lap cushion support (15) onto the support shaft on the weight stack frame (1), aligning the locking pin in the
4
support with a drilled hole in the weight stack frame ratchet.
2
8
Secure the lap cushion support (15) to the weight stack frame (1) using one washer (63), screw (72) and aluminum wash-
6
er (34). Tighten the screw securely.
4
6
2
3. Assemble the Weight Stack
3
2 NOTE: Two people are required to assemble the
6
weight stack; one to hold the weight stack guide
15 posts in position, and one to assemble the
6
weight stack components onto the posts.
38
Slide one weight stack support (55) onto each
3
weight stack guide post (57).
4
4 Insert the weight stack guide posts (57) into
the retaining holes in the base of the weight
stack frame (1). BE SURE the drilled ends of
the weight stack guide posts face upwards,
toward the top of the weight stack frame.
WARNING:
STALL THE WEIGHTS ONE AT A TIME.
Install weights (59, 93, 94) on the weight stack
guide posts (57), one at a time, in the following
sequence:
Weight, 15lb (94) - four required
Weight, 10lb (59) - six required
Weight, 5lb (93) - four required
Slide the looped end of the lanyard on the selector pin (27) onto the shaft of the top plate (58).
NOTE: BE SURE to hold the lanyard in place when installing the top plate.
Install the top plate (58) on the weight stack guide posts (57), inserting the top plate shaft through the holes in the
weights. Insert the selector pin (27) through one weight until it engages the top plate shaft.
Install one rubber cap (56) onto each weight stack guide post (57).
Lift up on one weight stack guide post (57) until the rubber cap (56) contacts the underside of the weight stack frame
crossmember. Secure the post to the weight stack with one screw (75) and one washer (88). Repeat for the remaining guide
post.
' M STAR TRAC INSTINCT LEG MACHINES O
WNER S ANUAL
75
88
56
57
58
93
59
94
TO PREVENT INJURY, IN-
55
' M
WNER S ANUAL
75
88
56
57
1
27
55
23