Stairmaster BoxMaster Installation guide

OWNERS

INSTALLATIO

N

MANUAL -

N

INSTRUCTIONS

Page left bl

a

nk intentionally

WA

R

Before using this product, it is es

s

installation Instructions. The Ow

n

members on how to use it correc

t

book or parts thereof in any form without first obtaining

Every effort has been made to keep this information cu

P

a

Every

effort

has

been

made

to

keep

this

information

cu

information herein, and these changes will be incorpor

a

names and logos are trademarks of their respective o

w

R

NING!

s

ential to read the ENTIRE operations manual and ALL

n

e

r

’s manual describes equipment setup and instructs

t

ly and safely.

rights reserved, including those to reproduce this

written permission from Star Trac.

urrent; however, periodically, changes are made to the

a

ge 3

urrent;

however,

periodically,

changes

are

made

to

the

a

ted into new editions of this publication. All product

w

ners. Printed in the USA.

TABLE OF CONTENTS

• Safety Instructions

• Installation Instructions

• Hardware

• Optional BoxMaster Base- Ins

• Optional Base Hardware

• Final Assembly Check Sheet

• Exercise Guidelines

• Maintenance and service

• Warning Labels and Stickers

P

a

5

7

19

tallation Instructions

20

22

23

24

25

26

• Warranty Coverage

28

a

ge 4

• Tool Required

18

Safety Instructions

BoxMaster

Safety Information an

BoxMaster

Safety

Information

an

Safety Information

Read the BoxMaster Owner's Manual carefully be

! WARNING: Serious in

j

ur

y

o

r

jy

safety precautions

1. DO NOT use the BoxMaster in any wa

y

manufacturer. It is imperative that the B

2. Use the machine ONLY for the intende

d

machines

.

3. Keep hands, feet, head, limbs, fingers

a

avoid injury. Use appropriate positionin

4. DO NOT use any equipment that is da

m

replacement parts supplied by BoxMas

t

5. Before each use ins

p

ect to make sure t

p

fasteners and adjustments are tight an

d

6. DO NOT attempt to fix a broken or jam

m

contact BoxMaster approved dealers a

7. DO NOT wear loose or dangling clothin

moving parts.

8. YOU MUST always wear recommende

d

using this product, failure to do so may

9. Children MUST NOT be allowed near t

h

10. Obtain a medical exam prior to beginni

n

11. If at any time during exercise you feel f

a

hii

your p

h

ys

i

c

i

an.

12. It is the purchaser's sole responsibility t

personnel as to the proper operating pr

o

recommended that the end users physi

c

exercise program.

13

MAINTAIN

LABELS AND NAMEPLATE

P

a

13

.

MAINTAIN

LABELS

AND

NAMEPLATE

contain important information. If unread

dealers and distributors for a replacem

e

nd General Exercise Guidelines

nd

General

Exercise

Guidelines

fore assembling, servicing or using this product.

r

death could occur if these

are not observed:

y

other than designed or intended by the

oxMaster is used properly to avoid injury.

d

use. Obtain instruction and DO NOT modify the

a

nd hair clear at all times from moving parts to

g, speed and controlled movements.

m

aged and or has worn or broken parts. Use only

t

er dealers and distributors.

he base is secure and that all

p

ads

,

hardware

,

p, ,

d

the unit is in complete working order.

m

ed machine. Contact appropriate staff and

nd distributors for service and service parts.

g while using the BoxMaster. Keep away from all

d

protective wrist wraps and hitting gloves when

result in serious injury.

h

ese machines. Teenagers must be supervised.

n

g an exercise program.

a

int, dizzy or experience pain, stop and consult

o properly instruct its end users and supervising

o

cedures of the BoxMaster equipment. It is

c

al condition be evaluated prior to beginning any

S: Do not remove labels for any reason They

a

ge 5

S:

Do

not

remove

labels

for

any

reason

.

They

able or missing, contact BoxMaster approved

e

nt.

14. SECURING EQUIPMENT: BoxMaster

e

stabilize and eliminate rocking or tippin

g

contractor.

15. Make sure that each machine is set up

install equipment on an uneven surface

16. MAINTAIN

A

LL EQUIPMENT: Preventa

equipment as well as keeping your liabi

equipment prior to use. DO NOT use i

f

17

Ensure

that any person (s) making adju

17

.

Ensure

that

any

person

(s)

making

adju

any kind is qualified to do so.

18. Perform regular maintenance checks o

n

attention to all areas most susceptible t

o

19. Keep a repair log of all maintenance ac

t

20. Immediatel

y

re

p

lace worn or dama

g

ed

c

y

pg

worn or damaged components then re

m

service until the repair is made.

21. Make sure there is enough room for sa

f

equipment.

22. Use only BoxMaster approved dealers

a

iti/ ith

BMt

i

ma

i

n

t

a

i

n

/

repa

i

r

th

e

B

ox

M

as

t

e

r

equ

i

pm

e

23. UNDERSTANDING EACH AND EVER

Y

IF ANY OF THESE WARNINGS ARE

U

STAR TRAC PERSONNEL.

NOTE: It is the sole responsibili

NOTE:

It

is

the

sole

responsibili

operator to ensure that regular

SAVE THIS

P

a

e

quipment MUST be secured to the floor to

g

over. This must be performed by a licensed

fOO

and operated on a solid level sur

f

ace. D

O

N

O

T

.

tive maintenance is the key to smooth operating

lity to a minimum. Inspect the BoxMaster

f

damaged or inoperable.

ustments or performing maintenance or repair of

ustments

or

performing

maintenance

or

repair

of

n

the BoxMaster equipment. Also, pay close

o

wear.

t

ivities.

c

om

p

onents. If unable to immediatel

y

re

p

lace

pyp

m

ove the BoxMaster piece of equipment from

f

e access and operation of the BoxMaster

a

nd distributors supplied components to

t

e

n

t

.

Y

WARNING TO THE FULLEST IS IMPORTANT.

U

NCLEAR, ASK FOR CLARIFICATION FROM

ity of the user/owner or facility

ity

of

the

user/owner

or

facility

maintenance is performed.

INSTRUCTIONS

a

ge 6

Installation Instructions

GENERAL NOTES:

• Unless otherwise noted Loctite 242/243 or equivalent thr

e

thread locker when a Nyloc nut is used.)

• All BoxMaster equipment MUST be secured to the floor

u

• BoxMaster equipment can be secured to the floor using

M

• This Installation Instructions Manual must be used in con

j

ld ib i t t di t t b

manua

l

d

escr

ib

es equ

i

pmen

t

se

t

up an

d

i

ns

t

ruc

t

s mem

b

e

• BOXMASTER requires at least two people to perform th

e

THREAD LOCKER APPLICATION: Clean all threa

d

Thru Holes

1.

2

8mm

1.

2

6mm

Threa

d

Bolt Size

Metric Steel Bolts T

o

1.

7

10mm

• Torque all hardware to values as specified above, unless

n

• See hardware sheet of this manual for fastener sizing info

• Note: All torque values are in N-m unless otherwise state

d

1.

2

12mm

Should any component not be present or if you have any ope

r

web @ www.startrac.com .

PACKAGING REMOVAL:

Carefully remove all packaging materials that wrap the equi

p

CUTTER AS YOU MAY DAMAGE THE EQUIPMENT. At th

the pallet and set aside for later assembly.

PACKAGING REMOVAL:

Carefully remove all packaging materials that wrap the equi

p

CUTTER AS YOU MAY DAMAGE THE EQUIPMENT. At th

the pallet and set aside for later assembly.

P

a

e

ad locker must be used on all threaded fasteners. (Do not use

u

sing either 10mm or 3/8in. (grade 5 minimum) bolts.

M

AXIMUM of either 20mm or 3/4in. (grade 5 minimum) bolts.

j

unction with the equipment’s Owner’s Manual. The Owner’s

ht it tl dfl

rs on

h

ow

t

o use

it

correc

tl

y an

d

sa

f

e

l

y.

e

installation.

d

s and holes, apply no more than 3-4 drops per bolt.

Blind Holes

25.5 to 28.5 (19 to 21)

2

5

10 to13.5 (8 to10)

2

5

Torque, N-m (lbs-ft)

d

Pitch

o

rque Specifications

55.5 to 58 (41 to 43)

7

5

n

oted otherwise.

rmation; for reference only.

d

.

61 to 65 (45 to 48)

2

5

r

ational questions, please refer to your owner’s manual or on the

p

ment. DO NOT USE A KNIFE OR BOX

is time remove any sub-components from

p

ment. DO NOT USE A KNIFE OR BOX

is time remove any sub-components from

a

ge 7

STEP #1 - UNPACK AND ASSEMBLE #1 PAD & #2 P

A

1

Remove

and

unwrap

all

product

from

shipping

b

1

.

Remove

and

unwrap

all

product

from

shipping

b

assembly.

2. Locate #1 PAD and UPPER-PAD SPRING ARM

BOLTS), and three (M6, FLAT WASHERS) do no

t

3. Locate #2 PAD and UPPER-PAD SPRING ARM

BOLTS), and three (M6, FLAT WASHERS) do no

t

4. Tighten all bolts.

P

a

A

D ASSY:

boxes

Lay

all

parts

out

in

a

clean

open

area

to

prepare

for

boxes

.

Lay

all

parts

out

in

a

clean

open

area

to

prepare

for

as below. Loosely Install three (1/4”-20*3/4”, SOCKET HEAD

t

tighten at this time.

as below. Loosely Install three (1/4”-20*3/4”, SOCKET HEAD

t

tighten at this time.

a

ge 8

SOCKET HEAT BOLT

FLAT WASHER

#1 PAD

#2 PAD

UPPER-PAD SPRING ARM

STEP #2 - ASSEMBLE #3 PAD ASSY:

1.

A

s shown locate #3 PAD and UPPER RIGHT SP

R

BOLTS), and three (M6, FLAT WASHERS).

2. Tighten the three bolts.

P

a

R

ING

A

RM. Loosely Install three (1/4”-20*3/4”, SOCKET HEAD

SOCKET HEAD BOLT

UPPER RIGHT SPRING ARM

#3 PAD

FLAT WASHER

a

ge 9

STEP #3 - ASSEMBLE #4 PAD ASSY:

1. Slide #4 PAD into UPPER RIGHT SPRING

A

R

M

and three (M6, FLAT WASHER).

2. Tighten the three bolts.

UPPER LEFT SPRING ARM

SOCKET

HEAD BOLT

#4 PAD

FLAT WASHER

SOCKET

HEAD

BOLT

Pa

g

M

. Loosely Install three (1/4”-20*3/4”, SOCKET HEAD BOLT),

g

e 10

STEP #4 – ASSEMBLE MIDDLE POSITION PAD ASS

Y

1. Locate MIDDLE SPRING ARM and MIDDLE POSITION PAD as below, loosely install twelve (M8, FLAT

WASHERS) and twelve (M8x25MM, SOCKET HEAD BOLTS), at the same time, make sure the LOWEST

MIDDLE CENTER SOCKET HEAD BOLT throught the EYELET.

2. Tighten all the bolts.

3. Assemble the MIDDLE COVER PAD by adhering

t

Pa

g

Y

:

t

o the MIDDLE POSITION PAD.

g

e 11

MIDDLE COVER PAD

SOCKET HEAD BOLT

MIDDLE SPRING ARM

FLAT WASHER

EYELET

LOWEST MIDDLE

CENTER SOCKET

HEAD BOLT

MIDDLE POSITION PAD

BOXMASTER

How to fit middle position pad with middle cover pad.

STEP 1

Take middle cover pad and roll tightly and secure with tape for 5 minutes. This

will assist correct contour when fixing cover pad to middle position pad.

STEP 2

A) Untape middle cover pad and loosely place on top of middle position

pad so velcro surfaces lightly touch.

B) Lay securing string eyelet inside middle position pad frame.

page 12

page 13

STEP3

Now that securing string eyelet is inside frame turn the frame over and firmly adhere the two surfaces together.

(Important note: Try to keep the outside rim of middle cover pad back 1-2cm from the edge of the middle

position pad to avoid being lifted whilst punching).

Once the pad is fitted lay the middle position pad on it’s back elevate the spring 15cm to access

inner alan key head bolt.

STEP 4

Remove the center socket head bolt and washer, place securing string eyelet over hole and

proceed to tighten bolt onto string eyelet.

Note: this will assist in stopping the middle pad cover from lifting whilst being punched.

INCORRECT CORRECT

EYELET STRING AROUND&UNDER WASHER

SECURE SOCKET HEAD BOLT

STEP #5 – ASSEMBLE #10 PAD ASSY:

1. Locate LOWER LEFT SPRING ARM and #10 P

A

three (1/4”-20*3/4”, SOCKET HEAD BOLTS).

2. Tighten the three bolts.

SOCKET HEAD BOLT

#10 PAD

FLAT WASHER

Pa

g

A

D as below, loosely install three (M6, FLAT WASHERS) and

LOWER LEFT SPRING ARM

g

e 14

STEP #6 – ASSEMBLE #11 PAD ASSY:

1. Locate LOWER LEFT SPRING ARM and #11 P

A

three (1/4”-20*3/4”, SOCKET HEAD BOLTS).

2. Tighten the three bolts.

LOWER RIGHT SPRING ARM

Pa

g

A

D as below, loosely install three (M6, FLAT WASHERS) and

SOCKET

HEAD BOLT

FLAT WASHER

SOCKET

HEAD BOLT

#11 PAD

FLAT WASHER

g

e 15

STEP #7 – INSTALL LOWER CUBIC TUBE ASSY:

1. Install the GAS SPRING into the UPPER

A

DJUS

T

2. Slide the UPPER ADJUSTMENT FRAME into th

e

ASSY.

3. Locate three ADJUSTMENT SET HANDLEBAR

a

shown..

ADJUSTMENT SET HANDLEBAR

PULL PIN ASSY

UPPER ADJUSTMENT FRAME

PULL PIN ASSY

GAS SPRING

Pa

g

T

MENT FRAME.

e

LOWER MAIN FRAME, and then assemble with PULL PIN

a

nd tighten them into the UPPER ADJUSTMENT FRAME as

LOWER MAIN FRAME

g

e 16

STEP #7 Completed

STEP #8 – ASSEMBLE ALL ASSYS:

1. Install #1 PAD & #2 PAD ASSY, #3 PAD

A

SS

Y

A

SSY and #11 PAD

A

SSY using twenty-four

(

SPRING WASHERS) and twenty-four (M10, FLA

T

2. Install #12 PAD ASSY using six (1/4”-20*1”,

SO

3. Tighten all bolts.

#1 PAD & #2 PAD

#4 PAD ASSY

BOLT

#10 PAD ASSY

MIDDLE POSITION PAD ASSY

SPRING WASHER, FLAT WASHER

#12 PAD ASSY

Pa

g

Y

, #4 PAD ASSY, MIDDLE POSITION PAD ASSY, #10 PAD

(

M10 x 25MM, SOCKET HEAD BOLTS), twenty-four (M10,

T

WASHERS).

O

CKET HEAD BOLTS) and six (M6, FLAT WASHERS).

ASSY

#3 PAD ASSY

#11 PAD ASSY

LOWER CUBIC TUBE ASSY

FLAT WASHER, BOLT

g

e 17

STEP #8 Completed

2

1

BOXMASTER

Tools required for assembly and installation

1. 8mm alan key for all spring arms.

2. 6mm allan key for socket head bolt inside middle position pad behind

target number9.

3.3/16 imperial alan key for pad 1 , pad 2 and pad 12 socket head bolts.

4.18mm spanner for base safety anchor/dyna bolts.

page 18

2

12

1

Hardware

Pa

g

e 19

1"

Optional BoxMaster Base- In

STEP #9 – BASE ASSEMBLY:

Pa

g

stallation Instructions

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Stairmaster BoxMaster Installation guide

Stairmaster BoxMaster Installation guide

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