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Assembly & Setup
STAR TRAC FITNESS 1 of 14 635-4175 Rev: B
TreadClimber
®
INSTALLATION INSTRUCTIONS
Assembly & Setup
STAR TRAC FITNESS 2 of 14 635-4175 Rev: B
NOTICE
Installation of this product requires that 2 or more people are available
to safely perform certain steps outlined by this document.
Assembly & Setup
STAR TRAC FITNESS 3 of 14 635-4175 Rev: B
1. Locate an open area to unbox the packaged
TreadClimber
®
(Fig.1).
Fig. 1
2. Cut all straps to remove the cardboard packaging along
with any protective wrapping to expose the palletized
TreadClimber base and assembly components (Fig. 2).
Fig. 2
3. Move all unattached components off the TreadClimber
base (Fig. 3).
Components:
A. Console Frame
B. Neck Mast
C. Rear Corner Shroud (Left & Right)
D. Hardware Pack
E. Handrail Grommets
F. Owner’s Manual
G. Neck Grommet
H. Power Cord
I. Rear Shroud
J. Upper Handrails (Left & Right)
K. Lower Handrails (Left & Right)
Fig. 3
Assembly & Setup
STAR TRAC FITNESS 4 of 14 635-4175 Rev: B
4. Breakaway the rear bottom section (Fig. 4) of the
cardboard pallet.
Fig. 4
5. Remove the alternator shroud (Fig. 5) located under
the two treadle assemblies at the front of the
TreadClimber base.
Fig. 5
6. Locate the two transport grip handles (Fig. 6) that come
with the packaged base and attach them to the “J”
hooks located near each front corner of the
TreadClimber base.
Fig. 6
Assembly & Setup
STAR TRAC FITNESS 5 of 14 635-4175 Rev: B
7. With two people, pull the TreadClimber base
backwards (Fig 7) until all four wheels are driven off the
pallet and the base is safely on to the ground.
Fig. 7
8. Remove and store the transport grip handles (Fig. 8)
once the TreadClimber base is safely on the floor. The
transport grip handles can be reattached for future
transport.
Fig.8
9. Mount the neck mast (Fig. 9) to the base by lightly
torquing four socket head cap screws in place at the
front of the base frame.
Hardware:
o 5/16-18 X .75” Socket Head Cap Screw (Location – A)
o 5/16-18 X 1.0” Socket Head Cap Screw (Location – B)
QTY: 2 Each
o 5/16 Split Lock Washer
o 5/16 Flat Washer
QTY: 4 Each
Final Torque:
o
240 In-Lbs (27 Nm)
Fig. 9
Assembly & Setup
STAR TRAC FITNESS 6 of 14 635-4175 Rev: B
10. Connect the cables extruding through the lower section
of the neck mask into the corresponding locations on
the lower base (Fig. 10).
Fig. 10
ASSEMBLY TIP
For ease of component alignment; installation of the handrail & console frame components requires that the
corresponding securing screws are initially loosely threaded until instructed to apply final torque to each piece of
hardware in step 17 of the assembly process.
11. Mount the left & right lower handrail sections to the
TreadClimber base and loosely thread four socket head
cap bolts to each handrail mount (Fig. 11) along with
sliding on the corresponding left & right handrail
grommets into place.
Hardware:
o 5/16-18 X 1.0” Socket Head Cap Screw
o 5/16 Flat Washer
o 5/16 Split Lock Washer
QTY: 4 Each
Final Torque:
o
240 In-Lbs (27 Nm)
Fig. 11
12. Slide a beauty ring onto each lower handrail section
(Fig. 12) and mount the upper handrail by loosely
threading two button head cap screws in place. Verify
that the radius cutout clears the lower securing screw.
Hardware:
o 1/4-28 X 3/8” Button Head Cap Screw
QTY: 2 Each
Final Torque:
o
35 In-Lbs (4.0 Nm)
Fig. 12
Assembly & Setup
STAR TRAC FITNESS 7 of 14 635-4175 Rev: B
13. Slide on the second set of beauty rings (Fig. 13) onto
each upper handrail while making sure the radius
cutouts clear the available threaded holes.
Fig. 13
14. Slide the console frame onto each upper handrail
(Fig. 14) and rest the center of the console frame on
top of the neck mast plate.
Fig. 14
15. Loosely thread four socket head cap screws (Fig. 15)
with washers through the neck mast mount plate on to
the console frame mount plate.
Hardware:
o 5/16-18 X 1.0” Socket Head Cap Screw
o 5/16 Flat Washer
o 5/16 Split Lock Washer
QTY: 4 Each
Final Torque:
o
240 In-Lbs (27 Nm)
Fig. 15
Assembly & Setup
STAR TRAC FITNESS 8 of 14 635-4175 Rev: B
16. Secure the console frame to the handrails (Fig. 16) by
loosely threading two button head cap screws through
the rail into the console frame.
Hardware:
o 1/4-28 X 3/8” Button Head Cap Screw
QTY: 2 Each
Final Torque:
o
35 In-Lbs (4.0 Nm)
Fig. 16
17. Using a torque wrench, go back to steps: 9, 11, 12, 15,
& 16 to thread all bolts mentioned in each step to their
corresponding final torque (Fig. 17) specifications
which are listed in the notes section of the step
instructions.
Fig. 17
18. Hover the top half of the display (Fig. 18) over the
console frame.
Fig. 18
Assembly & Setup
STAR TRAC FITNESS 9 of 14 635-4175 Rev: B
19. Mate all the applicable electrical connections coming
from the neck (Fig. 19) to the back of display electronics
board (Fig. 20).
Fig. 19
NOTE
Audio and coaxial connections are only used if a
personal television is mounted to the machine.
Otherwise these cables remain unused.
Fig. 20
20. Slide the left & right display alignment studs (Fig. 21)
into the corresponding console frame guide holes to
rest the top half of the display on to the console frame.
WARNING
Verify that during mounting of the console; the alignment studs do
not interfere or damage the cable harness that runs through the
tube. Any cable interference will prevent the console from settling
correctly on the console frame.
Fig. 21
21. From the back of the display (Fig. 22) secure the
display’s grounding wire to the frame using a washer &
phillips head screw.
Hardware:
o #8-18X 3/4” Phillips Pan Head Thread Tap Screw
o M4 Flat Washer
QTY: 1 Each
Fig. 22
Assembly & Setup
STAR TRAC FITNESS 10 of 14 635-4175 Rev: B
22. Secure the display to the console frame by installing
five phillips head screws with washers at the
corresponding circled locations (Fig. 23).
Hardware:
o #8-18X 3/4” Phillips Pan Head Thread Tap Screw
o M4 Flat Washer
QTY: 5 Each
Fig. 23
23. Mate the back shroud of the display with the rest of the
assembly by installing eight phillips head screws at the
corresponding circled locations (Fig. 24).
Hardware:
o #8-18X 3/4” Phillips Pan Head Thread Tap Screw
QTY: 8 Each
Fig. 24
24. Dislodge the rear step shroud from the TreadClimber
base (Fig. 25) and move the handrail grommets up the
handrails.
Fig. 25
Assembly & Setup
STAR TRAC FITNESS 11 of 14 635-4175 Rev: B
25. Mount the rear shroud to the TreadClimber base and
secure it in place by installing the corresponding five
phillips head screws to the top (Fig. 26) and
lower (Fig. 27) sections at the circled locations.
Fig. 27
Fig. 26
Hardware:
o M5x0.8-16mm Phillips Pan Head Machined Screw
QTY: 2 Each (Fig. 26)
o #10-24x1/2” Phillips Pan Head Thread Tap Screw
QTY: 3 Each (Fig. 27)
26. Mount the left & right corner shrouds (Fig. 28) and
secure them in place by installing the corresponding
four phillips head screws to each shroud at the circled
locations.
Hardware:
o #8 x1.25” Phillips Pan Head Thread Tap Screw
QTY: 4 Each
Fig. 28
27. Mount the rear step shroud (Fig. 29) and wedge the
left & right handrail grommets into the available open
space between the shrouds. Secure the rear step
shroud by installing the corresponding five phillips head
screws at the circled locations.
Hardware:
o M5x0.8-16mm Phillips Pan Head Machined Screw
QTY: 2 Each (Location – A)
o #10-24x1/2” Phillips Pan Head Thread Tap Screw
QTY: 3 Each (Location – B)
Fig. 29
Assembly & Setup
STAR TRAC FITNESS 12 of 14 635-4175 Rev: B
28. Install the front alternator shroud (Fig. 30) and secure it
in place by installing the corresponding two phillips
head screws at the circled locations.
Hardware:
o #8-0.75” Phillips Pan Head Thread Tap Screw
QTY: 2 Each
Fig. 30
29. Wedge the neck grommet (Fig. 31) between the
alternator shroud and neck mast.
Fig. 31
30. Locate the stabilizing feet (Fig. 32) and thread the jam
nuts onto the threaded stud of each foot until the base
of each stud is reached.
Hardware:
o 1/2 -13 Jam Nut
QTY: 1 Each
Fig. 32
Assembly & Setup
STAR TRAC FITNESS 13 of 14 635-4175 Rev: B
31. With two or more people, have one person carefully tilt
the assembled TreadClimber (Fig. 33) at an angle by
pushing up at the center of each handrail while the
second person installs the rear stabilizing feet.
Fig. 33
32. Transport/push (Fig. 34) the TreadClimber to its final
location by rolling it into position.
WARNING
This product should only be transported to its final destination
using the wheels that are fixed to the base of the product.
In the event that a four wheel moving dolly is used; it is prohibited
to place it under the middle section of the frame as this can
potentially cause damage to the mechanical components found in
the area and pinch high voltage wires that run parallel to the side
of the product.
A four wheel moving dolly can only be placed at the front and rear
end of the base.
Fig. 34
33. Dislodge the rear step plugs (Fig. 35) to expose the
wheel jacking bolts. Turn the bolts in a counter clock-
wise direction to retract the rear wheels into the base
and rest the machine on the rear stabilizing feet.
NOTE
Each stabilizing foot may need to be independently adjusted
according to floor level once the wheels are retracted into the
base to prevent the product from possibly rocking due to un-even
flooring.
Re-adjusting of each foot requires that step 31 be repeated until
the product is stable.
Fig. 35
Assembly & Setup
STAR TRAC FITNESS 14 of 14 635-4175 Rev: B
34. Wedge the cover plugs back into the rear step shroud
once the TreadClimber is resting on the stabilizing feet.
35. Plug the power cord into the power & connections
panel located at the front of the machine (Fig. 36).
Fig. 36
36. Power on the machine and enter into “Maintenance
Mode” to process a “Motor Calibration” procedure.
Once “Motor Calibration” is complete; the TreadClimber
is ready for initial use.
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