Star Trac CORE HEALTH & FITNESS BOXMASTER BM-K9401 User manual

OWNER'S
MANUAL
CORE HEALTH & FITNESS
BOXMASTER

Page 1
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS................................................................................................................2
IMPORTANT LABEL LOCATIONS ........................................................................................................................4
PRODUCT SPECIFICATIONS ................................................................... 4
ASSEMBLY ........................................................................................................................6
OPTIONAL BASE 400-1120 ................................................................. 10
MAINTENANCE ......................................................................................................................11
TOOLS ................................................................. 11
MAINTENANCE SCHEDULE ................................................................. 12
SUPPORT & SERVICE ......................................................................................................................13

Page 2
Before using this product, it is essential to read the ENTIRE Owner’s Manual and ALL
installation instructions. The Owner’s Manual describes equipment assembly and instructs
members on how to use correctly and safely.
Read all warnings posted on the machine.
Health related injuries may result from incorrect or excessive use of exercise equipment.
Core Health & Fitness strongly recommends you to encourage 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.
WARNING!
WARNING: to reduce the risk of serious injury to
persons using this equipment, read and follow all of
these warnings:
24 in (0.6 m)
Fig. 1 Required Clearance
1. Assemble and operate the unit on a solid level
surface. Position the machine with a minimum of
24 inches (0.6 meters) of clearance on one side
to allow for ease of mounting and dismounting.
Leave a minimum of 19.7 inches (0.5 meters)
between two adjacent units. These dimensions
are the recommended minimum distances.
The actual area for access and passage shall be
the responsibility of the facility and should take
into account this training envelope, Americans
with Disabilities Act Accessibility Guidelines
(ADAAG) requirements and any required local
codes or regulations (www.access-board.gov/
ada).
2. This equipment is designed for use in a
commercial gymnasium or health club. To ensure
the proper use of the equipment in a safe manner,
all users of the equipment should read this
manual before using the machine. This machine
should be made a part of your club training
program in order that the equipment is used by
your members in a safe manner as intended. In
addition to instructing the club members in the
proper use of the equipment, the club member
should obtain a complete physical examination
form their health care provider before beginning
any exercise program.
3. The safety and integrity of this machine can only
be maintained when the equipment is regularly
examined for damage and wear and repaired.
It is the sole responsibility of the owner of this
equipment to ensure that regular maintenance
is performed. Worn or damaged parts must be
replaced immediately or the equipment removed
from service until the repair is made.
4. Use only replacement components supplied by
Core Health & Fitness. Substitutes are forbidden
and will void all warranties.
5. This machine is not intended to be used by
persons with reduced physical, sensory, or
mental capabilities or lack of experience and
knowledge, unless given instruction and under
the personal supervision concerning use of the
machine by a person responsible for their safety.
6. Keep children away.
7. Ensure all adjustment and locking features are
properly secured before using the equipment.
IMPORTANT SAFETY INSTRUCTIONS

Page 3
8. When adjusting any seat, knee stabilization pad,
range of motion limiter, foothold pad or any other
type of adjuster, make certain that the adjusting
pin is fully engaged in the hole to avoid injury. If
any of the adjustment devices are left projecting,
they could interfere with the user’s movement.
9. Wear proper exercise clothing and athletic shoes
during a workout. Avoid wearing loose clothing.
Tie back long hair and keep towels away from
the moving parts. Face forward at all times and
never attempt to turn around while the machine is
moving.
10. Do not over exert yourself during exercise. Stop
exercising if you feel pain or tightness in your
chest, become short of breath or feel faint. If you
feel pain or experience any abnormal symptoms,
stop exercising and consult your health care
provider.
11. It is the purchaser’s sole responsibility to properly
instruct its end users and supervising personnel
as to the proper operating procedures of all
equipment.
SAVE THESE INSTRUCTIONS

Page 4
This page shows the location of the warning labels and communication stickers placed on the equipment as part of the manufacturing process. It is critical that
owners maintain the integrity and placement of these stickers. If you find any stickers missing or damaged the replacement numbers are shown on the support
site and following pages. See Support and Service to order replacements.
731-0517
Serial Label
731-5350
731-0512
731-2430
050-5577
731-5351
731-5349
731-5348
Fig. 2
PRODUCT SPECIFICATIONS
SKU: BM-K9401 Desc: Boxmaster
Unit Weight Width Length Height
246 lbs
112 kg
33 in
84 cm
30 in
76 cm
82 in
208 cm
IMPORTANT LABEL LOCATIONS

Page 5
050-5577
STICKER,NOTICE TO OIL
731-0512
STICKER,CAUTION,PINCH
731-0517
STICKER, WARNING, BOLT
DOWN
731-5350
BOXMASTER, LOGO, STICKER
731-5348
STICKER, CAUTION, DO NOT HIT
BACK OF PAD
731-5349
STICKER, CAUTION, WEAR
PROPER WRIST WRAPS/
GLOVES
731-5351
STICKER, CAUTION, DO NOT
LEAN ON UNIT/HOLD SPRINGS
731-2430
STICKER,WARNING, STANDARD INSTRUCTIONS
Notice: images are not to scale

Page 6
All equipment MUST be secured
(bolted and tightened) to a solid, level
surface, using all of the anchoring
holes provided, to stabilize and
eliminate rocking or tipping over. Shim
any mounting surface that does not
rest thoroughly on the floor using flat
washers, DO NOT force the foot to
contact the ground with anchors.
Fasteners must be a 16mm bolt of grade 12.9 or a 5/8” bolt of grade 8 or better and be installed per the bolt
manufacturer’s specifications.
Due to the wide variety of flooring on which equipment may be anchored or installed and differences in
applicable local building codes, Core Health & Fitness is not responsible for any damage to the flooring that
may result due to anchoring or installing equipment to the floor and for compliance with local building codes.
Only licensed contractors or certified installers should be used to insure proper anchoring, installation, and
compliance with local building code.
Required Tools:
• Metric Allen Key Set
• Loctite Blue1
• Torque Wrench
• Metric Open-Ended Wrench Set
• Large Adjustable Crescent Wrench
THREAD LOCKER APPLICATION: Clean all threads and holes, apply no more than 3-4 drops per bolt.
Thru Holes Blind Holes
PACKAGING REMOVAL:
Unit is heavy and requires two people for assembly.
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 pallet and set aside for later assembly. Once all packaging
has been removed, lay all parts out in a clean open area to prepare for assembly. Should any component not
be present or if you have any operational questions, please refer to SUPPORT & SERVICE
After assembly, a complete visual inspection, and test of the features and functions of the assembled unit must
be made prior to use.
1 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.)
ASSEMBLY
Metric Steel Bolts Torque Specifications
Bolt Size Thread Pitch Torque, N-m (lbs-ft)
6mm 1.25 10 to13.5 (8 to10)
8mm 1.25 25.5 to 28.5 (19 to 21)
10mm 1.75 55.5 to 58 (41 to 43)
12mm 1.25 61 to 65 (45 to 48)
• Torque all hardware to values as specified above, unless noted otherwise.
• See procedure of this manual for fastener sizing information; for reference only.
Note: All torque values are in N-m unless otherwise stated.

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PROCEDURE
1. Locate #1 pad and Upper Spring Arm.
Loosely install three (1/4”-20*3/4”, SOCKET
HEAD BOLTS), and three (M6, FLAT
WASHERS). Tighten all bolts evenly.
2. Locate #2 pad and Upper Spring Arm.
Loosely install three (1/4”-20*3/4”, SOCKET
HEAD BOLTS), and three (M6, FLAT
WASHERS). Tighten all bolts evenly.
Fig. 3
3. Locate #3 pad and Upper Right Spring Arm
(shown). Loosely install three (1/4”-20*3/4”,
SOCKET HEAD BOLTS), and three (M6, FLAT
WASHERS). Tighten all bolts evenly.
4. Repeat for #4 pad and Upper Left Spring Arm
using three (1/4”-20*3/4”, SOCKET HEAD
BOLTS), and three (M6, FLAT WASHERS).
Tighten all bolts evenly.
Fig. 4
5. Locate MIDDLE SPRING ARM and MIDDLE
POSITION PAD. Loosely install twelve (M8,
FLAT WASHERS) and twelve (M8x25MM,
SOCKET HEAD BOLTS)
6. Tighten all the bolts.
7. Swing top of pad down and secure with
Velcro tabs
Middle Spring Arm
Lowest Middle Center Socket Head Bold
Flat Washer
Socket Head Bolt
Middle Cover Pad
Middle Position Pad
Middle Spring Arm
Lowest Middle Center Socket Head Bold
Flat Washer
Socket Head Bolt
Middle Cover Pad
Middle Position Pad
Fig. 5

Page 8
8. Locate #10 pad and Lower Left Spring
Arm. Loosely install three (1/4”-20*3/4”,
SOCKET HEAD BOLTS), and three (M6, FLAT
WASHERS). Tighten all bolts evenly.
9. Locate #11 pad and Lower Right Spring
Arm. Loosely install three (1/4”-20*3/4”,
SOCKET HEAD BOLTS), and three (M6, FLAT
WASHERS). Tighten all bolts evenly.
Fig. 6
10. Install the lower cubic tube assembly.
a. Install the gas spring into the upper
adjustment frame.
b. Slide the upper adjustment frame onto
the lower main frame.
c. Assemble with the Pull Pin Assembly.
A
C
B
A
C
B
Fig. 7

Page 9
11. Locate the three adjustment set handlebars
and tighten them into the upper adjustment
frame.
Fig. 8
12. Install #1 thru #11 pad assemblies using
twenty-four (M10x25mm Socket Head Bolts),
twenty-four (M10 Spring Washers), and
twenty-four (M10, Flat Washers)
Fig. 9
13. Install the #12 pad assembly using six (1/4”-
20*1” socket head bolts) and six (M6, Flat
Washers).
14. Tighten all bolts.
15. Tower assembly is complete.
Fig. 10

Page 10
OPTIONAL BASE 400-1120
Fig. 11
16. Assemble the Base:
Place the two horizontal fixed plate assemblies flat ( ), then attach the vertical plates and upper fixed
plate ( ) with four bolts (731-5340) for the upper fixed plate and twelve bolts (731-0390) for the vertical
fixed plates.
17. Attach the Boxmaster tower to the assembled
mat with the tower mounting plate (731-5332) and
eight bolts 731-5338
731-5332
731-5338
Fig. 12

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TOOLS
Working on this product will require basic and/or sometimes specialty tools based on the type of service that
will be performed at any time. To assist, we recommend having the tools listed available when performing
maintenance.
Tool
Metric Allen Key Set Screwdriver Set, Phillips
Metric Open-Ended Wrench Set Screwdriver Set, Flat
Large Adjustable Crescent Wrench Torque Wrench
Metric Socket Set
MAINTAIN ALL EQUIPMENT: Preventative maintenance is the key to smooth operating equipment as well
as keeping the product in safe operating condition. Failure to conduct preventative maintenance by the owner
may cause the product to operate in an unsafe manner. Equipment needs to be inspected and maintained at
regular intervals per the preventative maintenance schedule provided in this manual.
Cleaning
Keeping your Strength units clean is an important component of preventative maintenance and the overall
aesthetics of your product. While your clients will appreciate clean equipment free of sweat, dirt and other
contaminants proper care and cleaning will extend the life of your product and reduce premature aging and
wear. See the maintenance schedule for recommended frequency.
• For general cleaning: A solution of 10% mild soap with warm water applied with a soft damp cloth OR
Formula 409 applied to a cloth then wiped onto the upholstery.
Note – do not use cleaners that contain solvents, alcohol or abrasives.
• For disinfecting: 1:10 Bleach/Water mix. After cleaning, rinse area with clean water, then dry with a
clean, lint-free cloth. Failure to remove chemical residue will cause discoloration of the coated fabric
surface to manifest earlier in the life cycle of the product
• Inclusion in this document does not imply “fit for use.” Customers should first determine if products are
appropriate for use on their surfaces
• Should other cleaning methods or products be employed, carefully try them in an inconspicuous area
to determine potential damage to the material. Never use harsh solvents or cleaners which are intended
for industrial applications. To clean stained or soiled areas, a soft white cloth is recommended. Avoid
use of paper towels.
CAUTION: Cleaning products may be harmful/irritating to your skin, eyes, etc. Use protective
gloves and eye protection. Do not inhale or swallow any cleaning product. Protect surrounding area/
clothing from exposure. Use in a well-ventilated area. Follow all product manufacturer’s warnings.
CORE Health and Fitness cannot be held responsible for damage or injuries resulting from the use or
misuse of cleaning products.
MAINTENANCE

Page 12
MAINTENANCE SCHEDULE
With durable, high performance components, this equipment is designed for heavy usage with minimal
maintenance required. To keep it in top condition, perform regular daily, weekly and monthly preventive
maintenance routines outlined below.
The safety and integrity of this machine can only be maintained when the equipment is regularly examined for
damage and wear and repaired. It is the sole responsibility of the owner of this equipment to ensure that regular
maintenance is performed. Worn or damaged parts must be replaced immediately or the equipment removed
from service until the repair is made.
Daily Weekly Monthly Bi-Annually
Inspect
Fasteners X
Upholstery X
Labels X
Main Frame X
General Maintenance
Lubricate Adjustment Levers X
Lubricate Post Slide Assembly X
Cleaning
Upholstery X
Main Frame X
Inspection
Visual inspection of your units will insure a safe environment for your clients and alert you to any issues that
may require maintenance prior to equipment failure. Proper, timely visual inspection is a critical component to
the long term care of your product.
• Fasteners, hardware and attachments should be checked monthly for looseness. Tighten as required
using appropriate tools.
• Main frame should be inspected every six months for signs of unusual wear, corrosion or structural
integrity issues.
• Upholstery should be inspected for wear or damage monthly and replaced as needed.

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SUPPORT & SERVICE
For Technical Support, Service, Parts Orders or any Customer Service needs, please contact us direct by phone,
email, or through our 24 hour support site:
To help us support you, please provide the following information when requesting assistance with your equipment:
Facility Name & Address Product Serial Number Description of Issue
Our goal is to provide fast, reliable support to all your product support requests. We strive to answer all support
requests under an average hold time of 3 minutes, all support emails within 1 business day and all field service
requests within 48 hours.
PREVENTATIVE MAINTENANCE
Protect your product & assure it always runs like new with a Core Advantage Preventative Maintenance or Extended
Warranty Package. Contact your service manager for more information: [email protected]
To request access scan or visit:
CONNECT.COREHANDF.COM
• General Inquiries
• Warranty Registration
• Preventative Maintenance
• Service Requests
• Parts Orders
• Automated partner payment
• Product technical library
• Transparency on service performance
• 24-Hour Automated Assistant
• Live Chat
OFFERS 24-HOUR SELF SERVICE ACCESS TO:
Core Connect is your portal to all things service! Whether you need to
order parts or register your warranty, Core Connect is the most effective
way to get what you need fast and keep your facility operating smoothly.
CORE CONNECT
GLOBAL SUPPORT CENTER
4400 NE 77th Avenue, Suite 300 Vancouver, WA 98662
Tel: [phone] • [phone] • ser[email protected]
Warranty information: https://corehandf.com/warranty
Core Connect is accessible through our app on mobile devices

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© 2020 CORE HEALTH & FITNESS LLC PART NUMBER 620-8152, REV C
All rights reserved. Star Trac, the Star Trac logo and StairMaster are registered trademarks of Core Health & Fitness, LLC. Schwinn and Nautilus are registered
trademarks of Nautilus Inc. used under license to Core Health & Fitness LLC. Throwdown is a registered trademark of Throwdown Industries, LLC.