Star Trac INSPIRATION STRENGTH IP-S6331 User manual

ABDOMINAL MACHINE
IP-S6331
INSTALLATION INSTRUCTIONS

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Copyright 2009. Star Trac by Unisen, 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.

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INSTALLATION INSTRUCTIONS
1• TORQUE WRENCH
••••••••••••••••••••••••••••••••••••••••
1• 8MM HEX KEY SOCKET
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• #2 CROSS-HEAD (PHILLIPS) SCREWDRIVER
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11• 6MM HEX KEY SOCKET
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1• 13MM SOCKET
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1• 5MM HEX KEY SOCKET
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1• 19MM OPEN-END WRENCH
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1• 4MM HEX KEY SOCKET
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1• 17MM OPEN-END WRENCH
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1• 3MM HEX KEY SOCKET
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2• 13MM OPEN-END WRENCH
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1• 2.5MM HEX KEY SOCKET
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REQUIRED TOOLS:
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 four mounting points inside the weight stack and one in either of the small feet.
• 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.
• The Abdominal Machine weighs approximately 260 Kg (573 lbs) when fully assembled and occupies an area 155 cm
wide by 108 cm deep. Star Trac recommends the addition of 1-2 people during assembly, and when moving the
equipment to its designated point of use.
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.
THREAD LOCKER APPLICATION: Clean all threads and holes, apply no more than 3-4 drops per bolt.
Thru Holes Blind Holes
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 pallet and set aside for later assembly.
• Torque all hardware to values as specified above, unless noted otherwise.
• See Page 11 of this manual for fastener sizing information; for reference only.
• Note: All torque values are in N-m unless otherwise stated.
26 to 30 (35 to 40)1.75
10mm
9.5 to 12 (13 to 16)1.258mm
4.5 to 6 (6 to 8)1.25
6mm
Torque, N-m (lbs-ft)Thread PitchBolt Size
Metric Steel Bolts Torque Specifications

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2. Grip the top of the outside SHROUD and lift
to remove it from the weight stack.
Carefully store the SHROUD for later use.
Now repeat with the inside SHROUD.
REMOVE THE SHROUDS:
1. Using a 4MM hex key remove the
(M6,30MM,Button Head Bolt) from the
rear of the weight stack. Save this bolt
as you will need it to re-install later. After
the bolt has been removed rotate the
black TOP BUMPER towards the front of
the weight stack then lift it off and set
aside.
REMOVE FROM PALLET:
1. With the shrouds removed, locate and
remove the two bolts that secure the
equipment to the pallet. There will also be
a bolt through each of the equipment’s
feet.
2. Once all bolts fastening the equipment to
the pallet have been removed, carefully
remove equipment off of the pallet and
place in desired location.
PROTECTIVE FEET:
1. Your equipment shipped with a set of
PROTECTIVE FEET. Tilt the equipment
towards the weight stack until the two
smaller feet lift off the ground; slip the
PROTECTIVE FEET on and set the
equipment back down.
2. Now tilt the equipment onto the two
small feet lifting the weight stack off the
ground. Install the large PROTECTIVE
FOOT and set the equipment back
down.

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INSTALLING THE ARM PIVOT BRACKET:
1. Locate the six (M12,70MM,Button Head
Bolts), six (M12,Washers), ARM
BRACKET, & ARM PIVOT BACK
PLATE. Align components and tighten
bolts using an 8MM hex key.
2. Secure the ARM BRACKET CROSS
BRACE to the FRONT TUBING with four
(M8, 20MM, Button Head Screw) and
four (M8, Washers). Tighten with a 4MM
hex key.
Back
Plate
Cross
Brace
Arm Pivot
Bracket
INSTALLING THE ARM PIVOT:
1. Place the ARM PIVOT assembly in
between the ARM PIVOT BRACKET and
align with the PIVOT SHAFT.
2. Install END CAPS as shown with a M8
Washer and (M8, 20MM, Socket Head
Screw) on each side. NOTE: Place the
END CAP with the red rotational sticker
toward the user.
Arm
Pivot
Pivot
Shaft
End Cap w/
Red Sticker
Spacer w/
25mm ID
Spacer w/
8.4mm ID
2X M8
Washer

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INSTALLING THE ARM PIVOT (CAM SIDE):
1. Install the CAM/SHAFT assembly thru the
bearings in the ARM PIVOT BRACKET
and into the ARM PIVOT.
2. Install END CAP as shown with a M8
Washer and (M8, 20MM, Socket Head
Screw). NOTE: Place the END CAP with
the red rotational sticker toward the user.
3. Align the thru holes in the ARM PIVOT
with the threaded holes in the
CAM/SHAFT and screw in two (M8,
25MM, Socket Head Screw). Tighten
using a 4MM hex key.
Arm
Pivot
Arm Pivot
Bracket
Cam / Shaft
Assembly
Spacer w/
25mm ID
ATTACHING THE CABLE:
1. Locate the loose cable end and loop
around the pulleys as shown taking
care not to fray the stranded wire.
2. Pull and insert the CABLE END into
the CABLE MOUNT of the CAM until the
end of the CABLE is visible in the sight
hole.
3. Secure with the four sets screws (M8)
included, using a 4MM hex key. Torque
to 15-17 N-m.
Sight Hole
INSTALLING THE SEAT BOTTOM:
1. Align and install the ADJUSTABLE
SEAT using four (M8,16MM,Socket
Head Bolts) and four (M8,Washers)
Tighten using a 6MM hex key.
2. Pull up on the red handle and verify that
the seat assembly slides up and down
smoothly.

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GUIDE ROD LUBRICATION:
1. Apply a general purpose lubricant (such
as 3-in-1 oil) that does not contain Teflon
to a cotton cloth, then run the cotton
cloth up and down the guide rods as
needed.
2. Also apply oil to the incremental weight
guide tracks.
3. Verify that the Top Plate and Incremental
Plate slide smoothly.
Incremental
Guide Track
Guide Rod
M8 Jam Nut (2X)
Frame
No Gap
Washer
REAR FOOT ADJUSTMENT:
1. Verify that the equipment is at the
desired location and then check to make
sure the feet contact the ground and
leveled.
2. If the machine rocks or is tippy, adjust
rear foot by loosening the two Nyloc nuts
using a 13MM open-end wrench and a
6MM hex key.
3. Slide the foot up or down until the
machine is leveled.
4. Re-tighten the bolts and nuts.
TOP PLATE & CABLE ADJUSTMENT:
1. Engage pin at maximum
weight and actuate arm 3 to 4 times to
fully seat the weight stacks.
2. Disengage pins and
verify that there is no gap between the
Top Plate and the lower weight plate. If
a gap exists or if there is too much slack
on the cable, then the cable tension
needs to be adjusted.
3. Using two 13MM open end wrench,
loosen the upper M8 Jam Nuts. Adjust
cable tension until the Top Plate drops
and rests on to the weight stack.
4. Hand tighten the jam nuts and check to
make sure the gap is gone. Cable
should deflect no more than ±25mm
from centerline without raising the Top
Plate. Check for smooth
pin engagement.
5. Tighten jam nuts.

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GAP
SCREWS
INCREMENTAL WEIGHT ADJUSTMENT:
1. Check to make sure the gap between
the TOP PLATE pin and the 20mm hole
of the INCREMENTAL WEIGHT plate is
3mm or less when engage.
2. If gap is greater than 3mm, loosen but
do not remove the two BUTTON HEAD
SCREWS (M6) using a 4MM hex key.
3. Slide the bracket up or down to create a
3mm gap.
4. Re-tighten the two BUTTON HEAD
SCREWS.
INCREMENTAL WEIGHT PLATE
INSTALLING THE SHROUDS:
1. Insert the SHROUDS from the top
sliding downward. The SHROUDS
have seven hooks for mounting.
Before the shroud can be slide
down into place the SHROUD hooks
need to be aligned with the corres-
ponding mounting slots found on the
weight frame of the equipment. Once
the SHROUD hooks are in the slots,
slide the SHROUD into place and verify
that the top of the SHROUD is aligned
with the top of the weight stack. If the
SHROUD is not aligned use the palm of
your hand and tap the SHROUD down
until it is aligned.
2. Repeat step 1 with the inside shroud and
verify alignment.

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INSTALLING THE TOP BUMPER:
1. After both shrouds have been installed
install the black TOP BUMPER by first
inserting the two tabs (1) found on the
large end of the TOP BUMPER into the
equipment main frame. Now rotate (2) the
TOP BUMPER down until it is sitting flush
on top of the weight frame. Install the
(M6,30MM,Button Head Bolt) (3) through
the weight frame into the TOP BUMPER
as shown and tighten to 1.0 N-m max.
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.
WARNING!
MACHINE CLEARANCE AND SPACING
For the safe operation of Inspiration Strength™ Star Trac recommends that a clearance of 24 inches
(60.96cm) be maintained between and behind machines including moving arms and levers. To insure
safe entry and exit to each unit a walkway of at least 36 inches (91.44cm) inches is recommended
front of, or on the entry side of each machine.

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Part No. 620-7938, Rev B., 21 Aug 2009
STAR TRAC
14410 Myford Road
Irvine, California 92606
Telephone: [phone]
Fax: [phone]
www.startrac.com