Star Trac Leverage IP-L3005 User manual

IP-L3005
HIGH ROW
OWNERS MANUAL -
INSTALLATION INSTRUCTIONS

Page 2
Copyright 2011. Star Trac by CORE INDUSTRIES. 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.

TABLE OF CONTENTS
•SAFETY INSTRUCTIONS / WARNINGS
•WARNING LABLES WITH PART NUMBERS
•EXERCISE GUIDELINES
•MAINTENANCE AND SERVICE
•WARRANTY COVERAGE
4
6
7
8
9
•INSTALLATION INSTRUCTIONS
•HARDWARE
11
18
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Safety Instructions
LEVERAGE Safety Information and General Exercise Guidelines
Safety Information
Read the LEVERAGE Owner's Manual carefully before assembling, servicing or using the LEVERAGE.
! WARNING: Serious injury or death could occur if these
safety precautions are not observed:
1. Do not use the LEVERAGE in any way other than designed or intended by the
manufacturer. It is imperative that the LEVERAGE as well as any other STAR TRAC
manufacturer. It is imperative that the LEVERAGE as well as any other STAR TRAC
STRENGTH equipment is used properly to avoid injury.
2. Keep hands, feet, head, limbs, fingers and hair clear at all times from moving parts to
avoid injury. Use appropriate positioning, speed and controlled movements.
3. DO NOT use any equipment that is damaged and or has worn or broken parts. Use only
replacement parts supplied by STAR TRAC.
4. DO NOT wear loose or dangling clothing while using the STAR TRAC equipment. Keep
away from all moving parts.
5. Obtain a medical exam prior to beginning an exercise program.
6. If at any time during exercise you feel faint, dizzy or experience pain, stop and consult
your physician.
7. Children must not be allowed near these machines. Teenagers must be supervised.
8. DO NOT attempt to fix a broken or jammed machine. Contact appropriate staff of Star
Trac Service.
9.
Use the machine only for the intended use. Obtain instruction and DO NOT modify the
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9.
Use the machine only for the intended use. Obtain instruction and DO NOT modify the
machines.
10. Load plates evenly and carefully to avoid tipping equipment and possible crushing
injuries. DO NOT exceed maximum load of 540 lbs (244.9 kgs) DO NOT exceed 270 lbs
(122.5 kgs) per side of loaded weight.
11. USE A SPOTTER for all activities.
12. MAINTAIN LABELS AND NAMEPLATES: Do not remove labels for any reason. They
contain important information. If unreadable or missing, contact STAR TRAC for a
replacement.

13. SECURING EQUIPMENT: All STAR TRAC equipment MUST be secured to the floor to
stabilize and eliminate rocking or tipping over. This must be performed by a licensed
contractor. DO NOT use the Weight equipment if it is not set up and located on a solid
level surface.
14. Make sure that each machine is set up and operated on a solid level surface. DO NOT
install equipment on an uneven surface.
15. MAINTAIN ALL EQUIPMENT: Preventative maintenance is the key to smooth operating
equipment as well as keeping your liability to a minimum. Inspect the STAR TRAC
equipment prior to use. DO NOT use if damaged or inoperable.
16. Ensure that any person (s) making adjustments or performing maintenance or repair of
any kind is qualified to do so.
17. Routinely inspect all fasteners that join attachments and framework tighten as needed to
maintain the integrity of the unit.
18.
It is the purchaser's sole responsibility to properly instruct its end users and supervising
18.
It is the purchaser's sole responsibility to properly instruct its end users and supervising
personnel as to the proper operating procedures of all STAR TRAC equipment. It is
recommended that the end users physical condition be evaluated prior to beginning any
exercise program.
19. Perform regular maintenance checks on the STAR TRAC equipment. Also, pay close
attention to all areas most susceptible to wear.
20. Keep a repair log of all maintenance activities.
21. Immediately replace worn or damaged components. If unable to immediately replace
worn or damaged components then remove the STAR TRAC piece of equipment from
service until the repair is made.
22. Make sure that all users are properly trained on how to use the STAR TRAC equipment.
23. Make sure there is enough room for safe access and operation of the STAR TRAC
equipment.
24. Use only STAR TRAC supplied components to maintain/repair the STAR TRAC
equipment.
25. UNDERSTANDING EACH AND EVERY WARNING TO THE FULLEST IS IMPORTANT.
IF ANY OF THESE WARNINGS ARE UNCLEAR, ASK FOR CLARIFICATION FROM
STAR TRAC PERSONNEL.
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NOTE: It is the sole responsibility of the user/owner or facility
operator to ensure that regular maintenance is performed.
STAR TRAC PERSONNEL.

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731-3081

Exercise Guidelines
• Like most exercise, strength training involves an element of risk. Utilize this information to
assist you and/or your members in making the experience on STAR TRAC equipment both
productive and safe.
• Prior to engaging in any strength-training program, individuals with known health conditions
and/or individuals whom are unfamiliar with the risk (s) involved with weight training, should
first consult with a physician.
• All training sessions should be supervised by trained personnel.
• Be certain that the warning stickers affixed on STAR TRAC equipment, remain on the product
and unaltered. Also, be certain that all the stickers (safety, instructional and/or other) are read
and unaltered. Also, be certain that all the stickers (safety, instructional and/or other) are read
and understood by each user.
• All users should be instructed on the proper use of STAR TRAC equipment as well as those
actions that should be avoided.
In an attempt to minimize user and/or bystander injury:
• Do not lean against framework, plate holders or any component whether it is dynamic or static.
• Stay clear of any components while in a dynamic state of motion. Keep hands and feet away
from all moving parts. The convergence of these components can cause serious injury.
• Exercising on free weight and selectorized products should be performed with the assistance of
a spotter.
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MAINTENANCE AND SERVICE
LEVERAGE requires very little upkeep to keep your equipment performing at its best, the following
guidelines are suggested.
GENERAL CLEANING
Wipe LEVERAGE with a light all-purpose cleaner, such as diluted Simple Green at a
30:1 solution.
Dry LEVERAGE with a soft cloth to prevent rust.
BEARING GREASE PACKING
BEARING GREASE PACKING
Before bearings 731-0842 and 731-2595 installed they must be fully
packed with general purpose Lithium Grade 2 grease.
Pack with grease
TIGHTENING OF THE TAPERED ROLLER BEARING ON ALL SHAFTS
To properly torque the tapper roller bearing:

With the tab washer NOT installed torque the bearing nut to 40
-
42 Lbs
-
Ft.(This will
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
With the tab washer NOT installed torque the bearing nut to 40
-
42 Lbs
-
Ft.(This will
square and seat the bearings)
Back the nut off, then install the tab washer.
Torque the nut to 7- 9 Lbs-Ft, now bend tabs on washers to lock in place.

Warranty Coverage
Star Trac commercial exercise equipment (.Product.) is warranted to be free of all defects in material and
workmanship.
Star Trac warrants all structural frameworks for a period of 10 years. This limited warranty on structural frame
does not include coatings. The following moving parts are warranted for 5 years; rotary bearings and
structural moving parts. All unlisted parts, handles and accessories are warranted for 1 year. Upholstery is
warranted for 6 months.
Who is covered
The original purchaser or any person receiving the product as a gift from the original purchaser.
Who pays for transportation and insurance for service
If the Product or any covered part must be returned to a service facility for repairs, We, Star Trac, will pay all
transportation and insurance charges for the first year. You are responsible for transportation and insurance
If the Product or any covered part must be returned to a service facility for repairs, We, Star Trac, will pay all
transportation and insurance charges for the first year. You are responsible for transportation and insurance
charges during the second and third years (if applicable).
What Star Trac will do to correct covered defects
We will ship to you any new or rebuilt replacement part or component, or, at our option, replace the Product.
Such replacement parts are warranted for the remaining portion of the original warranty period.
What is not covered
Any failures or damage caused by unauthorized service, misuse, accident, negligence, improper assembly or
installation, debris resulting from any construction activities in the Product’s environment, rust or corrosion as
a result of the Product’s location, alterations or modifications without our written authorization or by failure on
your part to use, operate and maintain the Product as set out in your Operation Manual (.Manual.).
All terms of this warranty are void if this product is moved beyond the continental borders of the United States
of America (excluding Alaska, Hawaii and Canada) and are then subject to the terms provided by that
country’s local authorized Star Trac representative.
Operation Manual
It is very important that you read and review this manual before operating the Product. Remember to perform
the periodic maintenance requirements specified in the Manual to assure proper operation and your continued
satisfaction.
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How to get parts and service
Contact Star Trac Customer Support Services Monday through Friday from 8:00 a.m. to 6:00 p.m. Pacific
Standard Time, and tell them your name, address and the serial number of your Product. They will tell you
how to get a replacement part, or, if necessary, arrange for service where your Product is located or advise
you on how and where to ship the Product for service.
Visit us on line at http://www.startrac.com/us-en/Support
Customer Services Hot Line: 1 800 503 1221
Fax: [phone]
[e-mail]
International Customer Services: [phone]
Fax: [phone]
[e-mail] or ServiciosEnE[email protected]

Exclusive warranties
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OF ANY KIND EITHER
EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND ALL OTHER OBLIGATIONS
OR LIABILITIES ON OUR PART.
We neither assume nor authorize any person to assure for us any other obligation or liability concerning the
sale of this Product. Under no circumstances shall we be liable under this warranty, or otherwise, of any
damage to any person or property, including any lost profits or lost savings, for any special, indirect,
secondary, incidental or consequential damages of any nature arising out of the use of or inability to use this
Product. Some states do not allow the exclusion or limitation of implied warranties or of liability for incidental
or consequential damages, so the above limitations or exclusions may not apply to you.
Changes in warranty that are not authorized
No one is authorized to change, modify or extend the terms of this limited warranty.
Effects of state laws
This warranty gives you specific legal rights and you may have other rights, which vary, from state to state.
This warranty gives you specific legal rights and you may have other rights, which vary, from state to state.
Our commitment to you
Our Products are designed and manufactured to the highest standards.
We want you completely satisfied with our Products and will do everything possible under the terms of this
warranty to meet and exceed your expectations.
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INSTALLATION INSTRUCTIONS
1
1
• 5mm Hex Key Socket…………………………………...
• 6mm Hex Key Socket……………………………………
1
1
1
• 13mm Box / Open-End Wrench ……………….....
• 13mm Socket……………………………………………
• Torque Wrench…………………………………………
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.
• 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.
manual describes equipment setup and instructs members on how to use it correctly and safely.
• LEVERAGE requires at least two people to perform the installation.
THREAD LOCKER APPLICATION: Clean all threads and holes, apply no more than 3-4 drops per bolt.
Thru Holes Blind Holes
55.5 to 58 (41 to 43)1.7510mm
• Torque all hardware to values as specified above, unless noted otherwise.
• See hardware sheet of this manual for fastener sizing information; for reference only.
61 to 65 (45 to 48)1.2512mm
25.5 to 28.5 (19 to 21)1.258mm
10 to13.5 (8 to10)1.256mm
Torque, N-m (lbs-ft)Thread PitchBolt Size
Metric Steel Bolts Torque Specifications
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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 Leverage serial number and model number labeled on your equipment.
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.
• Note: All torque values are in N-m unless otherwise stated.
WARNING: All taper roller bearings should ship from the factory packed with grease. It is the installers responsibility to
verify that ALL taper roller bearings are fully packed with grease before assembly of the LEVERAGE product begins. If
any bearing needs grease added use a general purpose Lithium Grade 2 grease. Fully pack the roller bearing with
grease by forcing the grease under the bearing cage between the rollers from the large end of the roller until it oozes
thru the small end.
Failure to correctly lubricate bearings and maintain proper lubrication may result in damage that could cause bearing to
fail during operation, creating a risk of serious bodily harm.
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.

STEP #1 - UNPACK AND ASSEMBLE MAIN FRAME:
1. Remove and unwrap all product from shipping boxes. Lay all parts out in a clean open area to prepare for assembly.
2. Locate the FRONT FRAME, MAIN FRAME, and REAR FRAME as shown below.
3. Slide FRONT FRAME into MAIN FRAME. Loosely Install three (M8 X 25MM, BUTTON HEAD BOLTS), and three
(M8, FLAT WASHERS) do not tighten at this time.
4. Slide REAR FRAME into MAIN FRAME. Loosely Install three (M8 X 25MM, BUTTON HEAD BOLTS), and three
(M8, FLAT WASHERS) do not tighten at this time.
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STEP #1 Completed

STEP #2 - ASSEMBLE SIDE FRAMES:
1. Locate the SIDE FRAME LEFT, AND SIDE FRAME RIGHT as shown below.
2. As shown slide SIDE FRAME LEFT into STEP #1 ASSEMBLY. At each tube joint loosely Install three (M8 X 25MM,
BUTTON HEAD BOLTS), and three (M8, FLAT WASHERS) do not tighten at this time.
3. As shown slide SIDE FRAME RIGHT into STEP #1 ASSEMBLY. At each tube joint loosely Install three (M8 X
25MM, BUTTON HEAD BOLTS), and three (M8, FLAT WASHERS) do not tighten at this time.
4.Using a 5MM hex key tighten all (M8 X 25MM, BUTTON HEAD BOLTS) from STEP #1 and STEP #2 to specified
torque setting. Note: Each tube joint will have three bolts, one located on top, bottom, and side.
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STEP #2 Completed

STEP #3 – ASSEMBLE UPPER ARM ASSY AND LOWER LEVERAGE ARMS :
1. Locate one of the Upper Arm Assembly ,one of the Lower Leverage Arm and slide them onto the corresponding shaft
as shown below. The side of the them that has the bearing and seal pre-installed will slide onto the corresponding shaft
first.
2.After the Upper Arm Assembly and Lower Leverage Arm have been slid onto the corresponding shaft install a fully
greased (20MM ID TAPERED BEARING) with the small diameter of the bearing going first. Next install a (3MM thick,
17MM ID WASHER) followed by a (TAB WASHER) then a (BEARING NUT) as shown in Fig: A. Note: the Tab washer
will have a tab protruding through the ID, this will need to align with the slot in the shaft.
3. Using the provided nut driver tool tighten the Bearing nut to the 7-9 Lbs-Ft torque. Check to make sure the bearings are
fully seated by wiggling the Lower Leverage arms and Upper Arm Assembly , if there is excessive play in the arm you
need to tighten the bearing nut more.
4. Once the nut is tight, use a small flat screwdriver to bend one of the tabs on the tab washer into one of the four notches
in the bearing nut as shown in Fig: B.
in the bearing nut as shown in Fig: B.
5. Repeat steps 1 thru 4 with the remaining Lower Leverage arms and Upper Arm Assembly as shown.
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STEP #3 Completed
Fig: A
Fig: B
ALIGN 1 OF THE
6 TABS WITH
SLOT IN NUT.
BEND TAB INTO
SLOT .

STEP #4: INSTALL LINKAGE BARS
1. Locate one of the Linkage Bars to install. On the end with the spherical rod, insert two misalignment bushings and two
O-rings, one bushing and one O-ring on each side of the rod end as shown below.
2. Slide the assembled rod end into the stainless steel strap bracket then install one (M10 X 40MM, SHOULDER BOLT),
two (M10 FLAT WASHERS), and a (M8, NYLOCK NUT). Tighten to specified torque using a 5MM hex key,13MM socket-
torque wrench.
3. Slide the lower end of the Linkage Bars onto the Leverage weight arm mount as shown below. Install one (M10 X
25MM, SOCKET HEAD BOLT) and one (M10 FLAT WASHER) and torque to the specified torque.
4. Repeat steps 1 thru 3 with the remaining Leverage Linkage Bars.
NOTE: When completed test the motion of the Leverage machine to ensure smooth quiet operation. Then
tighten all the screws at this time.
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STEP#4: Completed

STEP #5: INSTALL KNEE PAD ASSEMBLY, SUPPORT BEAMS
1. Install the SUPPORT BEAM using FOUR (M8 X 25MM, BUTTON HEAD SCREWS) four (M8,FLAT WASHERS).
Tighten all the screws at this time.
2. Repeat steps 1 to install the another SUPPORT BEAM as shown below.
3. Insert the CHEST PAD into PAD FRAME make sure the holes face the handle bar, align the pop pin of handle bar and
fixed the KNEE PAD as shown below. Note: Before you use the machine, you can adjust the position of the CHEST
PAD ASSEMBLY according to your need.
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STEP#5:Completed

STEP #6 – INSTALL WEIGHT STORAGE, BEARING END CAPS:
1.Install the WEIGHT HORN weldment and BACKING PLATE using two (M8 X 75MM, SOCKET HEAD BOLTS) four
(M8,FLAT WASHERS) and two (M8, NYLOCK NUTS). Tighten to specified torque using a 6MM hex key and 13MM
wrench.
2. Slide the COVER and PLASTIC SLEEVE onto WEIGHT HORN weldment. Install the rubber END CAP using
one ( M8x25MM, SOCKET HEAD BOLT), one (M8, FLAT WASHER) as shown.
3.Repeat steps 1 and 2 to install all four weight storage horns.
4.After you have ensured smooth quiet operation of the Leverage unit, locate the four black CAPS and push them into
the end of the Leverage arms as shown.
NOTE: Ensure that you press the caps in straight and evenly when installing. Once installed pull out on the
cap to ensure they are fully snapped into place.
cap to ensure they are fully snapped into place.
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STEP #6: Completed

HARDWARE
731-0390 - M8*25mm
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FINAL ASSEMBLE CHECK SHEET
1. Make sure ALL fasteners are tightened to specifications is this
manual.
2. See Maintenance and Service page.
1. Perform all steps
MACHINE CLEARANCE AND SPACING
For the safe operation of Leverage 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
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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 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!
(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.

Part No. 620-8083, Rev A.,MARCH 2011
STAR TRAC
14410 Myford Road
Irvine, California 92606
Telephone: [phone]
Fax: [phone]
www.startrac.com