11
SERVICING THE WEIGHT STACK
For required parts, see HOW TO CONTACT CUS-
TOMER CARE on the back cover of this manual.
1. Remove the wingnuts under the tower cap and
remove the tower cap from the tower.
2. Remove the screw from the top of each guide
rod.
3. Lift the coupler cover and drive the roll pin from
the top weight coupler with an 1/8” punch and a
hammer—this will release the cable.
4. Lift the guide rods out of the top of the tower.
5. Lift and rotate the top weight and weight pin, and
remove them through the front opening of the
tower.
6. Servicing the weight stack involves replacing the
two guide bushings and the weight insert in the
top weight. First, use a punch to drive the two
existing guide bushings and weight insert out of
the top weight.
7. To insert the new guide bushings and weight
insert, hold a bushing square to the face of one
of the holes in the top weight, place a protective
piece of wood on top of the bushing, and lightly
tap the bushing into place. The bushing should
be flush with the surface. Repeat with the other
guide bushing and weight insert.
8. Replace the top weight and weight pin on top of
the weight stack.
9. Reattach the cable to the top weight coupler.
10. Clean and lubricate the guide rods by wiping
them with a soft cloth containing a lightweight
motor oil, 10W-40 or 10W-30 weight. Apply only a
light coating over the entire length.
Note: Do not
use TEFLON
®
or silicone-based lubricants.
11. Reinsert the guide rods through the top of the
tower and into the weight stack.
Note: If the weight stack has shifted, use a
short bar to realign the holes in the weight
plates. Hold the weight plates while inserting
the guide rods.
12. Reattach the guide rods to the top of the frame
with the two screws.
13. Insert the weight pin in the top weight. Lift the
leg lever, raising the top weight all of the way to
the top of the guide rods. Slowly return the leg
lever to the resting position. If the top weight
sticks, loosen one of the guide rod screws.
Raise the top weight to the top again. Retighten
the guide rod screw. Check the full travel again
and readjust the guide rods as necessary.
14. While slowly lifting the leg lever, have someone
check the cable guard on the top weight to
ensure that it is not dragging or rubbing on the
cable.
15. Replace the tower cap and retighten the
wingnuts onto the bolts.
Weight
Insert
Guide
Bushings
Top Weight
Top Weight
Coupler
WARNING:
Do not force the
guide rods into the weights; doing so will
damage the guide bushings and weight
inserts.
