11
WEIGHT STACK SERVICING
Servicing the weight stack involves replacing the two
guide bushings and the weight insert in the top weight.
To order these 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 nuts and washers from the top of each
weight guide.
3. Lift the coupler cover and loosen the four set
screws—this will release the cable (see the drawing
on page 10).
4. Lift the weight guides out of the top of the tower.
5. Remove the nut, star washer, and washer from the
top of the weight selector. Lift and rotate the top
weight, and remove it through the front opening of
the tower.
6. Use a punch to drive the two existing guide bush-
ings and the weight insert out of the top weight.
7. Hold one of the new guide bushings square to the
face of one of the holes in the top weight, place a
protective piece of wood on top of the guide bush-
ing, and lightly tap the guide bushing until it is flush
with the surface.
Insert the other guide bushing
and the weight insert in the same way.
8. Replace the top weight. Next, tighten the nut, star
washer, and washer onto the weight selector.
9. Reattach the cable to the top weight coupler.
Retighten the four set screws into the threaded
holes. Tighten the set screws equally until they
contact the cable. Then, tighten each screw alter-
nately 1/4 turn, until all are set to 85 inch/pounds
(9.6 Newton-meters).
10. Clean and lubricate the weight guides 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.
Do not use
TEFLON
®
-based lubricants.
11. Reinsert the weight guides 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 weights. Hold the weights while insert-
ing the weight guides.
12. Reattach the weight guides to the top of the frame
with the two nuts and washers.
13. Insert the weight pin into the top weight. Slowly per-
form a repetition, lifting the top weight as far as
possible. Then, slowly lower the top weight. If the
top weight sticks, loosen the nut at the top of one of
the weight guides. Slowly perform another repeti-
tion. Then, retighten the nut. Check the full travel
again and readjust as necessary.
14. Slowly perform a repetition using a light load and
have someone make sure that the cable is not
derailed from a pulley or rubbing on a cable trap.
15. Replace the tower cap and retighten the wingnuts
onto the bolts.
Weight
Insert
Guide
Bushing
Guide
Bushing
Top Weight
Top Weight
Coupler
WARNING:
Do not force the
Weight Guides into the weights; doing so
will damage the bushings and the weight
inserts.
