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General Safety and Maintenance Manual: Annual Maintenance

26

Inspect and Lubricate Pop Pins

Remove the pop pin assembly by loosening the hex head cap.

CAUTION: Pulling out the pop pin may cause the unit to adjust
position suddenly. To avoid injury, keep your hands and head
away from moving parts.

Inspect the plunger and spring for excessive wear and damage, and
replace as required.

Apply a small amount of silicone spray lubricant to the spring and
plunger, and then reinstall the entire assembly. Tighten hex head cap.
Wipe off any excess lubricant with a cloth.

Figure 13: Inspect pop pins (pop pin shown in exploded view for clarity)

Pop pin plunger
assembly shown with
telescoping sleeve type
adjustment

Hex head cap

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Summary of Contents for CW-411

Page 1: ...CW 411 ...

Page 2: ......

Page 3: ... The equipment is designed to be freestanding however equipment can be bolted to the floor for extra stability Consult a qualified general contractor for proper fastening methods Make sure that the equipment is installed with enough free space for safe operation With most equipment the general rule is to allow about a 4 foot 1 2 meter circle of space from the user s center For Functional Training ...

Page 4: ...cessory attachments that are not recommended by the manufacturer as such attachments may cause injuries Wear proper exercise clothing and shoes for your workout no loose clothing Do not overexert yourself or work to exhaustion Use reasonable judgment when working with weights Avoid using excessive weight which may cause injury If you feel pain or abnormal symptoms stop exercising immediately and c...

Page 5: ...rvice 3 Important Safety Information for Users 4 Preparations 6 Unpacking the Equipment 6 Required Tools 6 Installation Requirements 6 Hardware Kit 7 Assembly Instructions 9 Open the Box 9 Assemble the Unit 10 Assemble the Pads 13 Clean the Pads and Assembly 13 Product Specifications 16 Table of Contents ...

Page 6: ...re information refer to Obtaining Service Required Tools Tools that you need to obtain before assembling the unit include Wire cutter or utility knife inch open end wrench 3 32 inch Allen wrench Installation Requirements Follow these installation requirements when assembling the unit Review the Important Safety Guidelines for Owners Assemble the unit where it will be used Provide ample space aroun...

Page 7: ...rew A 4 Fastener Qty Hardware Kit Preparations continued 3 8 x inch Buttonhead screw D 8 Fastener Qty x1 inch Buttonhead screw H 2 x inch Buttonhead screw F 4 inch Locknut C 10 inch Washer B 20 3 8 inch Split washer E 8 Spacer J 2 inch Split washer G 6 ...

Page 8: ...dware Kit continued Fastener Qty Preparations continued Bumper K 4 x 5 inch Carriage bolt L 6 Hat washer M 10 inch Washer Q 10 x 3 inch Buttonhead screw N 4 x 1 inch Buttonhead screw R 6 inch Split washer P 10 Plastic cap N 10 x inch Set screw S 4 ...

Page 9: ...te With so many assembled parts proper alignment and adjustment is critical While tightening the fasteners be sure to leave room for adjustments Do not fully tighten fasteners until instructed to do so Open the Box Use wire cutters to open the box and remove the packing materials The illustration shows how the CW 411 will look when you have completed its assembly The callouts identify specific pie...

Page 10: ...hten the fasteners so the Upright Frame is stable but adjustments can be made when installing the Back Support 2 Turn the Back Support over and attach the Back Support Stabilizer to the Back Support using four inch buttonhead screws D four 3 8 inch split washers E Wrench tighten Assemble the Unit 4 5 buttonhead screws 8 washers 4 hat washers 4 locknuts 4 buttonhead screws 4 split washers Cross Bra...

Page 11: ...the mounting holes align with the holes in the Upright Frame 6 Secure the Weight Plate Holders using two 1 inch buttonhead screws H two inch split washers G two inch washers B two spacers J Wrench tighten Note For ease of assembly place a split washer a flat washer and a spacer onto each screw before inserting the screw 7 Slide a Bumper K onto each end of the Weight Plate Holders and press firmly ...

Page 12: ...the Holder Assembly and then place a Round Cap onto each end of the Roller Bar Slide the Round Caps against the Holder Assembly 12 Slide a Roller Pad onto each end of the Roller Bar followed by a Roller Cap Place an Aluminum Cap M on each end of the Roller Bar Insert and tighten two set screws S in each Aluminum Cap 13 Tighten the set screws at the end of the Holder Assembly to secure the Roller B...

Page 13: ... Attach the Thigh Pad to the Back Support using six 1 inch buttonhead screws S six 5 16 inch split washers Q six 5 16 inch washers R Wrench tighten This completes the assembly of the CW 411 Clean the Pads and Assembly To clean the pads moisten a clean soft cloth in a mild solution of soap and water and wipe all the parts thoroughly Dry the pads with a clean dry cloth Use the same procedure to clea...

Page 14: ...CW 411 Assembly Guide page 14 Notes ...

Page 15: ...CW 411 Assembly Guide page 15 Notes ...

Page 16: ...ects of its product design Any party contemplating the use of Precor s product designs is hereby forewarned that Precor considers the unauthorized appropriation of its proprietary rights to be a very serious matter Precor will vigorously pursue all unauthorized appropriation of its proprietary rights Precor Incorporated 20031 142nd Avenue NE P O Box 7202 Woodinville WA USA 98072 4002 1 800 347 440...

Page 17: ...General Safety Maintenance Manual Precor Icarian Line Commercial Strength Equipment ...

Page 18: ......

Page 19: ...htened Cables should be secured at both end connections and properly threaded Weight stacks should be secure and functioning properly Handle attachments should be properly connected Make sure that trainers facility personnel and maintenance technicians understand how to use the equipment know important safety guidelines and can recognize potential problems such as a worn cable loose hardware or cr...

Page 20: ...on varies please consult a professional building engineer for proper fastening Locate the equipment at least 40 inches 1 meter away from walls or furniture on either side of the equipment and 40 inches 1 meter away from objects behind the equipment For Functional Training equipment make sure that the operating space is large enough to allow the cables to be fully extended in all possible direction...

Page 21: ...in a raised position With the help of another person carefully return the machine to the proper position with the top plate resting on the first weight Inspect the cable to ensure that it is seated in all of the pulleys Whenever a weight can drop and hit a user such as with an Olympic bench Precor highly recommends that a helper or spotter be used to ensure a safe workout with the equipment Do not...

Page 22: ...mediately and consult your physician Keep head limbs fingers and hair clear of all moving parts while the equipment is in use Keep hands clear of racking pegs Never drop or insert objects into any opening in the equipment Check that all fasteners are securely tightened Cables should be secured at both end connections and properly threaded Weight stacks should be secure and functioning properly Han...

Page 23: ...Clean and Inspect Frames 10 Inspect All Fasteners 11 Inspect Cables and End Connections 11 Check Warning Labels and Instruction Placards 13 Weekly Inspection 15 Condition and Deep Clean Upholstery 15 Clean and Lubricate Cable Rod Ends 16 Clean and Lubricate Guide Rods 16 Inspect Cables Connections and Tension 17 Inspect Cable Handle Attachments 18 Inspect Pulleys 18 Inspect Weight Stack and Select...

Page 24: ...nspection 21 Inspect Frames and Movement Arms 21 Lubricate Pop Pins 22 Check and Lubricate Ratcheting Seat Lever 23 Inspect All Fasteners 24 Annual Maintenance 25 Weight Stack Annual Maintenance 25 Inspect and Lubricate Pop Pins 26 Recommended Maintenance Checklist 27 ...

Page 25: ...ervice beyond the maintenance procedures covered in this manual refer to Obtaining Service Important Always purchase replacement parts and hardware from Precor These parts are tested and manufactured specifically for the Precor Icarian line of commercial strength equipment If you use parts not approved by the manufacturer you could void the Precor Limited Warranty Use of parts not approved by Prec...

Page 26: ... of purchase for your Precor strength training equipment in the space provided You may want to list all equipment information below for easy reference Model _______ Serial _______________________ Date purchased _________________________ Model _______ Serial _______________________ Date purchased _________________________ Model _______ Serial _______________________ Date purchased _________________...

Page 27: ...d connections for wear Check warning and instructional labels for readability Check that all fasteners are properly secured Clean Upholstery To remove surface dirt and perspiration clean upholstery daily with a mild soap and water solution in a spray bottle Spray upholstered surfaces lightly and wipe dry with a clean cloth Important To clean the upholstery do not use cleaning products that have an...

Page 28: ...s or use pads not approved by Precor Clean and Inspect Frames To remove grease and dirt clean frames daily with a mild soap and water solution in a spray bottle Wipe the equipment down with a damp cloth and dry completely Be sure to wipe down both painted parts and chrome or plated parts To restore and maintain luster of chrome parts use a commercial chrome cleaner As you clean inspect the frames ...

Page 29: ...Obtaining Service Important Fastener quality and specifications vary considerably Replace only with the Precor approved fastener specifically engineered for the precise application Failure to do so will void the Precor Limited Warranty Inspect Cables and End Connections CAUTION Carefully inspect the cables pulleys fasteners and related hardware regularly Replace any cable at the first sign of wear...

Page 30: ... following Ensure that each cable is properly adjusted and tightened at the top of the weight stack Check cable pulleys end connections and end fittings Make sure all connections are tight adjusting cable tension as necessary Make sure that the cable bolt is threaded at lease seven turns into the selector stem or a minimum of inch 13 mm The distance shown should be inch 19 mm or less Tighten the l...

Page 31: ...oroughly with a soft cloth The following figure shows an example of a user instructional label Figure 3 shows a typical user instruction placard Figure 3 Sample user instruction placard Improper use of this machine will result in injury Before using consult a qualified instructor Inspect cables and connections and do not use if any component is worn or damaged CAUTION PULLDOWN 304 Select appropria...

Page 32: ...abel may appear on weight stacks with a pulley mounted at the top Figure 5 This warning label may appear on or near weight stacks where a cable bolt is threaded into the selector stem Figure 6 A version of this warning label appears on the equipment frame KEEP HANDS AND FEET CLEAR WHILE MACHINE IS IN USE The weight stack cable bolt must be inserted a minimum of seven full turns into the selector s...

Page 33: ...s Inspect cables connections and tension Inspect cable handle attachments Inspect pulleys Inspect each weight stack and selector pin Inspect and lubricate bearings and bushings Check seat adjustment and test pop pins Condition and Deep Clean Upholstery Condition and deep clean the upholstery weekly with a lanolin based hand cleaner or upholstery cleaner Important To clean the upholstery do not use...

Page 34: ...pect the exposed areas of the guide rods for cleanliness Using a dry cloth wipe any buildup of dirt or grease from the rods Lubricate the exposed areas of the guide rods by applying a light coat of a silicone spray lubricant Spray the silicone lubricant on a cloth and then wipe the guide rods with the cloth Be careful with any lubricant spray it can stain carpet and clothing CAUTION Do not attempt...

Page 35: ...ccordingly Also make sure that the locking jam nut is tight against the selector stem Check the cable especially near all pulleys wheels and cams Check the cable as it terminates at the cam which is stationary on most equipment Inspect the bolt passing through the cam end fitting to be sure the two jam nuts are tightened against each other Also check the entire cable routing to verify that there i...

Page 36: ...ause severe damage to the cables and must be replaced at the first sign of wear or damage Be certain that the wheels turn freely as the equipment is used Inspect each pulley for excessive side to side play which indicates worn bearings or loose mounting bolts If excessive play is discovered remove the pulley to inspect the bearings and replace the entire pulley if necessary Inspect Weight Stack an...

Page 37: ...rom the outside environment and require no lubrication While cleaning the equipment wipe down the guide rods and external bearing surfaces with a cloth to prevent the build up of dust and perspiration Linear Bearings Case hardened guide rods are used in areas that use linear bearings refer to Figure 10 Inspect each end of the rod to ensure they are fastened correctly and all bolts are tight Wipe d...

Page 38: ... inch telescoping sleeve adjustment for most seat assemblies inch slotted plate adjustments used on most free weight bench adjustments Inspect all adjustments for proper fit and function Inspect plastic sliders for excessive wear or damage Adjustments use either a high tensile pop pin plunger assembly or a ratcheting lever assembly Inspect and tighten all pop pin caps ...

Page 39: ...and Movement Arms Inspect frames and movement arms monthly for proper function and integrity Check for cracks chipped paint or rust Touch up dings and chips in the paint as needed Replace any component at first signs of wear Note You can order touch up paint from Precor by calling Customer Support Refer to Obtaining Service Inspect frames for cracks particularly at the joints If any cracks are fou...

Page 40: ...the above methods use a fine grit cleanser Do not use solvents lacquer thinner acetone or finger nail polish remover For high wear areas ABS shields have been provided Replacement shields are available from Precor Customer Support For additional information refer to Obtaining Service Lubricate Pop Pins Pull out the pop pin as far as it goes and apply a small amount of silicone spray lubricant Wipe...

Page 41: ...eting seat lever each month to see if it sticks when used You also want to ensure that the pin fully engages in each adjustment hole To test if the seat lever needs lubrication slightly elevate the seat while pressing and releasing the lever The lever should snap back out easily If the lever sticks lubricate the pivot pin in the lever with silicone spray lubricant Wipe off any excess lubricant wit...

Page 42: ... check fasteners at bolted joints to ensure connection is secure If the fastener is loose but in good condition retighten it If you are concerned about the integrity of the fastener remove it clean the threads and inspect it for any damage such as cracks bad threads corrosion or rust Reinstall the fastener if it appears to be in good condition Otherwise remove the equipment from service until a ne...

Page 43: ...roughly Cracked or broken plates should be replaced immediately refer to Obtaining Service to purchase replacements Clean each plate individually and inspect guide bushings Inspect the bushings of the top weight plate and each individual weight plate and replace a plate if it is excessively worn or broken Clean the selector stem and inspect it for wear and damage Reassemble the weight stack Wipe d...

Page 44: ... hands and head away from moving parts Inspect the plunger and spring for excessive wear and damage and replace as required Apply a small amount of silicone spray lubricant to the spring and plunger and then reinstall the entire assembly Tighten hex head cap Wipe off any excess lubricant with a cloth Figure 13 Inspect pop pins pop pin shown in exploded view for clarity Pop pin plunger assembly sho...

Page 45: ...k lubricate ratcheting seat Inspect all fasteners Annual Check Weight stack maintenance Date Initials Inspect lubricate pop pins or ratcheting lever Date Initials Maintenance Tips Upholstery Wipe clean using a mild soap and water solution or other appropriate cleaner for vinyl Cable Replace any cable that shows signs of wear or damage Frames Wipe clean using a mild soap and water solution Guide ro...

Page 46: ...General Safety and Maintenance Manual Recommended Maintenance Checklist 28 Notes ...

Page 47: ......

Page 48: ...e www precor com NOTICE Precor is widely recognized for its innovative award winning designs of exercise equipment Precor aggressively seeks U S and foreign patents for both the mechanical construction and the visual aspects of its product design Any party contemplating the use of Precor product designs is hereby forewarned that Precor considers the unauthorized appropriation of its proprietary ri...

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