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3  

 

2

 

Check the ease of functioning of the pull-pin 

or other methods of adjusting  
 
PULL-PIN ADJUSTMENT: 

The spring loaded pin should click in any location 
hole without force. 
In failing to do so, unscrew the knurled cap, re-
place pin if bent. Replace spring if damaged then lightly grease the entire pin before 
returning into the housing. Should the up or down movement be difficult remove any 
burr which may have been formed around the location holes with 
a smooth file. 
 

PULL-TWIST ADJUSTMENT 

If force is required to twist and lock this adjustment in a differ-
ent position, a burr may have been formed on the slot groove. 
Remove the stud and lift the shaft out of its casing, the burr  
can now easily filed away with a smooth file. 

3

 

Check alignment of the weight plates by inserting 

the weight stack pin in random positions 

 
The alignment might be out if the unit has recently 
been moved and/or is not level. Check and level the 
weight-stack support by placing spacers under the 
legs. Once level, insert the selector pin in the lowest 
plate, lift the whole stack and drop +/- 100mm 

  

 

 

 

4

 

Check the operating smoothness of the weight-

stack by lifting the weight a few times to its highest 
position 

 

 
If any shuddering occurs wipe the guide rods clean over 
their entire length and then lubricate with a light coat of 
medium weight automotive engine oil 
 
It is also important to check  

that there is lateral move-

ment 

of the guide bars, if tight then  lower the two bushes 

slightly until  the grommets above the bush and the guide 
bars are able to move freely. 

Burr

1

 

Inspect for loose nuts and bolts - tighten as required

 

 
Bolts and nuts are secured with a spring washer, it is however essential (from a 
safety point of view) to ensure all bolts and nuts are tightened.  

Support 

Bush 

Guide

 

Summary of Contents for LUXLINE Z2205

Page 1: ...LUXLINE LUXLINE Strength equipment SERVICE AND MAINTAINENCE MANUAL MAY 2011 ...

Page 2: ...ting the stack a few times to its highest position 3 5 Check the free movement before the weight stack is lifted if more then 15mm cable tension should be adjusted 4 6 Inspect the cable for kinks damaged or worn outer sheath and ex posed cable wire including all connection points With any visual damage replace cable immediately 4 7 Check the upholstery for dirt rips and tears clean at least twice ...

Page 3: ...e weight stack pin in random positions The alignment might be out if the unit has recently been moved and or is not level Check and level the weight stack support by placing spacers under the legs Once level insert the selector pin in the lowest plate lift the whole stack and drop 100mm 4 Check the operating smoothness of the weight stack by lifting the weight a few times to its highest position I...

Page 4: ...ok the cable back in the eye bolt and check if the free movement is 15mm If correct tighten the locknut and turn the nylon cable lock back against the eye bolt Note Replace cable when the other end has a crimped on Thimble Bolt Locknut Locknut Nylon lock 6 Inspect the cable for kinks damaged or worn outer sheath and exposed ca ble wire With any visual damage replace cable immediately Each new LUXL...

Page 5: ...drop of light engine oil In a rare event a glass rein forced nylon bush can be replaced by removing the shaft and the brass lock pin from the bush housing before the bush is pulled out When the bush has been re placed re drill the pin hole 2 8mm and replace the brass pin Older models may not have a brass lock pin in this event we advice to knock in a brass lock pin by drilling a 2 8mm hole 10 mm f...

Page 6: ... devel oped ZEST surface cleaner on all painted surfaces right from the beginning and once cleaned a ZEST wax emulsion is applied this creates a thin layer of durable wax on the surface to protect it against perspiration salts and make the removal of skiff marks easier Cleaning warm water HEAVY duty dilute 1 10 MEDIUM duty 1 50 LIGHT duty 1 200 Wipe down the painted surface with a soft damp cloth ...

Page 7: ... 25 Allen cap screw 14 M10x10 Grub screw on cam 5 M8 Flat washer 15 Nylon bush 49 25 25 x 17 5 6 M10 Stud lift twist adjuster 16 Pulley assembly 7 Nylon bush 42 35 25 x 22 5 8 PVC handgrips 9 Roller pad 150 dia x 500 10 Pull pin replacement kit Note To replace the nylon bushes 15 firstly remove the tapered pin 13 by carefully tapping with a hammer the thin end to loosen it then remove the collar 1...

Page 8: ...ion Ref no 1 Pulley assembly 11 Feet covers 2 Grommet 18 I D 12 M10x100 Allen cap Dome nut 3 Collar S Steel 32 20 x 25 13 Swivel pulley bottom 4 M8 x 8 mm Grub screw 14 Handrail 5 M24 Lock nut 15 6 Nylon bush 42 35 25 x 22 5 7 Swivel pulley top 8 Cage panels set 9 M10 x 65 Allen cap Dome nut 10 Weight selector pin ...

Page 9: ...onsequential corrosion thereof caused by scraping chipping and abrasive cleaning is not covered by the warranty Our warranty shall be null and void if the equipment is not used for its intended purpose mishandled and or abused All warranty will be null and void in the event of a repair or a modification being executed by any technical service without the written prior authorisation of Zest Manufac...

Page 10: ...er placed by ______________________ Fax no _______________________ Tel no _______________________ Cable type A B C D Quantity Model No ZP Serial Asset No Weight stack kg Cable length mm A B C D Form completed by ____________________________ Date _______________________ Please note 1 The physical length of the existing cable should be accurately measured as illustrated below 2 There are 4 cable typ...

Page 11: ...rder placed by _______________________ Fax no _______________________ Tel no _______________________ Since we strife to improve our hand build units the position of the fixing holes may vary from unit to unit for this reason all upholstery parts will be supplied without nut inserts However the upholstered part will come with an easy to follow instruction special designed nut inserts M8 x 35 cap sc...

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