8
WEEKLY
1. Hardware:
• Check all nuts and bolts. Tighten them as
required.
2. Cables:
• Check all cables for proper tension.
• Check the entire length of each cable by pulling
each handle individually to its fully extended
position and inspecting the cable that is
exposed on the exterior of the machine, as well
as the cable inside of the tower.
• Run your fingers along each cable, paying close
attention to the bends and attachment points.
• Watch for the following conditions that may indi-
cate a worn cable in need of replacement (see
the drawings below):
A. Torn or split cable sheath that exposes the
cable
B. Kinked or severely bent cable
C.Curled or twisted sheath
D.Stretched cable sheath, showing a thinning
cross-section
MONTHLY OR AS REQUIRED
1. Grips:
• Check all grips and replace them as needed.
2. Weight stack guide rods:
• Clean and lubricate the full length by wiping
using a soft cloth containing automotive engine
oil. Only a light coating over the entire length is
needed.
CUSHION ATTACHMENT
Important:
All FreeMotion Fitness
®
cushions are fabri-
cated using dense plywood with tee-nuts installed for
bolting to the machine framework. Because these tee-
nuts are held by the plywood, they will not withstand
the torque that standard nuts and bolts will. Therefore,
when tightening the cushion bolts, turn them only until
they are snug and the cushion does not move or feel
loose. Overtightening may strip the tee-nuts from the
plywood and make it impossible to remove the cushion
in the future.
CABLE TENSION CHECK
1. Insert the weight pin into the top weight plate.
2. Slowly raise and lower the top weight by normal
machine use. The top weight should come to rest
just on top of the second weight when the handle
is returned to the resting position.
• If there is too much tension on the cable, the top
weight will not rest on the second weight, and it
may be difficult to insert the weight pin into the
weight plates.
• If there is not enough tension on the cable, the
top weight will not be lifted immediately when
one of the handles is pulled. Ideally, the han-
dle/cable should not move more than 1.3 cm
(1/2 in.) from the resting position before the top
weight begins to be lifted.
3. If there is too much or not enough tension on the
cable, adjust the cable as described in CABLE
ADJUSTMENTS, on page 9.
A
B
D
C
9
CAUTION:
After making any cable adjustment, pull the
handle using a light load and have someone make
sure that the cable is not derailed from a pulley or rub-
bing on a guard (see CABLE GUARDS on page 10).
INITIAL ADJUSTMENT
Top Weight Pulley Adjustment
—All machines.
Tools required: 9/16" open or box-end wrench, 5/16"
Allen wrench
Note:
This is the primary adjustment for all
machines. If this adjustment does not remove the
excess slack, refer to ADDITIONAL ADJUST-
MENTS, at the right.
1. Remove the access cover by pulling it free at the
bottom and then sliding it up until the two sets of
tabs release.
2. Using a 5/16" Allen wrench and a 9/16" open or
box-end wrench, loosen the nut holding the pulley
in the bracket on the top weight.
3. To increase the tension, slide the pulley down in
the slot. To decrease the tension, slide the pulley
up.
4. Tighten the nut and check the tension as
described in CABLE TENSION CHECK, on page
8. If necessary, readjust the pulley.
5. Replace the access cover.
ADDITIONAL ADJUSTMENTS
Handle End Adjustment
—All machines with a
strap and handle
Tools required: 1/8" Allen wrench, cable cutters, utili-
ty knife, torque wrench
Note:
Make this adjustment only if the pulley in the
top weight has been fully adjusted to the bottom of
the slot and the cable requires more tension.
Note:
This adjustment is only for increasing the
cable tension because it requires shortening the
cable. Only one end of the cable should be short-
ened.
1. Create slack in the cable by removing the weight
pin and pulling the handle out 15–20 cm (6–8 in.).
Insert the weight pin into the third weight plate
and the tube on the bottom of the top weight.
2. Push the black rubber cover off the aluminum
coupler and slide the cover up the cable to con-
tact the pulley in the swivel arm.
3. Loosen the four oval-point, 1/4-20-unc set screws
in the coupler and pull the cable free.
4. Cut off 2.5 cm (1 in.) of the cable end using cable
cutters.
Note: Using any other tool may flatten
or disrupt the end strands so that it may be
difficult to reinsert the cable into the hole of
the coupler.
5. Cut off 2.5 cm (1 in.) of the black cable sheath
from the end of the cable.
6. Reinsert the cable and the sheath into the coupler
so that all of the bare cable is in the hole.
7. 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).
8. Slide the rubber cover over the coupler, remove
the weight pin, and lower the handle.
9. Check for proper tension on the cable as described
in CABLE TENSION CHECK, on page 8.
Pulley
Slot
Top Weight
CABLE ADJUSTMENTS
