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 four 5/8" jamnuts and 5/8" lock
washers from the top of each guide rod.
3. Lift the coupler cover off the top weight coupler.
Remove the two set screws from each side of
the weight coupler.
4. Lift the guide rods out of the top of the tower.
5. Lift and rotate the top weight and the weight pin,
and remove them through the front opening of
the tower.
6. Use a punch to drive the two existing guide
bushings and the weight insert out of the top
weight.
7. To insert the new guide bushings and weight
insert, hold a guide bushing square to the face of
one of the holes in the top weight, place a pro-
tective piece of wood on the guide bushing, and
lightly tap the guide bushing into place. The
guide bushing should be flush with the surface.
Repeat with the other guide bushing and the
weight insert.
8. Replace the top weight and the 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 silicon-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 four 5/8" jamnuts and 5/8" lock washers.
13. Insert the weight pin into the top weight. Pull the
handle, lifting the top weight all of the way to the
top. Slowly return the handle to the resting posi-
tion. If the top weight sticks, loosen one of the
guide rod screws. Lift 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 pulling the handle, 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 button bolts.
Weight
Insert
Guide
Bushings
Guide
Bushings
Top
Weight
Top Weight
Coupler
WARNING:
Do not force the
guide rods into the weights; doing so will
damage the bushings and weight inserts.