If you have any questions,
PLEASE contact the full-service dealer
where you purchased this machine.
Assembly Instructions
Tools Required:
Wrenches: One each (7/16”, 1/2”, 9/16”, 3/4”)
Hex Keys: Two 5mm (provided) and one 7/32” (provided)
Phillips screwdriver
1.
Select location for your machine. Set machine up in a well-lighted and well-ventilated area where
you will enjoy exercising. Use rubber floor matting or carpet remnants to protect your floor, if desired. It is
necessary to have access to all sides of the unit during assembly. Once the unit is assembled, it may be
moved against a wall or into a corner for use.
2.
Unbox entire unit.
NOTE: LEAVE ALL CABLE RETAINERS IN PLACE.
Leave any wrapping labeled “leave
in place during setup” on until instructions say to remove it. Some wrapping is intended to assist with the
assembly of the pulley arm by holding cables back and by helping protect the paint during assembly. Lay
large items, such as the main column down until needed to prevent them from accidentally falling over.
To make assembly as easy as possible, many cables are pre-routed at the factory. Route and attach cables
when instructions call for it. After routing any cable, resecure it to prevent it from coming unrouted before
going on. In general, tighten all bolts very tight at the completion of each step, unless the instructions say
otherwise.
3.
In preparation for assembly, remove the Footplate/Lat Hold Downs (L & M on
Fig. 7
) from the Base
Frame (D). They are shipped bolted to the frame differently than they are bolted on to the assembled unit.
See figure 1 for a view of how the Base Frame should look after these are removed. Also, if you are assembling
the unit under a ceiling that is 7’6” (229 cm) or less, it will be necessary to lower the High Pulley Member
(A) before proceeding. To lower this pulley member, locate two bolts, one in each side at the top of the Stack
Column (B). These bolt heads are just above the bolts that go into the guide rods. You’ll need a 9/16”
wrench. Loosen the bolts just one or two turns each. Once the bolts are loose, push the High Pulley Member
all the way down. Retighten the two bolts.
FIG. 1
4.
The Guide Rods (C) need to be in Stack Column (B) now because ceiling height might make later
insertion difficult or impossible. Install 4 rubber feet on the Base Frame (D). Now carefully assemble the
Stack Column (B) to Base Frame (D) (3/8-16 X 3/4 flat head bolts, Qty: 4, holes in front of stack column.
3/8-16 X 3/4 hex bolts, Qty: 4, holes further back).
IMPORTANT:
To prevent scratches to the parts during
this step, cover parts of the base frame with discarded wrapping material.
The stack column is heavy and
could scratch the base frame if slid into place.
So cover the base frame with wrapping material (foam,
cardboard, etc.), get the column into position, and then pull out the wrapping material. This step requires
a 7/32” hex key (the largest of those provided) and a 9/16” wrench. Before proceeding, ensure that these
bolts are very tight.
FIG. 1
5.
Now remove the Adjustment Rack Shroud (E) but not the wrapping material just under it. Also remove
the Bushing Retainers (F) from the back of the Stack Column (B) noting carefully how they fit (left vs. right)
and which screws come out of which holes.
FIG. 1
Locate the Black Bushings (G) on the pivot tube of
the Adjustable Pulley Arm (H) and make sure they are spread about as far apart as they will go. The Bushing
Retainers (F) removed above engage with the grooves in these bushings once the pulley arm is in place on
the Stack Column (B). These bushing grooves also engage the brackets on the back of the stack column that
the bushing retainers attach to. Familiarizing yourself with these parts is a good idea so that assembly will
go easier once you are supporting the weight of the Adjustable Pulley Arm (H) in the next step.
FIG. 2
6.
Now insert the Adjustable Pulley Arm (H) through the toothed adjustment rack of the stack column
(the near side of
Fig. 2
). Insert the end of the pulley arm that does NOT have the ”Release Lever” into the
side of the stack column that has the toothed rack on it. The Release Lever points down. The wrapping
material should be holding all cables back out of the way as they all belong rearward in the machine from
the arm. IMPORTANT: This step is best done with two people.
Go slow and use great care to prevent
scratches to the adjustable pulley arm and stack column.
Once the arm is centered relative to the stack
column, raise the ends to about six feet off the floor and place the “latch pin” into the lowest slot in the
“toothed rack”. Now line up the grooves in the Black Bushings (G) with the brackets on the back of the
Stack Column (B). Rock the arm (pivoting on the “latch pin”) such that the grooves in the two Black Bushings
(G) engage the two brackets on the back of the stack column. Now reinstall the two Bushing Retainers (F)
removed earlier. First put in the long screws that go in from the back, but don’t tighten them. Next remove
the wrapping material that passes through the rack and holds the cables back. Now put in the screws that
go in from the sides. Adjusting the pulley arm to various heights is required to get these screws in. Bolt
head access for each bolt is provided at a certain pulley arm position. Once the side screws are snug,
tighten the screws that go in from the back to remove any play in the pulley arm. Now tighten the screws
that go in from the sides.
FIG. 3
7.
Install the two Counter-Balance Springs on the back of the Adjustable Pulley Arm (H). In preparation
for this, adjust the pulley arm to its highest position. Doing so minimizes the amount that the springs must
be stretched. Now (using gloves and care to prevent injury) stretch each spring and hook the lower end into
a hole in a bracket on the Stack Column (B).
FIG. 4
8.
Remove the pulley bracket (J) from the stack column (B) to make more room for loading the weight
stack. Note how it fits for reassembly later. Don’t take out the pulley itself, just remove the two bolts that
go up into the frame and remove the entire bracket leaving it threaded on the cable. Carefully place it on
the floor out of the way.
FIG. 1
9.
Now install the weight stack inside the Stack Column (B) from the top. Ensure that the guide rods
are in place as mentioned in step 4 above. Unbolt the top of the guide rods and lift them up a few inches
one at a time and position the rubber stack bumper on the bottom of each guide rod. Do this by reaching
in the weight pin slot on the
front of the column. Replace
lower end of the guide rods
through holes in the base of
the stack column and push
them down as far as they
will go to make room at the
top for loading the weight
stack. Load the 15 weight
plates for a 160 lb. stack
(20 for the optional 210 lb.
stack) one at a time by
placing them on the guide
rods at the top of the column
with selector groove on the
bottom facing out.
IMPORTANT:
To safely keep
plates from banging
together the following
procedure is suggested:
after releasing each plate,
pull the guide rods apart to
slow the fall of the plate. DO
NOT try to catch plates with
hands or feet.
USE EXTREME
CAUTION.
FIG. 5
10.
After all plates are
in the column, assemble the
top plate, selector shaft,
rubber finish washer and U-
clip to the end of the “stack
cable”, securing with 3/8-
16 X 3 hex bolt. To do this
first slide the rubber finish
washer onto the cable. Next,
insert the cable end into the
keyhole in the U-clip. Insert
the blunt end of the selector
shaft from below into the
center hole of the top plate
until it is approximately flush
on top. Now insert the U-clip
ends down into the top plate
around the selector shaft
end. Secure with the cross
bolt, and make sure it is very
tight. Now slide the rubber
finish washer down onto the
top of the U-clip.
FIG. 5
11.
Now lower the top plate assembly down the guide rods making sure the cable is not tangled around
anything. Replace and tighten the guide rod bolts making sure that there is a nylon spacer in the top of each
guide rod. Using the cable, lift the top plate to the top and make sure the guide rod spacing is such that the top
plate does not bind. If it does, loosen a guide rod bolt and adjust the guide rod spacing, then retighten the bolt.
Make sure that the cable feeds straight down to the stack and doesn’t go around a guide rod.
FIG. 5
12.
Install weight plate number labels per instructions with labels. Attach the weight pin lanyard ring
around the stack cable just above the rubber finish washer. This is most easily done through the access
slot in the front of the Stack Column (B).
13.
Reattach the pulley bracket (J) to the stack column (B) and tighten these bolts very tight. This
pulley bracket goes on such that it protrudes as far as possible. Compare to welded on bracket on other
side to make sure it is positioned correctly.
FIG. 1
14.
In preparation for cabling the Adjustable Pulley Arm (H), remove the 4 pulleys (R10, R11, L10, &
L11) from the arm. Use 5mm hex keys (provided). Refer to the cable diagram on the other side of this
manual as needed. Now, on the left side of the column (near side of
Fig. 6
), take the cable that comes down
from pulley (L9) pulley bracket (J), and feed it into the pulley bracket on the arm straight below it. From
here it enters a steel tube. Push it through the steel tube until it exits through a pulley bracket at the front
end of the arm. Reinstall the 2 pulleys (L10 & L11) in this side of the arm to secure the cable using the
screws and tube nuts removed earlier. Repeat this process with the cable coming down from R9 for the
other side of the adjustable pulley arm. Tighten these screws very tight.
FIG. 6
15.
Test the adjustable pulley arm to verify that it adjusts to all positions and latches fully (latch pin
hitting the back of each slot in the rack). Adjust screw near latch pin if necessary. This is adjusted at the
factory and is unlikely to require adjustment. After any adjustment, retighten jam nut against brass cable end
to keep adjustment from changing over time.
FIG. 3
Cover this area with Adjustment rack shroud (E)
(1/4-20 X 1/2” phillips head screws, Qty: 4)
FIG. 1
16.
Next adjust the height of the two high pulleys (L6 & R6 on cable diagram) in the High Pulley
Member (A) to the desired height. If ceiling height does not allow or if you don’t wish to raise the height
of these pulleys, skip this step. To raise these pulleys, loosen the two bolts, one in each side. These bolt
heads are just above the bolts that go into the
guide rods. You’ll need a 9/16” wrench and you
can reach them from above or below. Loosen the
bolts just one or two turns each. Push the pulleys
up to the desired height, taking into account user
heights and ceiling height. Once the desired
position has been reached, retighten the two bolts.
Important:
to prevent the high pulleys from moving
in use these bolts must be tightened
very tight
.
Now remove any wrapping from the plastic cover
just below the High Pulley Member (A). It is held
in place by a spring. Make sure that it is seated
against the column up against the high pulley
member. There should be no reason to remove this
part, but to do it without ruining the spring, you
must reach up inside the column and unhook the
back end of the spring. This will require pliers or
a hook.
FIG. 1
17.
Raise the pulley arm to its highest position for
this step. Next tension the cable system by locating the
adjustment bolt between the two pulleys (#13 and #14 on
cable diagram) of the adjustable pulleys bracket (K). A
3/4" wrench is required. Tighten this bolt until the top plate
lifts slightly. Depending upon which
stack was installed, a lot of turns
might be required. Loosen the bolt
until the top plate just touches the
weight plates. Check that the weight
selector pin engages at each weight
plate completely.
FIG. 7
18.
Make sure that all cables move freely when all cable ends are pulled. Immediately fix any cable
rubbing problems. If a pulley is rubbing or otherwise making a noise while turning, the problem can usually
be cured by tightening its bolt.
19.
Attach left Footplate/Lat Hold Down (L) and right Footplate/Lat Hold Down (M) to Base Frame (D)
(3/8-16 X 3/4 flat head bolts, Qty: 2 per side). This step requires a 7/32” hex key
(the largest of those provided).
FIG. 7
20.
Install 2 rubber feet onto bench frame
(N). Install Leg Developer Mount Assembly (P) to
Bench Frame (N), (3/8-16 X 3/4" Hex Head Bolts,
Qty: 3). Connect leg developer cable to cam by
inserting small end into keyhole on cam. Use plastic
hole plug in keyhole to prevent disconnection. Attach
the other end of this cable to the storage location at the other end of the bench frame.
FIG. 8
21.
Attach the cushions to the bench (1/4-20 X 3/4 hex screws, Qty: 10). Tighten mounting screws
firmly.
FIG. 8
22.
Hang the exercise charts on the wall where they can be referred to easily. Read the exercise charts,
all product labels, and this manual before beginning an exercise program.
FIG. 3
FIG. 4
FIG. 5
FIG. 6
FIG. 7
FIG. 8
FIG. 1
FIG. 2
