15.
Now install the weight stack inside
the stack column (I). Ensure that the guide
rods are in place as mentioned in step 11
above: the bottom end of each one holding
a rubber bumper and positioned over a
locator tube. Load the weight plates (15
for a 160 lbs. stack or 20 for a 210 lbs.
stack) one at a time by placing them on
the guide rods at the top of the column
with selector pin groove on the bottom
facing away from the back of the machine.
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. 12
16.
After all weight plates are in place,
assemble the top plate, selector shaft,
rubber finish washer, U-clip, and weight
pin lanyard ring to the end of the loose
cable (PN 67120), securing with 3/8-16 x
3 hex bolt. To do this, first slide the pin
lanyard ring, then 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. Once the bolt is very
tight, slide the rubber finish washer onto
the cable and down onto the top of the
U-clip.
FIG. 12
6.
In this step, you
will install the press arm
(E), along with the press
adjustment plate (F) to the machine.
(large 1/2” i.d. washer, Qty: 1, and 1/2-13 x 1 button head bolts, Qty: 2).
Begin by placing the press adjustment plate onto the press arm such that
the latch pin is in one of the notches and the large hole is over the post on
the end of the press arm. Next place one of the bolts through the ball bearing
installed in the main column frame member (D). Thread the washer onto this
bolt. Now position the press arm assembly according to the diagram and
thread this bolt into the internally thread post mentioned above. Insert the
second bolt through the bearing at the top of the press post (B) and into the
press arm assembly. The press adjustment
plate should be supported in a “V” shaped
notch in the main column frame member.
Tighten the two bolts installed in this step
very tight with a 5/16” hex key.
FIG. 3
4.
Now assemble press station frame
member (C) to press post (B) (3/8-16
x 1/2 hex bolts, Qty: 4). To do this, first
route the cable exiting the side of the
press post (B) into the frame member,
down its length, around the pulley (#11)
and out. To do this it will be necessary
to temporarily remove the pulley.
Ensure that the pulley bolt is very tight
after reinstalling it. Leave the four bolts connecting the frame member to
the press post a little loose, until told to tighten them later in these instructions.
(Note: any pulley numbers mentioned in the text or shown on these drawings
correspond with the cable diagram on the other side of this manual. Refer
to that diagram as necessary during the assembly process if you’d like another
perspective.)
FIG. 2
5.
Now attach main column frame member (D) to press station frame
member (C) (3/8-16 x 3/4 hex bolts and nuts, Qty: 3 ea).
FIG. 2
If you have any questions, PLEASE
contact the full-service dealer where
you purchased this machine.
Tools Required:
Wrenches: one each 7/16”, 1/2”, and two each
9/16” end wrenches
Hex key: 5/16”
Phillips screwdriver, hammer, pliers
FIG. 1
FIG. 2
Assembly Instructions
3.
Assemble squat platform (A) to press
post (B) (3/8-16 X 1/2 hex bolts, Qty: 2).
Make sure the rubber tread on the squat
platform (A) is on the opposite side of that
shown in Fig. 1. Before proceeding, ensure
that these bolts are very tight, as tightening
them later would be difficult.
FIG. 1
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 slid into a corner for use.
2.
Unbox entire unit, taking care to not bang parts together lifting them
from their foam supports.
(NOTE: LEAVE ALL CABLE RETAINERS IN
PLACE.)
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 the instructions call for it. After routing any cable, resecure it to prevent
it from coming unrouted before going on. Some bolts should be tightened
very tight only after the instructions say to do so. All bolts should be tight
at the end of assembly.
FIG. 3
9.
Now assemble the main
column (H) to the main column frame
member (D) (3/8-16 x 1/2 hex bolts, Qty: 2).
Before standing the main column up, route the cable
into the hole in its bracket, and around the pulley (#16) located there such
that it heads up inside the column.
IMPORTANT:
There is a small diameter
pin near this pulley. Make sure the cable
passes between the pin and the pulley. To
do this remove the lower plastic access panel
and feel under the pulley. Next stand the
main column up and bolt it to the frame
member pulling any spare cable into the
main column.
FIG. 6
10.
With both plastic access panels
removed, continue routing the cable inside
the main column (H). From pulley #16 it goes
straight up inside the main column to the
lower pulley (#17) of a double moving pulley
assembly located there. It is important that
the cable go around the lower pulley in the
correct direction to prevent twisting. First
make sure that the double moving pulley
is hanging straight down with the cables
which support it hanging straight. Route
the cable such that it goes up the rear of
the column (the side near you when looking
into the access cutouts), over pulley #17,
and then down near the front of the main
column. Terminate this cable at a single
moving pulley bracket #19 that you will
find loose inside the column. To attach it,
insert the ball end into the keyhole shaped
hole in the pulley bracket. Secure it by
inserting a plastic hole plug into the large
end of the keyhole.
Ensure that the
cables below this
pulley bracket do
not loop around the
cable going up from
pulley #16.
FIG.7
7.
Now route the cable emerging from
the press station frame member (C) as
follows: first route it around one pulley
(#12) of the double moving pulley unit (G),
next it goes under pulley #13, over pulley
#14, and then down into the main column
frame member (D) and around pulley #15.
It needs to continue along the length of
this frame member and exit through the
large round hole in the bracket welded on
its end. Place the double moving pulley
unit (G) on the floor for now.
FIG. 4
NOTE: Cable goes
between pulley #16
and this pin
H
D
16
FIG. 5
19.
Install 2 rubber feet onto bench frame (N).
Install Leg Developer Mount Assembly to Bench
Frame (3/8-16 x 3/4” hex bolts, Qty: 3). Attach the two cushions to the bench
(1/4-20 x 3/4 hex bolts, Qty: 10). Tighten pad mounting bolts firmly.
FIG. 14
11.
In preparation for attaching
the stack column (I) to the two
frame members, place the guide
rods inside. First, place a rubber
bumper (located inside of the top
plate hardware box) around the
end of each guide rod at the end
that does not have the bolt. The
two guide rods now go into the
open back of the stack column
such that the end with the rubber
bumper ends up on a locator tube
at the base of the column.
IMPORTANT:
The guide rods
need to be in stack column (I) now
because ceiling height might make
later insertion difficult or
impossible. Now assemble the
stack column (I) to the frame
members (C & D) (3/8-16 x 1/2 hex
bolts, Qty: 4) Because the stack column needs to be held off the ground to align
the holes, placing 3 or 4 layers of scrap cardboard under the stack column on
the floor will save time and effort. At this stage you may tighten the stack
column bolts and the bolts that hold the two frame members to each other.
FIG.8
13.
Connect cables to cross chest fly cam. Use plastic hole plugs in
keyholes to prevent disconnection.
FIG. 10
21.
Now that all the cable ends are
attached, the cable system may be
completed behind the stack column.
Route the cable from the stack over
the pulley (#4) on the stack column
frame member (R) and down to double
moving pulley unit (G) from step 7
above. Route the cable around pulley
#5 such that double moving pulley
unit (G) is between the stack column
and the press arm. Route the
cable around this pulley in
the direction that matches
the diagram to prevent twisted
cables. Secure the cable end to the
stack column frame member (R) at
one of the two provided attachment
points. The upper hole should be
used with the 210 lb. stack. The
lower hole should be used with
the 160 lb. stack. First remove the
small bracket with the keyhole,
insert the cable end in the keyhole,
then reattach the bracket to the
correct hole.
FIG. 13
22.
Check the press arm adjustment
lever’s operation at this point. When
the lever is operated in either direction,
the pin should retract fully, allowing
the press handle to rotate. When the
lever is released, the pin should lock
the press handle by snapping all the way into the next notch. Adjust with
phillips screwdriver if necessary. The adjustment screw is behind the stack
a few inches from the latch pin. When correctly adjusted, the latch pin will
be forced by the spring all the way against the far end of the position notch.
When operated, the adjustment lever will pull it free of the notches such that
no clicking is heard during adjustment.
It is very important
that it be adjusted
such that it goes all the way to the end of each notch with just the pressure
of the spring. There is a jam nut on the adjustment screw — tighten it against
the brass fitting to prevent the adjustment from changing over time.
23.
At this point, all assembly behind the stack is complete, and all the bolts
in that region should be tight. The machine may now be moved into a corner.
24.
Adjust the center of the bench at this point. Move it side to side
until it is centered in the press arm. Once it is centered, tighten the four bolts
securing the press station frame member (C) to the press post (B).
FIG.16
20.
Now attach the bench
assembly to the weight machine.
Align the bench hitch section
(portion with the wheel), and start it onto the
square frame, just enough such that the wheel is on the frame. Now the two
cable ends need to be attached to opposite ends of the bench. The cable end
farthest from the weight stack loops back around the larger pulley of the bench
pulley bracket (S) and attaches inside the bench hitch section near the wheel.
Insert the ball end into the keyhole and secure with a plastic hole plug. The
second cable end, the one nearer the weight stack attaches to a similar keyhole
on the leg developer cam. After inserting it, secure it with a plastic hole plug.
Next slide the bench further onto the frame and slide the bench pulley bracket
(S) back onto the frame. Secure it with the two bolts (3/8-16 x 1/2 hex bolts,
Qty: 2), tighten them firmly.
FIG. 15
25.
Adjust the high pulley member
(T) height now if necessary. Adjust it up
to provide additional pre-stretch for the
tallest user, ceiling height allowing. To do
this, loosen the bolts that pass through
pulley #2 at the top of the main column (H).
You will need two 9/16” end wrenches for
this as most other wrenches will not fit. Now tighten (or loosen if adjusting
down) the bolt on the top of the back of the high pulley member (T). Once the
chosen adjustment is reached, retighten the bolts that pass through pulley
#2. They must be very tight. The lower two frame bolts that attach the main
column frame member (D) to the main column (H) should now be tightened,
taking care to see that the base of the main column is flat on the floor.
FIG.17
26.
Tension the cable system by locating the adjustment screw on the right
of the high pulley member (T) at the top of the main column (H). Adjust the
cable tension as follows: tighten the adjustment screw until the top plate lifts
slightly. Loosen the bolt until the top plate just touches the first weight plate.
Check that the weight selector pin can be inserted in all weight plates.
FIG. 17
27.
Make sure that all cables move freely when all stations are operated.
Immediately fix any cable rubbing problems.
28.
Attach lat bar to cable at high pulley.
29.
Apply weight stack number labels per instructions printed on label
sheets. Affix the “PRESS ARM ADDS 10 lbs.” label (located on the weight
stack label sheet) to the press arm. Hang the Exercise Chart on the wall
nearby for convenient reference, frame or laminate as desired.
8.
If the optional Foot Hold-Downs
are being installed, attach them now
to the bottom of the main column (H)
(3/8-16 x 1/2 hex bolts, Qty: 4).
The bolts go from the inside of column down into the Foot Hold-Downs. They
can be tightened with a common wrench from below as shown. These may
be assembled to an upright column, but it is more difficult and requires
different wrenches. Tighten very tight before proceeding.
FIG. 5
FIG. 6
12.
Install right cross chest fly arm (J) (arm closest to stack column) on
pivot bar. The right arm is the one with the cam at the lowest point on the
arm. Install 1” washer and then cotter pin, bend end.Repeat this process
for the left arm (L).
FIG. 9
14.
Install seat bottom (N) (1/4-20x3/4 hex bolts, Qty. 2). Install the
Lat Hold-Down (O) with the lever on the right pointing up. Line up the 1/2”
holes and insert the pivot (1/2” diameter rod and shaft retainers). Install
shaft retainer with a hammer. Install seat bak (P) (1/4-20x3/4 hex bolts,
Qty. 4). Install one single handle per side (Q).
FIG. 11
17.
Now lower the
top plate assembly
down the guide rods
making sure the side
with the bolt is toward
the back of the
machine. Leave the
cable hanging out the
top of the column for
a moment and attach
the guide rods to the
support bracket at the top
of the stack column (I). To
do this remove the bolt in
the top of each guide rod,
and reinsert it through the
bracket. Make sure that the
nylon bushings are in the
top of the guide rods on top
of the threaded inserts
installed at the factory.
Tighten these bolts, and
test the guide rod spacing
by pulling the top plate to
the top of the column using
the cable. If the top plate
is sticky near the top of the
guide rods, loosen the bolts
and adjust the spacing
before proceeding.
FIG. 12
18.
Now install
the stack column frame member (R) as shown (3/8-16
x 1/2 hex bolts and nuts, Qty: 4 ea.). This frame member goes on the inside
of the angle of the main column frame member (D), not on its outside.
Tighten these four bolts very tight.
FIG. 13
I
D
C
FIG. 7
FIG. 16
FIG. 15
25
21
B
S
Hole Plug
17
19
16
20
18
2
1
3
H
FIG. 8
FIG. 9
NOTE:
These 4
bolts
adjust
bench to
press arm
alignment
E
13
14
15
11
C
D
FIG. 4
Note:
Cable goes
between
pulley #13
and this pin
LEFT CAM
DETAIL
FIG. 10
FIG. 11
N
O
P
Q
J
Lever
FIG. 12
FIG. 14
N
Rubber feet
FIG. 17
Loosen to adjust
high pulley, then
retighten.
Cable system
adjusting bolt
High pulley height
adjusting bolt
T
FIG. 13
4
5
12
13
11
Secure
cable here
for 210 lb.
stack
Secure
cable here
for 160 lb.
stack
R
G
D
A
B
B
C
D
11
Washer
E
F
D
B
RIGHT
LEFT
FR
ONT VIEW
1" Washer
Cotter pin
1" Washer
Cotter pin
J
L
