Precor Icarian CW-116 fitness equipment Assembly Guide


CW-116
Important Safety Instructions
Before beginning any fitness program, you should
obtain a complete physical examination from your
physician.
French equivalent of the preceding paragraph, for the
Canadian market: Il est conseillé de subir un examen
médical complet avant d’entreprendre tout programme
d’exercise. Si vous avez des étourdissements ou des
faiblesses, arrêtez les exercices immédiatement.
When using exercise equipment, basic precautions
should always be taken, including the following:
•
Read all instructions before assembling the
CW-116. These instructions are written for your
safety and to protect the unit.
•
Do not allow children or those unfamiliar with its
operation on or near the equipment. Do not leave
children unsupervised around the unit.
•
Read each step in the assembly instructions and
follow the steps in sequence. Do not skip ahead. If
you skip ahead, you may learn later that you have
to disassemble components and that you may have
damaged the equipment, which would void the
Precor Limited Warranty.
Important Safety Instructions
•
•
•
•
Use the equipment only for its intended purpose.
Do not use accessory attachments that are not
recommended by the manufacturer, as such
attachments may cause injuries.
Wear proper exercise clothing and shoes for your
workout and avoid loose clothing. Do not wear
shoes with heels or leather soles. Tie long hair
back.
Do not overexert yourself or work to
exhaustion. Use reasonable judgement when
working with weights. Avoid using excessive
weight, which may cause injury.
If you feel pain, faintness, dizziness, or abnormal
symptoms, stop exercising immediately and
consult your physician.
•
Assemble and operate the CW-101 on a solid, level
surface. Locate the unit a few feet from walls or
furniture to provide easy access.
•
Do not use outdoors.
•
Do not attempt to service the CW-116 yourself. The
unit does not contain any user-serviceable parts.
Obtaining Service
For information about product operation or
service, refer to the Precor web site at www.
precor.com where you can also find customer
support numbers or a list of Precor authorized
service centers.
If you contact Customer Support, have the
serial number available.
You can find the serial number printed on
a label affixed to the CW-116. For future
reference, write the serial number in the space
provided below.
Serial number:
_______________________
IMPORTANT SAFETY INSTRUCTIONS
CW-116 Assembly Guide
page 3
CW-116 Assembly Guide
Table of Contents
Important Safety Instructions............................................................................................... 3
Obtaining Service..................................................................................................................................................... 3
1
2
Preparations............................................................................................................................ 5
Unpacking the Equipment........................................................................................................................................ 5
Required Tools.......................................................................................................................................................... 5
Installation Requirements......................................................................................................................................... 5
Hardware Kit............................................................................................................................................................. 6
Assembly Instructions........................................................................................................... 7
Open the Box............................................................................................................................................................ 7
Assemble the Unit.................................................................................................................................................... 8
Assemble the Pads................................................................................................................................................... 9
Clean the Pads and Assembly.................................................................................................................................. 9
Product Specifications...........................................................................................................12
Table of Contents
page 4
CW-116 Assembly Guide
1
Required Tools
Tools that you need to obtain before assembling the
unit include:
❏ Wire cutter or utility knife
Preparations
The CW-116 parts are inspected before shipment.
Each unit contains several pieces that require
assembly. You may find it helpful to ask for assistance
during the assembly process.
Unpacking the Equipment
When you open a box, carefully unpack the pieces
and lay them on the floor near the location where you
plan to use them.
CAUTION: Be careful when you remove the
packaging material with a utility knife. Do not cut
the upholstery or scratch the paint.
If any items are missing, contact the dealer from whom
you purchased the unit. For more information, refer to
Obtaining Service.
Preparations
Installation Requirements
Follow these installation requirements when
assembling the unit:
•
Review the Important Safety Instructions.
•
Assemble the unit where it will be used.
Provide ample space around the unit.
•
Install components in the sequence shown.
•
Insert all fasteners in the same direction.
For aesthetic purposes, insert all the fasteners
in the same direction unless specified (in text or
illustrations) to do otherwise.
•
Leave room for adjustments. Tighten the
fasteners to keep the unit stable, but leave room
for adjustments. Do not fully tighten fasteners until
instructed to do so.
page 5
CW-116 Assembly Guide
Hardware Kit
Fastener
Qty
3
3
⁄8 x 3⁄4-inch Buttonhead screw (A)
⁄8-inch Split washer (B)
Qty
8
5
⁄16 x 3-inch Buttonhead screw (G)
8
5
⁄16-inch Split washer (H)
8
8
½ x 1¼-inch Buttonhead screw (C)
1
½-inch Split washer (D)
1
½-inch Washer (E)
1
Spacer (F)
1
Preparations, continued
Fastener
⁵⁄₁₆-inch Washer (J)
8
page 6
CW-116 Assembly Guide
2
Assembly
Instructions
Assembly of the CW-116 takes about 20 minutes to
complete. If this is the first time you have assembled
this type of equipment, plan on allowing more time.
Back Pad
Be careful to open boxes and assemble components in
the sequence presented in this manual.
Note: With so many assembled parts, proper
alignment and adjustment is critical. While tightening
the fasteners, be sure to leave room for adjustments.
Do not fully tighten fasteners until instructed to do
so.
Open the Box
Seat Pad
Stabilizer
Main Frame
Use wire cutters to open the box and remove the
packing materials.
The illustration shows how the CW-116 will look when
you have completed its assembly. The callouts identify
specific pieces.
Assembly Instructions
Foot Rest
page 7
CW-116 Assembly Guide
Assemble the Unit
1. Attach the Main Frame to the Stabilizer using
four ¾-inch buttonhead screws (A)
four 3⁄8-inch split washers (B)
Wrench tighten.
4 - ¾” buttonhead screws
4 - split washers
Note: Make sure the wheels on the Stabilizer are
positioned as shown in the illustration.
2. Attach the Back Support to the Main Frame using
four ¾-inch buttonhead screws (A)
four 3⁄8-inch split washers (B)
Wrench tighten.
4 - ¾” buttonhead screws
4 - split washers
3. Slide the Foot Rest through the Main Frame and
secure it using
one 1¼-inch buttonhead screw (C)
one ½-inch split washer (D)
one ½-inch washer (E)
one spacer (F)
Wrench tighten.
Note: For ease of assembly, place a split washer,
a flat washer, and a spacer onto each screw
before inserting the screw.
Assemble the Unit
1 - 1¼” buttonhead screw
1 - split washer
1 - washer
1 - spacer
page 8
CW-116 Assembly Guide
Assemble the Pads
1. Attach the Back Pad to the Back Support using
four 3-inch buttonhead screws (G)
four 5⁄16-inch split washers (H)
four 5⁄16-inch washers (J)
Wrench tighten.
4 - 3” buttonhead screws
4 - split washers
4 - washers
2. Attach the Seat Pad to the Main Frame using
four 3-inch buttonhead screws (G)
four 5⁄16-inch split washers (H)
four 5⁄16-inch washers (J)
Wrench tighten.
This completes the assembly of the CW-116.
Clean the Pads and Assembly
To clean the pads, moisten a clean, soft cloth in a
mild solution of soap and water and wipe all the parts
thoroughly. Dry the pads with a clean, dry cloth.
Use the same procedure to clean the main structure.
Frequently vacuum the floor underneath the CW-116
to prevent the accumulation of dust and dirt. If
necessary, use the Foot Rest to lift the front end and
tip the CW-116 onto its wheels to roll it to a different
location.
Assemble the Pads
4 - 3” buttonhead screws
4 - split washers
4 - washers
page 9
CW-116 Assembly Guide
Notes:
page 10
CW-116 Assembly Guide
Notes:
page 11
CW-116 Specifications
Length: 46 inches (117 cm)
Height: 33 inches (82 cm)
Width: 30 inches (76 cm)
Shipping weight: 65 lb (30.48 kg)
Precor Incorporated
20031 142nd Avenue NE
P.O. Box 7202
Woodinville, WA USA 98072-4002
1-800-347-4404
Precor, Icarian, and Move Beyond are registered trademarks of Precor Incorporated.
Copyright 2014 Precor Incorporated.
Specifications subject to change without notice.
www.precor.com
NOTICE:
Precor is widely recognized for its innovative, award winning designs of exercise equipment. Precor aggressively seeks U.S. and
foreign patents for both the mechanical construction and the visual aspects of its product design. Any party contemplating the use
of Precor’s product designs is hereby forewarned that Precor considers the unauthorized appropriation of its proprietary rights to
be a very serious matter. Precor will vigorously pursue all unauthorized appropriation of its proprietary rights.
CW-116 Assembly Guide CW33688-102 rev B
30 November 2014
General Safety &
Maintenance Manual
Precor Icarian Line
Commercial Strength Equipment
Important Safety Guidelines for Owners
Follow these guidelines to maintain proper working condition of the
equipment:
• Qualified technicians must perform all regular maintenance.
• Check that all fasteners are securely tightened. Cables should be
secured at both end connections and properly threaded. Weight
stacks should be secure and functioning properly. Handle
attachments should be properly connected.
• Strength training requires a significant focus by the facility and its
staff to maintain the quality of the fitness environment. If possible,
the facility should provide direct supervision of the fitness
equipment at all times by people knowledgeable about the safe
operation of the equipment and trained to recognize potential
problems.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners
IMPORTANT SAFETY GUIDELINES
Important: Do not modify the equipment or any of its parts, or
permanently remove any part from the equipment. Do not use
accessory attachments that are not recommended by Precor, as
such attachments might cause injuries.
• Make sure that trainers, facility personnel, and maintenance
technicians understand how to use the equipment, know
important safety guidelines, and can recognize potential
problems such as a worn cable, loose hardware, or cracked
weld.
1
• Locate the equipment at least 40 inches (1 meter) away from
walls or furniture on either side of the equipment, and 40 inches
(1 meter) away from objects behind the equipment. For
Functional Training equipment, make sure that the operating
space is large enough to allow the cables to be fully extended in
all possible directions.
• Make sure the equipment is stable and placed on a solid, level
surface. The equipment is designed to be freestanding; however,
it can be bolted to the floor for extra stability. Precor highly
recommends that the equipment be bolted to the floor to reduce
the risk of toppling the equipment due to improper use. Since
floor construction varies, please consult a professional building
engineer for proper fastening.
• Check the equipment thoroughly based on the recommended
inspection schedules outlined in this manual, including daily,
weekly, monthly and annual checks. Ensure all bolt connections
are tight and that the threaded cables are properly and tightly
secured at both ends.
• Place an “out-of-order” sign on the equipment during
maintenance of the equipment or the surrounding area. Users
should never be allowed to operate the equipment until it has
been inspected and works properly. If a piece of equipment
needs service, keep it out of use until it is repaired.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners
IMPORTANT SAFETY GUIDELINES
• If any staff member witnesses unsafe use of the equipment, he or
she should address the user directly, demonstrate the proper
technique, and review the Important Safety Information for
Users. Precor recommends posting a copy of the Important
Safety Information for Users near the equipment in a prominent
location.
2
• When working with the weight stacks, do not attempt to free any
jammed assemblies without assistance as this may cause injury.
With the help of another person, carefully return the weight stack
to the proper position with the top plate resting on the first
weight.
• Do not place the equipment outdoors or on wet surfaces.
Safety Approval
Certain Precor commercial strength equipment is Class S/C
certified according to EN957 –1/2 standards. See an authorized
Precor dealer for a complete and current listing of certified
machines.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners
IMPORTANT SAFETY GUIDELINES
• Do not allow the equipment to be used if the top plate or weight
stack is pinned in a raised position. With the help of another
person, carefully return the machine to the proper position with
the top plate resting on the first weight. Inspect the cable to
ensure that it is seated in all of the pulleys.
• Whenever a weight can drop and hit a user, such as with an
Olympic bench, Precor highly recommends that a helper or
spotter be used to ensure a safe workout with the equipment.
3
Important Safety Information for Users
• Never drop or insert objects into any opening in the equipment.
Before beginning any fitness program, you should obtain a complete
physical examination from your physician.
• Check that all fasteners are securely tightened. Cables should be
secured at both end connections and properly threaded. Weight
stacks should be secure and functioning properly. Handle
attachments should be properly connected. Pay particular attention
to the condition of cables and cable ends. If you notice a loose
cable end or any fraying of the cable or cable jacket, do not use the
product and contact someone in the facility immediately.
French equivalent of the preceding paragraph, for the Canadian
market: Il est conseillé de subir un examen médical complet avant
d’entreprendre tout programme d’exercise. Si vous avez des
étourdissements ou des faiblesses, arrêtez les exercices
immédiatement.
When using exercise equipment, you should always take basic
precautions, including the following:
• If you do not understand how to operate a piece of equipment, ask
someone from the facility such as a trainer to demonstrate how to
use it and explain any safety instructions.
• Do not allow children on or near the equipment. Do not leave
children unsupervised around the equipment.
• Use the equipment only for its intended purpose. Do not use
accessory attachments that are not recommended by the
manufacturer, as such attachments may cause injuries.
• Wear proper exercise clothing and shoes for your workout—no loose
clothing.
• Do not overexert yourself or work to exhaustion. Use reasonable
judgment when working with weights. Avoid using excessive
weight, which may cause injury.
• If you feel pain, faintness, dizziness, or abnormal symptoms, stop
exercising immediately and consult your physician.
• Always check the equipment before using it. If you spot a potential
problem, contact someone in the facility immediately. Do not use the
equipment until the facility has verified that the equipment is working
properly. Do not attempt to fix broken or jammed equipment.
• Do not use the equipment outdoors.
• Do not drop or slam the weight stack while exercising.
• Be sure the selector pin is completely inserted. Use only the pin
provided by the manufacturer. If unsure, contact someone in the
facility.
• Never pin the weights in an elevated position. Do not use the
equipment if the top plate or weight stack is pinned in a raised
position. Notify facility’s personnel to repair the equipment and
ensure that it is working properly.
• Do not use the equipment if an “out of order” sign has been placed
on it.
• Read all posted instructions, including all safety instructions and
warnings.
• Keep head, limbs, fingers, and hair clear of all moving parts while the
equipment is in use. Keep hands clear of racking pegs.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners
4
Table of Contents
Important Safety Guidelines for Owners ...........................1
Safety Approval ............................................................................... 3
Important Safety Information for Users ...................................... 4
Before You Begin .....................................................................7
Recommended Tools ..................................................................... 7
Obtaining Service ........................................................................... 8
Daily Inspection ........................................................................9
Clean Upholstery ............................................................................ 9
Inspect Pads for Wear ................................................................10
Clean and Inspect Frames .........................................................10
Inspect All Fasteners ...................................................................11
Inspect Cables and End Connections .....................................11
Check Warning Labels and Instruction Placards .................13
General Safety and Maintenance Manual: Table of Contents
Weekly Inspection ................................................................. 15
Condition and Deep Clean Upholstery ...................................15
Clean and Lubricate Cable Rod Ends .....................................16
Clean and Lubricate Guide Rods .............................................16
Inspect Cables, Connections, and Tension ...........................17
Inspect Cable Handle Attachments .........................................18
Inspect Pulleys ..............................................................................18
Inspect Weight Stack and Selector Pin ..................................18
Inspect and Lubricate Bearings and Bushings .....................19
Check Seat Adjustment and Test Pop Pins ...........................20
5
Monthly Inspection ................................................................21
Inspect Frames and Movement Arms ......................................21
Lubricate Pop Pins .......................................................................22
Check and Lubricate Ratcheting Seat Lever .........................23
Inspect All Fasteners ...................................................................24
Annual Maintenance ..............................................................25
Weight Stack Annual Maintenance ..........................................25
Inspect and Lubricate Pop Pins ................................................26
Recommended Maintenance Checklist ............................27
General Safety and Maintenance Manual:: Table of Contents
6
Before You Begin
Precor recommends implementing a thorough maintenance program
that incorporates regular safety inspections by qualified maintenance
technicians as outlined in this manual.
This manual explains how to maintain the Precor Icarian line of
commercial strength equipment. It provides information about items
that need to be inspected and maintained on a daily, weekly, monthly,
and annual basis. You should perform those tasks that are appropriate
for the equipment you are maintaining, and skip those tasks that do
not apply. To help you, a checklist is located at the back of this manual
that you can follow during your maintenance checks to ensure that
nothing appropriate is missed and that your inspection process is
documented.
This manual covers the general maintenance procedures that you can
perform in the fitness facility. However, if the equipment requires
service beyond the maintenance procedures covered in this manual,
refer to Obtaining Service.
Recommended Tools
We recommend that you put together a toolbox with the following
tools. This list covers the tools you may need when you inspect and
maintain the equipment.
• Complete combination box wrench set from ¹⁵⁄₁₆ to ¹₂-inch
• Complete socket set from ¹⁵⁄₁₆ to ¹₂-inch
• Hex nut driver: ¹₄-inch
• 12-inch adjustable wrench
• Complete hex key set from ³⁄₈ to ⁵⁄₆₄-inch
• Rubber mallet
• Straight shank punch: ¹₄-inch
Important: Always purchase replacement parts and hardware from
Precor. These parts are tested and manufactured specifically for the
Precor Icarian line of commercial strength equipment. If you use parts
not approved by the manufacturer, you could void the Precor Limited
Warranty. Use of parts not approved by Precor may cause injury.
Precor recommends that maintenance technicians thoroughly read
and understand the safety guidelines and maintenance procedures
covered in this manual.
Note: If the equipment requires assembly, a separate assembly guide
is provided. For information on how to use a piece of equipment, refer
to the instructional label found on the equipment.
General Safety and Maintenance Manual: Before You Begin
7
Obtaining Service
You should not attempt to service the strength equipment, except for
the maintenance tasks described in this manual. If any items are
missing, contact your dealer. If you need more information regrading
customer support numbers or a list of Precor authorized service
centers, visit the Precor website at www.precor.com.
If you have any questions regarding a piece of equipment, locate its
serial number and contact Precor Customer support. Precor uses the
serial number to establish the model and year of the product. You can
generally find the serial number underneath the seat support.
Model #: _______
Date purchased: _________________________
Model #: _______
Serial #: _______________________
Date purchased: _________________________
Model #: _______
Serial #: _______________________
Date purchased: _________________________
For future reference, write the serial numbers, model numbers, and
dates of purchase for your Precor strength training equipment in the
space provided. You may want to list all equipment information below
for easy reference.
Model #: _______
Model #: _______
Model #: _______
Serial #: _______________________
Serial #: _______________________
Serial #: _______________________
Date purchased: _________________________
Serial #: _______________________
Date purchased: _________________________
Date purchased: _________________________
Model #: _______
Model #: _______
Serial #: _______________________
Date purchased: _________________________
Serial #: _______________________
Date purchased: _________________________
Model #: _______
Serial #: _______________________
Date purchased: _________________________
General Safety and Maintenance Manual: Before You Begin
8
Daily Inspection
You will need to perform the following tasks each day to maintain the
equipment and keep it operating smoothly:
• Clean any upholstery on the equipment.
• Inspect pads for wear.
• Clean and inspect equipment frames.
• Inspect cables and end connections for wear.
Clean Upholstery
To remove surface dirt and perspiration, clean upholstery daily with a
mild soap and water solution in a spray bottle. Spray upholstered
surfaces lightly and wipe dry with a clean cloth.
Important: To clean the upholstery, do not use cleaning products that
have any of these ingredients: solvents, alcohol, ammonia, or
petroleum. Use a mild detergent-based cleaner instead.
• Check warning and instructional labels for readability.
• Check that all fasteners are properly secured.
General Safety and Maintenance Manual: Daily Inspection
9
Inspect Pads for Wear
Clean and Inspect Frames
Inspect pads for cracks in the upholstery, broken and loose stitching,
loose staples, and loose mounting bolts. Replace pads as needed
(refer to Obtaining Service to purchase new pads.)
To remove grease and dirt, clean frames daily with a mild soap and
water solution in a spray bottle. Wipe the equipment down with a
damp cloth and dry completely. Be sure to wipe down both painted
parts and chrome or plated parts.
Important: Do not reupholster pads or use pads not approved by
Precor.
To restore and maintain luster of chrome parts, use a commercial
chrome cleaner.
As you clean, inspect the frames for cracks, rust, or other damage.
Make sure welds are solid and fasteners are properly secured.
General Safety and Maintenance Manual: Daily Inspection
10
Inspect All Fasteners
Inspect Cables and End Connections
Fasteners can loosen with normal use. Inspect all nuts, bolts, screws
and other fasteners to make sure they are tight and installed correctly.
CAUTION: Carefully inspect the cables, pulleys, fasteners, and
related hardware regularly. Replace any cable at the first sign of
wear using only Precor-supplied replacement parts. With regular
use, a cable can become worn and might fail. Sudden failure of
a worn cable can cause severe injury to a user. Refer to
Obtaining Service to purchase replacement parts.
Be sure to check fasteners at bolted joints to make sure the
connections are secure. If a fastener is loose but in good condition,
retighten it. If you are concerned about the integrity of the fastener,
remove it, clean the threads and inspect it for any damage such as
cracks, bad threads, corrosion, or rust. Reinstall the fastener if it
appears to be in good condition. Otherwise, remove the equipment
from service until a new fastener can be installed properly. You can
order new fasteners from Customer Support. For additional
information refer to Obtaining Service.
Important: Fastener quality and specifications vary considerably.
Replace only with the Precor approved fastener specifically
engineered for the precise application. Failure to do so will void the
Precor Limited Warranty.
General Safety and Maintenance Manual: Daily Inspection
Inspect the cables and end connections each day, and replace if
damaged. Check for kinks, frayed wires, or deterioration of the cable
coating. Look for signs of wear particularly at crimped ends of the
cable and near pulleys. (Refer to Figure 1.)
Important: Cables must be replaced immediately if they are
damaged to avoid possible injury to users.
11
Some obvious signs of cable damage are as follows:
1. Exposed inner wire, stretching or cuts in the coating, or broken
coating in the area that passes over a pulley
2. A zigzag or wavy pattern
In addition to inspecting the cables and end connections for damage,
check the following:
• Ensure that each cable is properly adjusted and tightened at the top
of the weight stack.
• Check cable pulleys, end connections, and end fittings. Make sure
all connections are tight, adjusting cable tension as necessary.
3. Kinks, which may indicate internal damage
4. A necked-down cover
• Make sure that the cable bolt is threaded at lease seven turns into
the selector stem or a minimum of ¹₂-inch (13 mm). The distance
shown should be ³₄-inch (19 mm) or less. Tighten the locking jam
nut to 600 in-lb (68 N-m). Refer to Figure 2.
5. A ‘ballooned” cover
Exposed inner wire
Zig-zag/wavy
Kinked
Cable bolt must be inserted a
minimum of 7 threads into the
selector stem.
Locking jam nut
Necked-down
Ballooned
Figure 1: Signs of cable damage
Figure 2: Proper cable bolt insertion
General Safety and Maintenance Manual: Daily Inspection
12
Check Warning Labels and Instruction
Placards
Figure 3 shows a typical user instruction placard.
Inspect warning and instructional labels daily tom make sure that all
the information can be clearly read. If any portion is not visible or part
of the label is not adhered properly, replace that label immediately
(refer to Obtaining Service for purchase information).
Clean labels and placards as needed with a mild soap and water
solution in a spray bottle, and dry thoroughly with a soft cloth.
The following figure shows an example of a user instructional label.
PULLDOWN 304
Select appropriate lifting weight.
Adjust thigh pad to rest securely
on top of legs.
Grip bar with hands evenly spaced.
Pull bar down to upper chest
with a slow, controlled movement,
pulling handles behind neck is
not recommended, as injuries
could result.
Slowly return to the start position.
CAUTION
Improper use of this machine will result in injury.
Before using, consult a qualified instructor.
Inspect cables and connections and do not use
if any component is worn or damaged.
Figure 3: Sample user instruction placard
General Safety and Maintenance Manual: Daily Inspection
13
Precor products come equipped with a number of standard warning
labels. The following figures show sample warning labels you may see
on the equipment depending on the model and product line:
KEEP HANDS AND FEET CLEAR WHILE MACHINE IS IN USE
Figure 4: This warning label may appear on weight stacks with a pulley
mounted at the top
The weight stack cable bolt must be
inserted a minimum of seven full turns
into the selector stem, and the jam nut
tightened down firmly against the
selector stem top.
Figure 5: This warning label may appear on or near weight stacks where
a cable bolt is threaded into the selector stem
Figure 6: A version of this warning label appears on the equipment frame
General Safety and Maintenance Manual: Daily Inspection
14
Weekly Inspection
This section covers the tasks you should do each week to maintain the
equipment. Perform the following tasks as appropriate for the unit you
are maintaining:
• Condition and deep clean upholstery.
• Clean and lubricate cable rod ends.
• Clean and lubricate guide rods.
Condition and Deep Clean Upholstery
Condition and deep clean the upholstery weekly with a lanolin-based
hand cleaner or upholstery cleaner.
Important: To clean the upholstery, do not use cleaning products that
have any of these ingredients: solvents, alcohol, ammonia, or
petroleum. Use a mild detergent-based cleaner instead.
• Inspect cables, connections, and tension.
• Inspect cable handle attachments.
• Inspect pulleys.
• Inspect each weight stack and selector pin.
• Inspect and lubricate bearings and bushings.
• Check seat adjustment and test pop pins.
General Safety and Maintenance Manual: Weekly Inspection
15
Clean and Lubricate Cable Rod Ends
Clean and Lubricate Guide Rods
Inspect the exposed areas of the guide rods for cleanliness. Using a
dry cloth, wipe any buildup of dirt of grease from the rods. Check
cable rod ends to ensure the shoulder bolt is secure. If cable rod ends
are noisy, you can lubricate them with a silicone spray lubricant, such
as Super Lube®. Spray the lubricant onto the joint where the spherical
portion is enclosed in the outer housing (refer to Figure 7). Wipe off
any excess lubricant with a cloth.
Inspect the exposed areas of the guide rods for cleanliness. Using a
dry cloth, wipe any buildup of dirt or grease from the rods.
Lubricate the exposed areas of the guide rods by applying a light coat
of a silicone spray lubricant. Spray the silicone lubricant on a cloth and
then wipe the guide rods with the cloth. Be careful with any lubricant
spray; it can stain carpet and clothing.
CAUTION: Do not attempt to lubricate the guide rods when the
equipment is in use. Attempting to lubricate between the weight
plates without completely disassembling the stack will result in
serious injury.
Lubricate here
Figure 7: Lubricate cable rod ends with silicone spray lubricant
Important: Do not use petroleum-based lubricants such as WD-40®,
Vaseline®, or motor oil.
General Safety and Maintenance Manual: Weekly Inspection
Important: Do not use petroleum-based lubricants or motor oil.
These lubricants tend to cause a rapid buildup of dirt and hair on the
weight plates, which can cause the plates to stick together.
Note: The CW802 Smith Machine has counter-balance guide rods
behind the maintenance shields, which should be cleaned and
lubricated weekly.
16
Inspect Cables, Connections, and
Tension
Each week, give the cables and connections a thorough inspection
and check cable tensions. The following lists the specific things you
need to inspect:
• Check the cable termination at the weight stack. Make sure that the
cable bolt is threaded at least a minimum of seven turns into the
selector stem or a minimum of ¹₂-inch (13 mm), so that there is no
more than ³₄-inches (19 mm) between the top of the jam nut and
base of the bolt head. Check and adjust accordingly. Also make
sure that the locking jam nut is tight against the selector stem.
• Check the cable as it terminates at the cam, which is stationary on
most equipment. Inspect the bolt passing through the cam end
fitting to be sure the two jam nuts are tightened against each other.
Also, check the entire cable routing to verify that there is no
interference with any structure.
• Inspect the ball end of the cable where the cable connection rests
in the clevis housing.
• Ensure that each cable is properly adjusted and tightened at the top
of the weight stack.
• Check cable pulleys, end connections, and end fittings. Make sure
all connections are tight, adjusting cable tension as necessary.
• Check the cable, especially near all pulleys, wheels, and cams.
General Safety and Maintenance Manual: Weekly Inspection
17
Inspect Cable Handle Attachments
Inspect Pulleys
Check the cable-to-handle attachment area very closely. Refer to
Figure 8. Look for frayed cable ends, broken thimbles, bent cables,
worn spring clips, worn handles, and any other unusual wear.
Precor uses precision ball bearing idler pulleys to smoothly guide
the cable.
Check these
areas closely.
Inspect each pulley for damage, including hairline cracks, chips, or
missing sections. Worn surfaces in the pulleys can cause severe
damage to the cables and must be replaced at the first sign of wear or
damage.
Be certain that the wheels turn freely as the equipment is used.
Inspect each pulley for excessive side-to-side play, which indicates
worn bearings or loose mounting bolts. If excessive play is discovered,
remove the pulley to inspect the bearings, and replace the entire
pulley if necessary.
Figure 8: Check connections to handles carefully
Also, check the spring clip gate and make sure it closes properly and
engages securely. Refer to Figure 9. Check the spring clip, links, and
cable to ensure integrity; replace any spring clip link that does not
function properly or shows wear.
Inspect Weight Stack and Selector Pin
Weight stacks are made of precision machine plates that are
designed as a single mechanism to stack precisely. Use only Precorsupplied add-on weights and weight selector pins.
On a weekly basis, inspect weight stacks and selector pins. Wipe
each plate with a damp cloth as needed. Inspect all plates for sharp
burs or damage. Wipe dirt and dust off the guide rods.
Spring clip gate
properly closed
Spring clip gate not
properly closed
Make sure the equipment uses only the original Precor selector pin. In
addition, make sure the selector pin can be fully inserted and retained
in each weight plate.
Figure 9: Check spring clip gate to ensure proper closure
General Safety and Maintenance Manual: Weekly Inspection
18
Inspect and Lubricate Bearings and
Bushings
Precor uses high quality bearings designed for strength applications
and long service life. Each week, do the following to maintain the
bearings and bushings on the equipment:
• Bronze bushings: Precor recommends using a small amount of
silicone spray lubricant to lubricate the bushings. Spray directly
onto the guide rod and then rotate the guide rod through its
complete range of motion several times. Inspect bushings for
excessive wear and damage. Be careful when using the spray
lubricant; it can stain carpet and clothing. Wipe off any excess
lubricant with a cloth.
• Nylon bushings: Lubricate the nylon bushings on the guide rods by
applying a light coat of silicone spray lubricant. Spray the silicone
lubricant on a clot, then wipe the cloth along the full length of the
guide rod.
• Linear Bearings: Case hardened guide rods are used in areas that
use linear bearings (refer to Figure 10). Inspect each end of the rod
to ensure they are fastened correctly and all bolts are tight.
Wipe down rods using a light application of a silicon spray lubricant
to remove dust, hair, and dirt. Polish the guide rod using fine grade
steel wool if surface rust or oxidation is present.
Important: Do not use petroleum-based lubricants or motor oil.
These lubricants tend to cause a rapid buildup of dirt and hair on
the weight plates, which can cause the plates to stick together.
If you lubricate the rods regularly, then the bearings will function as
designed. Otherwise, the rods may corrode, which can cause the
bearing to become clogged and jammed, leading to the bearing
actually gouging the rod. Be sure to remove surface rust and
oxidation from the hardened rails immediately.
• Sealed Bearing Pivot Points: These locations are protected from
the outside environment and require no lubrication. While cleaning
the equipment, wipe down the guide rods and external bearing
surfaces with a cloth to prevent the build up of dust and
perspiration.
Figure 10: Shows a typical location of a linear bearing in its housing
General Safety and Maintenance Manual: Weekly Inspection
19
Check Seat Adjustment and
Test Pop Pins
Precor strength equipment has two types of adjustments:
• 2x4-inch or 2x2-inch telescoping sleeve adjustment for most seat
assemblies
• ¹₂-inch slotted plate adjustments used on most free-weight bench
adjustments
Inspect all adjustments for proper fit and function. Inspect plastic
sliders for excessive wear or damage.
Adjustments use either a high-tensile pop pin plunger assembly or a
ratcheting lever assembly. Inspect and tighten all pop pin caps.
General Safety and Maintenance Manual: Weekly Inspection
20
Monthly Inspection
This section covers the tasks you should perform each month to
maintain the equipment. Perform the following tasks as appropriate for
the unit you are maintaining:
• Inspect frames and movement arms.
• Lubricate pop pins.
• Check and lubricate ratcheting seat lever
• Inspect all fasteners.
Inspect Frames and Movement Arms
Inspect frames and movement arms monthly for proper function and
integrity. Check for cracks, chipped paint, or rust. Touch up dings and
chips in the paint as needed. Replace any component at first signs of
wear.
Note: You can order touch-up paint from Precor by calling Customer
Support. Refer to Obtaining Service.
Inspect frames for cracks particularly at the joints. If any cracks are
found, immediately take the equipment out of service, and repair it
using a qualified maintenance technician. Refer to Important Safety
Guidelines for Owners and Obtaining Service).
General Safety and Maintenance Manual: Monthly Inspection
21
To remove surface rust from the frame, rub lightly with a fine wet/dry
sand paper or fine steel wool. Finish with Precor’s touch-up paint if
needed. Maintain paint luster with an application of a mild automotive
wax product.
To maintain the powder coated and chrome parts, use a mild
detergent-based cleaner for light dirt and grime removal. For removing
heavier dirt and grease and for polishing, use a good automotive
polish. For scuffs and marks that are not removed by the above
methods, use a fine-grit cleanser. Do not use solvents, lacquer thinner,
acetone, or finger nail polish remover. For high wear areas, ABS
shields have been provided. Replacement shields are available from
Precor Customer Support. For additional information refer to
Obtaining Service.
Lubricate Pop Pins
Pull out the pop pin as far as it goes and apply a small amount of
silicone spray lubricant. Wipe off any excess lubricant with a cloth.
(Refer to Figure 11.)
CAUTION: Pulling out the pop pin may cause the unit to adjust
position suddenly. To avoid injury, keep your hands and head
away from moving parts.
Test the pop pin for proper function and engagement in each
adjustment hole.
Figure 11: Lubricate the pop pin by pulling it out
General Safety and Maintenance Manual: Monthly Inspection
22
Check and Lubricate Ratcheting
Seat Lever
Precor designed the ratcheting seat so users can easily move the seat
to a comfortable position. After lowering the seat by pressing on the
lever to disengage, a user can sit on the seat and pull it up to the
desired position. As the seat moves, the ratcheting lever snaps in and
out of each hole, making an audible noise.
To test if the seat lever needs lubrication, slightly elevate the seat while
pressing and releasing the lever. The lever should snap back out
easily. If the lever sticks, lubricate the pivot pin in the lever with silicone
spray lubricant. Wipe off any excess lubricant with a cloth. (Refer to
Figure 12.)
The ratcheting seat requires little maintenance. However, because
seat safety is important to the safety of a workout, you should check
the ratcheting seat lever each month to see if it sticks when used. You
also want to ensure that the pin fully engages in each adjustment hole.
Lubricate on each side with a
silicone spray lubricant.
Figure 12: If needed, lubricate the pivot pin on the ratcheting seat lever
If desired, you can detach the seat by removing the retaining pin,
allowing you to remove the chrome for cleaning. Removing the seat
also allows clear access to the ratcheting lever to test its pivoting
action.
General Safety and Maintenance Manual: Monthly Inspection
23
Inspect All Fasteners
Precor products are assembled with Grade 5 fasteners or better. With
normal use, these fasteners can loosen. Inspect all nuts, bolts, hex key
bolts, screws, and other fasteners to ensure they are tight and
installed correctly.
Be sure to check fasteners at bolted joints to ensure connection is
secure. If the fastener is loose, but in good condition, retighten it. If
you are concerned about the integrity of the fastener, remove it, clean
the threads, and inspect it for any damage such as cracks, bad
threads, corrosion, or rust. Reinstall the fastener if it appears to be in
good condition. Otherwise, remove the equipment from service until a
new fastener can be installed properly. You can order new fasteners
from Customer Support. Refer to Obtaining Service.
General Safety and Maintenance Manual: Monthly Inspection
24
Annual Maintenance
Perform these tasks on an annual basis, as appropriate for your
equipment:
• Inspect the bushings of the top weight plate and each individual
weight plate and replace a plate if it is excessively worn or broken.
• Clean the selector stem and inspect it for wear and damage.
Weight Stack Annual Maintenance
• Reassemble the weight stack.
Once a year, Precor recommends disassembling the weight stack to
clean and inspect it thoroughly.
• Wipe down the weight stack enclosures (shrouds) with a damp
cloth as needed. Inspect all fasteners to ensure the shroud is
securely mounted.
• Carefully remove the cable and guide rods from the weight stack.
Completely disassemble the weight stack in a well-ventilated area,
away from the exercise floor.
• Inspect weight plates and clean them thoroughly. Cracked or
broken plates should be replaced immediately (refer to Obtaining
Service to purchase replacements). Clean each plate individually
and inspect guide bushings.
General Safety and Maintenance Manual: Annual Maintenance
Important: Precor recommends that you replace worn and damaged
cables during routine maintenance. It is recommended that all cables
be replaced annually.
25
Inspect and Lubricate Pop Pins
Remove the pop pin assembly by loosening the hex head cap.
CAUTION: Pulling out the pop pin may cause the unit to adjust
position suddenly. To avoid injury, keep your hands and head
away from moving parts.
Inspect the plunger and spring for excessive wear and damage, and
replace as required.
Pop pin plunger
assembly shown with
telescoping sleeve type
adjustment
Hex head cap
Apply a small amount of silicone spray lubricant to the spring and
plunger, and then reinstall the entire assembly. Tighten hex head cap.
Wipe off any excess lubricant with a cloth.
Figure 13: Inspect pop pins (pop pin shown in exploded view for clarity)
General Safety and Maintenance Manual: Annual Maintenance
26
Recommended Maintenance Checklist
Daily Check
Clean upholstery
Clean & inspect frames
Inspect pads for wear
Inspect cables & end connections
Check labels and placards
Please retain for your records.
Maintenance Record the Month of ______________________
Brand Name ______________________
Model Name & Number ______________________
Serial Number ______________________
In Service Date ______________________
Initial box when completed: write N/A if not applicable to the equipment.
1
2
3
4
5
6
7
8
9 10 11 12 13 14
7
Weekly Check
Condition & clean upholstery
Clean & lubricate cable rod ends
Clean & lubricate guide rods
Inspect cables/connections/tension
Inspect cable handle attachments
Inspect pulleys
Inspect each weight stack & Pin
Inspect & lube bearings & bushings
Check seat adjust. and pop pins or
ratcheting lever
15
16
14
Monthly Check
Inspect frames & movement arms
Inspect & lubricate pop pins or
ratcheting lever
Check & lubricate ratcheting seat
Inspect all fasteners
Annual Check
Weight stack maintenance
Inspect & lubricate pop pins or
ratcheting lever
Maintenance Tips
Upholstery
Cable
Frames
Guide rods
Important:
17
18
19
20
21
21
22
23
24
25
26
27
28
29
30
31
28
28
Date:
Initials:
Date
Initials:
Wipe clean using a mild soap and water solution or other appropriate cleaner for vinyl.
Replace any cable that shows signs of wear or damage.
Wipe clean using a mild soap and water solution.
Lubricate guide rods with silicone spray lubricant.
It is recommended that cables be changed annually. Only factory provided selector key, lanyard, handle attachment, and handle should be used on selectorized weight
stacks. Use of any parts other than those provided by the manufacturer will invalidate the product warranty and may cause injury to users.
General Safety and Maintenance Manual: Recommended Maintenance Checklist
27
Notes:
General Safety and Maintenance Manual: Recommended Maintenance Checklist
28
Precor, Icarian, Jade, and Move Beyond are registered trademarks of Precor Incorporated.
Super Lube is a registered trademark of Synco Chemical Corporation.
WD-40 is a registered trademark of CD-40 Company.
Vaseline is a registered trademark of Unilever.
Copyright 2014 Precor Incorporated.
Specifications subject to change without notice.
www.precor.com
Precor Incorporated
20031 142nd Ave NE
P.O. Box 7202
Woodinville, WA USA 98072-4002
NOTICE:
Precor is widely recognized for its innovative, award winning designs of exercise equipment. Precor
aggressively seeks U.S. and foreign patents for both the mechanical construction and the visual aspects of its
product design. Any party contemplating the use of Precor product designs is hereby forewarned that Precor
considers the unauthorized appropriation of its proprietary rights to be a very serious matter. Precor will
vigorously pursue all unauthorized appropriation of its proprietary rights.
General Safety & Maintenance Manual CW39162-111 rev A, en
31 October 2014