Batca Fusion 2 User manual

www.batcafitness.com Fusion 2 Owner’s Manual
Fusion 2
Owner’s Manual
Revision 0
Record Serial Number Here
Batca Fitness Systems
Tel. [phone]
www.batcafitness.com
Date of Purchase
January 2007

Batca Fitness Systems 2Fusion 2 Owner's Manual
__________ Page
Instructions 2
Parts Listing 3-5
Hardware Comparison 6-9
Cable Comparison 10
Main Frame Assembly 11-19
Cable Routing 20-25
Upholstery 26-27
Leg Press Option 28-33
Congratulations on the purchase of your new Fusion 2. This gym will provide you with a lifetime of enjoyment to meet your
strength training needs. Batca Fitness Systems strives to build the best quality multi-station gyms and to package these gyms in such
a way to avoid any damage during shipping.
In order to get started with your assembly you should first familiarize yourself with this manual. It is recommended that you
read through each step thoroughly before you begin. Begin by opening your boxes and separating all of your parts. Verify that all
parts are accounted for and have no damage. When all parts are accounted for, you may begin your assembly. Some items may
have been pre-assembled for your convenience. Please note that hardware quantities shown reflect total quantities for your gym and
may not reflect actual quantities in each bag. Assemble your gym on a solid level surface. This will ensure the best possible perfor-
mance, function, and safety for the gym and your workout.
Assemble your gym according to the step by step instructions found in this manual. Failure to do so will void your warranty
and may result in personal injury. After assembly, you should check each station to ensure correct operation. If a problem arises,
recheck your assembly with these instructions to verify correct assembly. If you are unable to correct a problem or have questions
with your assembly please contact your authorized Batca dealer.
Batca Fitness Systems has built this gym to give you a safe, effective and enjoyable workout. However,
there is a risk assumed by individuals who use this type of equipment. It is very important that all warnings and
instructions are read and followed before beginning any exercise program.
It is also very important to read and follow the preventative maintenance schedule described in this
manual. If any of the warning labels or stickers are worn, faded, torn, scratched or missing they should be replaced
immediately.
WARNING: There is a risk assumed by individuals who use this type of equipment. To minimize risk
always follow these rules.
1) It is essential that you consult with your physician before beginning any exercise program.
2) Inspect equipment before each use for loose, worn, or frayed parts (including cables, nuts and bolts). Replace
parts at first signs of wear (use only genuine BATCA replacement parts). Use of equipment that is damaged,
worn, frayed or not completely assembled on a solid, level surface may result in injury.
3) Make sure all adjustment pins are fully engaged before using equipment.
4) Keep all parts of the body and clothing outside the path of any moving parts of the gym. Be alert to the
possibility of injury. Do not be careless.
5) Minors and children should not be allowed to play on or around this gym.
6) If you have any questions on proper use or maintenance of this gym, do not hesitate to call your local BATCA
FITNESS SYSTEMS distributor or BATCA FITNESS SYSTEMS at [phone]. www.batcafitness.com
__________ Page
Leg Press Cable Routing 32
Leg Press Attachment 34
Weight Stack Decals and Serial Number 35
Cable Tension and Adjustments 36-37
Final Assembly and Troubleshooting 38
Maintenance 39
Warranty 40
Floor plan Layout 41-42
Table of Contents
Instructions
Warning

www.batcafitness.com 3Fusion 2 Owner’s Manual
Frame Components Accessories
Upholstery
ITEM NO. PART NO. DESCRIPTION QTY
156 BFC-10103 Strap Handle 4
ITEM NO. PART NO. DESCRIPTION QTY
31 BFU-10117 Large Bottom Pad 1
11 BFU-10119 Head Pad 1
32 BFU-10120 Back Pad With Lumbar 1
43 BFU-50187 Large Roller 1
28 BFU-50189 7" Roller 6
ITEM NO. PART NO. DESCRIPTION QTY
1BFM-10593 Rear Base 1
2BFM-10566 Right Vertical Support 1
3BFM-10567 Left Vertical Support 1
4BFM-10568 Middle Base 1
5BFM-10569 Middle Pole Assembly 1
6BFM-51044 Guide Rod Holder 1
7BFM-51022 1 1/4" Spacer 6
9BFM-50529 Rubber Donut 2
10 BFM-50256 Weight Plate 19
12 BFM-51051 Guide Rod 2
13 BFM-10570 Right Arm Assembly 1
14 BFM-10574 Left Arm Assembly 1
15 BFM-10573 Functional Arm Mount 1
16 BFM-10571 User Right Functional Arm 1
17 BFM-10572 User Left Functional Arm 1
18 BFL-50197 Middle Pole Connector Plate 2
19 BFL-50203 Pulley Holder Connector Plate 1
20 BFM-10577 8" Telespar 1
21 BFM-10578 Seat Frame Assembly 1
24 BFM-10579 10" Chrome Adjustment 1
25 BFM-10141 Knee Alignment Roller 1
30 BFM-10580 Back Chrome Adjustment 1
33 BFM-10581 Leg Extension/ Curl Frame 1
35 BFM-51080 .45” Spacer 1
36 BFM-10582 Functional Arm Swivel Pulley 2
37 BFM-10583 Top Swivel Pulley Holder 2
38 BFM-51082 Weight Stack Shroud 2
39 BFM-10584 Leg Extension Shaft 1
40 BFM-10585 Leg Extension Cam Assembly 1
41 BFM-51084 1 1/4" OD x .120 Wall x .225" Spacer 1
42 BFM-10586 Leg Extension Arm Assembly 1
44 BFL-50207 Hold Down Adjustment Plate 1
45 BFL-50211 Plate 1
46 BFM-10587 Knee Hold Down Assembly 1
47 BFM-51094 2” Axle 1
48 BFM-10588 Knee Hold Down Handle 1
50 BFL-50221 Pulley Plate 1
53 BFM-51143 8” Anti-Deflection Plate 1
54 BFM-51148 1" x 13 3/16" Arm Shaft 1
77 BFM-50505 3 1/2" Pulley Cover 11
79 BFM-10603 Left Arm Adjustment Handle 1
80 BFM-10602 Right Arm Adjustment Handle 1
87 BFM-51158 1" OD x 25/64" ID Spacer 1
91 BFM-10607 Press Arm 2
93 BFM-10609 Pulley Holder 2
94 BFM-10611 Criss-Cross Free Floater 1
96 BFM-10610 Lower Pulley Holder 2
105 BFM-10612 Cable Tie Out Plate 1
107 BFM-10299 Top Plate 1
108 BFM-50258 Selector Shaft 1
121 BFM-50222 2 9/16” Axle 1
122 BFM-50931 3” Axle 1
123 BFM-51173 Weight Stack Pull Pin 1
180 BFM-51130 Front Pivot 1
185 BFM-51158 Spacer 1

Batca Fitness Systems 4Fusion 2 Owner's Manual
Hardware
Cables
ITEM NO. PART NUMBER DESCRIPTION QTY
8BFH-50173 3 1/2" Pulley 31
22 BFH-50103 1/2" Flanged Bushing 4
23 BFH-50102 5/8" Flanged Bushing 2
26 BFH-50222 Rubber Bumper 2
27 BFH-50221 3" Plastic Washer 4
29 BFH-50252 Plastic Collar 6
34 BFH-50101 1" Flanged Bushing 28
49 BFH-50280 1" Round Plastic Cap 5
51 BFH-10002 Threaded Bearing 2
55 BFH-50165 1" Snap Ring 9
56 BFH-50146 3/8" Flat Washer (Black) 113
57 BFH-50122 HCS 3/8"-16 X 2 1/4" P5 21
58 BFH-50157 3/8"-16 Nylock (Black) 69
59 BFH-50270 HCS 3/8"-16 X 5 1/4" P5 8
60 BFH-50147 3/8" Lock Washer (Black) 16
61 BFH-50119 HCS 3/8"-16 X 1 1/4" P5 4
62 BFH-50124 HCS 3/8"-16 X 2 3/4" P5 8
63 BFH-50125 HCS 3/8"-16 X 3" P5 5
64 BFH-50251 1/2" Flat Washer (Black) 4
65 BFH-50138 HCS 1/2”-13 X 3 1/2” P5 1
66 BFH-50139 HCS 1/2”-13 X 4 1/4” P5 1
67 BFH-50136 HCS 1/2”-13 X 3” P5 1
68 BFH-50155 1/2"-13 Nylock (Black) 3
70 BFH-50121 HCS 3/8"-16 X 2" P5 12
72 BFH-50274 HCS 3/8"-16 X 4 3/4" P5 6
73 BFH-50285 HCS 3/8"-16 1 3/4" P5 2
74 BFH-50132 HCS 3/8"-16 X 5 1/2" P5 2
75 BFH-50605 3/8" Pulley Spacer 2
76 BFH-50123 HCS 3/8"-16 X 2 1/2" P5 3
92 BFH-50256 1/2” Jam Nut 6
95 BFH-50174 4 1/2" Pulley 4
98 BFH-50253 Beveled Leveler 2
99 BFH-50149 3/8"-16 Jam Nut (Zinc) 6
110 BFH-51174 Large Logo/Chrome & Red 2
111 BFH-50192 Weight Stack Decals 2
ITEM NO. PART NUMBER DESCRIPTION QTY
113 BFH-50250 1 1/4" Shoulder Bolt 2
114 BFH-50267 5/16"-18 Nylock (Black) 2
115 BFH-50144 FHSCS 3/8"-16 X 1" 2
116 BFH-50254 HCS 3/8”-16 X 3/4” P5 2
118 BFH-50279 HCS 3/8”-16 X 5" P5 4
119 BFH-50245 FHSCS 5/16"-18 X 1" 2
128 BFH-50188 Snap Hook 4
129 BFH-50211 2" Square Plastic Cap 1
130 BFH-50212 2" x 3" Plastic Cap 2
131 BFH-50215 1 1/2" Square Plastic Cap 6
133 BFH-50227 Cable Strap 5
136 BFH-50238 Pin 2
137 BFH-50239 Snap Ring 2
138 BFH-50244 1/2" Bronze Bushing 8
140 BFH-50248 13/32" Bushing 8
143 BFH-50297 1" Flanged Bushing x 1/2"L 2
144 BFH-50590 Plastic Sleeve 3
145 BFH-50602 1" ID Bearing 14
146 BFH-50604 2" Interior Snap Ring 26
147 BFH-50607 Pull Pin Threaded Cap 2
148 BFH-50608 5" Plastic Sleeve 1
149 BFH-50609 Molded Grip 1" ID 1
150 BFH-50611 2" Round Plastic Cap 3
151 BFH-50612 1 3/4" x 4" Rectangular Cap 4
152 BFH-50614 6" Rubber Grips 2
153 BFH-50618 Mounting Bracket 2
154 BFH-50203 1/2" Curved Pulley Spacer 8
155 BFH-50204 3/8” Curved Washer (Black) 8
181 BFH-50339 Large Flat Leveler 2
182 BFH-50337 Wavy Washer 5
183 BFH-50630 FHSCS 3/8”-16 X 3/4” 2
184 BFH-50631 HCS 3/8”-16 X 1/2” P5 4
186 BFH-50620 BHSCS 3/8”-16 X 3/4” 6
187 BFH-50622 Upholstery Cap 6
ITEM NO. PART NUMBER DESCRIPTION QTY
101 CAB-13021 Fusion Lat Pull to Functional Arm 2
109 CAB-13022 Fusion Weight Stack to Cable Tie Out 1
103 CAB-13024 Fusion Floating Pulley Cable 1
104 CAB-13025 Fusion Leg Extension Cable 1
106 CAB-13026 Fusion Tie Out Cable 1

www.batcafitness.com 5Fusion 2 Owner’s Manual
Leg Press Components
Tools Required
 1/2” Wrench
 9/16” Wrench
 9/16” Ratchet
 3/4” Wrench
 3/4” Ratchet
 Allen Wrench Set
 Tape Measure
 Snap Ring Pliers
Leg Press Hardware
Upholstery
Cables
ITEM NO. PART NUMBER DESCRIPTION Qty
102 CAB-13023 Fusion Leg Press Cable 1
ITEM NO. PART NUMBER DESCRIPTION Qty
61 BFH-50119 HCS 3/8"-16 X 1 1/4" P5 2
70 BFH-50121 HCS 3/8"-16 X 2" P5 1
76 BFH-50123 HCS 3/8"-16 X 2 1/2" P5 2
63 BFH-50125 HCS 3/8"-16 X 3" P5 2
69 BFH-50126 HCS 3/8"-16 X 3 1/4" P5 2
82 BFH-50127 HCS 3/8"-16 X 3 1/2" P5 3
83 BFH-50130 HCS 3/8"-16 X 4 1/4" P5 1
84 BFH-50131 HCS 3/8"-16 X 4 1/2" P5 1
85 BFH-50145 FHSCS 3/8"-16 X 2 1/4" 3
56 BFH-50146 3/8" Flat Washer (Black) 34
60 BFH-50147 3/8" Lock Washer (Black) 4
99 BFH-50149 3/8"-16 Jam Nut (Zinc) 3
58 BFH-50157 3/8"-16 Nylock (Black) 22
55 BFH-50165 1" Snap Ring 4
ITEM NO. PART NUMBER DESCRIPTION Qty
8BFH-50173 3 1/2" Pulley 5
90 BFH-50249 1 3/4 Shoulder Bolt 2
113 BFH-50250 1 1/4" Shoulder Bolt 1
64 BFH-50251 1/2" Flat Washer (Black) 2
98 BFH-50253 Beveled Leveler 1
114 BFH-50267 5/16"-18 Nylock (Black) 1
59 BFH-50270 HCS 3/8"-16 X 5 1/4" P5 4
73 BFH-50285 HCS 3/8"-16 1 3/4" P5 1
75 BFH-50605 3/8" Pulley Spacer 5
89 BFH-50610 1 1/2" Shoulder Bolt 2
92 BFH-50256 1/2” Jam Nut 1
181 BFH-50339 Large Flat Leveler 1
182 BFH-50337 Wavy Washer 2
188 BFH-50338 Sleeve 2
ITEM NO. PART NUMBER DESCRIPTION Qty
166 BFM-10597 Back Seat Frame 1
164 BFM-10598 Bottom Seat Frame 1
157 BFM-10605 Leg Press Frame 1
170 BFM-50252 Four Bar 2
171 BFM-51149 9 1/2" Shaft 1
168 BFM-51150 5 3/4" Shaft 1
159 BFM-51155 2 1/32" Axle 3
160 BFM-51157 3 1/32" Axle 1
180 BFM-51130 Front Pivot 1
ITEM NO. PART NUMBER DESCRIPTION Qty
172 BFL-50128 Foot Plate 1
162 BFL-50219 Bench Frame Plate 2
165 BFM-10106 Chrome Pad Adjustment 1
158 BFM-10575 Leg Press Connector Assembly 1
169 BFM-10590 Foot Plate Pivot 1
167 BFM-10591 Leg Press Pivot Arm 1
163 BFM-10595 Chrome Adjustment 1
161 BFM-10596 6" Telespar 1
ITEM NO. PART NUMBER DESCRIPTION Qty
173 BFU-10117 Large Bottom Pad 1
174 BFU-10120 Back Pad With Lumbar 1

Batca Fitness Systems 6Fusion 2 Owner's Manual
Bolt Length Note: Bolt length is measured from
the underside of the head of the bolt.

www.batcafitness.com 7Fusion 2 Owner’s Manual

Batca Fitness Systems 8Fusion 2 Owner's Manual

www.batcafitness.com 9Fusion 2 Owner’s Manual

Batca Fitness Systems 10 Fusion 2 Owner's Manual
ITEM NO. PART NUMBER DESCRIPTION QTY
101 CAB-13021 Fusion Lat Pull to Functional Arm 2
109 CAB-13022 Fusion Weight Stack to Cable Tie Out 1
102 CAB-13023 Fusion Leg Press Cable 1
103 CAB-13024 Fusion Floating Pulley Cable 1
104 CAB-13025 Fusion Leg Extension Cable 1
106 CAB-13026 Fusion Tie Out Cable 1
Cables
Cable Comparison Chart
71 5/8”
22 5/8”
187 1/2”
90 1/2”
85 1/4”
90 3/8”

www.batcafitness.com 11 Fusion 2 Owner’s Manual
Step 1:
Item # Part # Description Qty
1BFM-10593 Rear Base 1
2BFM-10566 Left Vertical Support 1
3BFM-10567 Right Vertical Support 1
4BFM-10568 Middle Base 1
37 BFM-10583 Top Swivel Pulley 2
55 BFH-50165 1” Snap Ring 4
56 BFH-50146 3/8" Flat Washer (Black) 8
57 BFH-50157 3/8"-16 Nylock (Black) 4
58 BFH-50270 HCS 3/8"-16 X 5 1/4" P5 2
118 BFH-50279 HCS 3/8-16 X 5" P5 2
182 BFH-50337 Wavy Washer 2
 All Flat Washers and Nylocks are 3/8”
PLEASE FOLLOW ALL DIRECTIONS VERY CAREFULLY FOR PROPER
INSTALLATION.
Note: For a more consistent appearance, position
all bolts in the direction shown in each
figure.
Figure 1
Do Not Tighten Hardware
Until Step 3

Batca Fitness Systems 12 Fusion 2 Owner's Manual
Figure 2
Step 2:
Item # Part # Description Qty
5BFM-10569 Middle Pole Assembly 1
18 BFL-50197 Middle Pole Connector Plate 2
56 BFH-50146 3/8" Flat Washer (Black) 10
58 BFH-50157 3/8"-16 Nylock (Black) 4
59 BFH-50270 HCS 3/8"-16 X 5 1/4" P5 4
60 BFH-50147 3/8” Lock Washer (Black) 2
76 BFH-50123 HCS 3/8"-16 X 2 1/2" P5 2
98 BFH-50253 Beveled Leveler 2
99 BFH-50149 3/8"-16 Jam Nut (Zinc) 4
181 BFH-50339 Large Flat Leveler 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Do Not Tighten Hardware
Until Step 3

www.batcafitness.com 13 Fusion 2 Owner’s Manual
Figure 3
Item # Part # Description Qty
13 BFM-10570 Right Arm Assembly 1
14 BFM-10574 Left Arm Assembly 1
35 BFM-51080 .45” Spacer 1
54 BFM-51148 1" Arm Shaft 1
55 BFH-50165 1" Snap Ring 2
182 BFH-50337 Wavy Washer 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 3:
Tighten All Hardware
From Steps 1, 2, and 3

Batca Fitness Systems 14 Fusion 2 Owner's Manual
Figure 4
Step 4:
Item # Part # Description Qty
107 BFM-10299 Top Plate 1
108 BFM-50258 Selector Shaft 1
111 BFH-50192 Weight Stack Decals 2
116 BFH-50254 HCS 3/8”-16 X 3/4” P5 2
118 BFH-50279 HCS 3/8"-16 X 5" P5 2
123 BFM-51173 Weight Stack Pull Pin 1
183 BFH-50630 FHSCS 3/8"-16 X 3/4" 2
184 BFH-50631 HCS 3/8"-16 X 1/2" P5 4
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Item # Part # Description Qty
6BFM-51044 Guide Rod Holder 1
9BFM-50529 Rubber Donut 2
10 BFM-50256 Weight Plate 19
12 BFM-51051 Guide Rod 2
38 BFM-51082 Weight Stack Shroud 2
56 BFH-50146 3/8" Flat Washer (Black) 10
58 BFH-50157 3/8"-16 Nylock (Black) 2
60 BFH-50147 3/8" Lock Washer (Black) 6

www.batcafitness.com 15 Fusion 2 Owner’s Manual
Step 5:
Figure 5 Item # Part # Description Qty
15 BFM-10573 Functional Arm Mount 1
16 BFM-10571 User Right Functional Arm 1
17 BFM-10572 User Left Functional Arm 1
36 BFM-10582 Functional Arm Swivel Pulley 2
56 BFH-50146 3/8" Flat Washer (Black) 4
58 BFH-50157 3/8"-16 Nylock (Black) 2
61 BFH-50119 HCS 3/8"-16 1 1/4" P5 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

Batca Fitness Systems 16 Fusion 2 Owner's Manual
Figure 6
Item # Part # Description Qty
20 BFM-10577 8" Telespar 1
24 BFM-10579 10" Chrome Adjustment 1
33 BFM-10581 Leg Extension/ Curl Frame 1
53 BFM-51143 8” Anti-Deflection Plate 1
56 BFH-50146 3/8" Flat Washer (Black) 6
58 BFH-50157 3/8"-16 Nylock (Black) 4
64 BFH-50251 1/2" Flat Washer Black 2
66 BFH-50139 HCS 1/2-13 X 4 1/4 P5 1
68 BFH-50155 1/2"-13 Nylock (Black) 1
74 BFH-50132 HCS 3/8"-16 X 5 1/2" P5 2
115 BFH-50144 FHSCS 3/8"-16 X 1" 2
122 BFM-50931 3” Axle 1
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 6:
8” Anti-Deflection Plate

www.batcafitness.com 17 Fusion 2 Owner’s Manual
Step 7:
Figure 7
Item # Part # Description Qty
21 BFM-10578 Seat Frame Assembly 1
30 BFM-10580 Back Chrome Adjustment 1
64 BFH-50251 1/2" Flat Washer (Black) 4
65 BFH-50138 HCS 1/2”-13 X 3 1/2” P5 1
67 BFH-50136 HCS 1/2”-13 X 3” P5 1
68 BFH-50155 1/2"-13 Nylock (Black) 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

Batca Fitness Systems 18 Fusion 2 Owner's Manual
Step 8:
Figure 8
Item # Part # Description Qty
25 BFM-10141 Knee Alignment Roller 1
39 BFM-10584 Leg Extension Shaft 1
40 BFM-10585 Leg Extension Cam Assembly 1
55 BFH-50165 1" Snap Ring 1
58 BFH-50157 3/8"-16 Nylock (Black) 1
70 BFH-50121 HCS 3/8"-16 X 2" P5 1
119 BFH-50245 FHSCS 5/16"-18 X 1" 2
121 BFM-50222 2 9/16” Axle 1
182 BFH-50337 Wavy Washer 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

www.batcafitness.com 19 Fusion 2 Owner’s Manual
Step 9:
Figure 9
Item # Part # Description Qty
42 BFM-10586 Leg Extension Arm Assembly 1
44 BFL-50207 Hold Down Adjustment Plate 1
45 BFL-50211 Plate 1
46 BFM-10587 Knee Hold Down Assembly 1
47 BFM-51094 2” Axle 1
55 BFH-50165 1" Snap Ring 2
56 BFH-50146 3/8" Flat Washer (Black) 6
58 BFH-50157 3/8"-16 Nylock (Black) 3
63 BFH-50125 HCS 3/8"-16 X 3" P5 3
182 BFH-50337 Wavy Washer 1
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

Batca Fitness Systems 20 Fusion 2 Owner's Manual
Figure 10
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Item # Part # Description Qty
8BFH-50173 3 1/2" Pulley 2
56 BFH-50146 3/8" Flat Washer (Black) 6
57 BFH-50122 HCS 3/8"-16 X 2 1/4" P5 3
58 BFH-50157 3/8"-16 Nylock (Black) 3
92 BFH-50256 1/2” Jam Nut 1
94 BFM-10611 Criss-Cross Free Floater 1
95 BFH-50174 4 1/2" Pulley 1
109 CAB-13022 Fusion Weight Stack to Cable Tie Out 1
113 BFH-50250 1 1/4" Shoulder Bolt 1
114 BFH-50267 5/16"-18 Nylock (Black) 1
71 5/8”
Cable Routing
Step 10:
Note: Each Cable with a threaded bolt on
either end must be threaded at least
1/2” into its attachment.