Batca fusion 4 User manual

www.batcafitness.com Fusion 4 Upper Body Station
March 2012
Revision 1
Serial Number Here
Date of Purchase
Owner’s Manual
Upper Body Unit
1207 New Hope Road, Raleigh, NC - 919.255.1233 - www.batcafitness.com

Batca Fitness Systems 2 Fusion 4 Upper Body Station
__________ Page
Instructions 2
Parts Listing 3-4
Hardware Comparison 5-8
Main Frame Assembly 9-13
Cable Routing 14-17
Upholstery 18
Functional Arm Option 19
__________ Page
Functional Arm Cable Routing 20-21
Weight Stack Decals and Serial Number 22
Cable Tension and Adjustments 23-25
Final Assembly and Troubleshooting 26
Maintenance 27
Warranty 28
Floor plan Layout 29
Table of Contents
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
Instructions
Warning
Congratulations on the purchase of your new Fusion 4 Upper Body Station. 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 performance, 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.

www.batcafitness.com 3 Fusion 4 Upper Body Station
ITEM
NO. PART NO. DESCRIPTION QTY
1 BFM-10566 Right Vertical Support 1
2 BFM-10593 Rear Base 1
3 BFM-10753 Middle Frame Assembly 1
4 BFM-10770 Front Base Support 1
5 BFM-10583 Top Swivel Pulley Holder 2
6 BFM-10567 Left Vertical Support 1
7 BFM-10299 Top Weight Plate 1
8 BFM-51082 Shroud 2
9 BFM-51487 Guide Rod Holder 1
10 BFM-51051 Guide Rod 2
11 BFM-50256 Weight Stack Plate 19
12 BFM-50529 Rubber Donut 2
13 BFM-10733 Right Swing Arm Assembly 1
14 BFM-10737 Left Swing Arm Assembly 1
15 BFM-10735 Right Press Arm Assembly 1
16 BFM-10736 Left Press Arm Assembly 1
17 BFM-51148 1” Arm Shaft 1
18 BFM-51080 Spacer 1
19 BFM-10741 Seat Frame Assembly 1
20 BFM-10580 Back Chrome Adjustment 1
21 BFM-10577 8” Adjustment Sleeve 1
22 BFM-10579 10” Chrome Adjustment 1
23 BFM-50931 Threaded Axle 1
24 BFM-10755 Press Arm Cable Lockout 1
25 BFM-10611 Criss-Cross Free Floater 1
26 BFM-10133 Free Floater 2
27 BFM-50345 4-1/2” Pulley Cover 2
28 BFM-51022 1-1/4” Pulley Spacer 6
29 BFM-50505 3-1/2” Pulley Cover 8
30 BFL-50197 Middle Frame Connector Plate 2
89 BFM-52410 Front Shroud with Logo 1
92 BFM-52416 Swivel Pulley Counter Weight 2
Accessories
Upholstery
ITEM NO. PART NO. DESCRIPTION QTY
31 BFM-51173 Weight Stack Pull
Pin
1
32 BFM-10771 Press Arm Lock 1
33 BFC-10103 Strap Handle 2
ITEM NO. PART NO. DESCRIPTION QTY
34 BFU-10118 Bottom Pad 1
35 BFU-10119 Head Pad 1
36 BFU-10120 Back Pad With Lumbar 1
37 BFU-50189 7” Upholstery Roller 2
Hardware
ITEM NO. PART NUMBER DESCRIPTION QTY
41 BFH-50253 Beveled Leveler 2
42 BFH-50337 Wavy Washer 4
43 BFH-50165 1” Snap Ring 6
44 BFH-50149 3/8” Jam Nut 2
45 BFP-52394 SHCS 3/8”-16 x 2-1/2” 2
46 BFP-51799 SHCS 3/8”-16 x 5” 4
47 BFP-51756 SHCS 3/8”-16 x 5-1/4” 6
48 BFH-50146 3/8” Flat Washer 82
49 BFH-50147 3/8” Lock Washer 16
50 BFH-50157 3/8” Nylock 39
51 BFP-52340 SHCS 3/8”-16 x 3/4” 2
52 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
53 BFH-50144 FHSCS 3/8”-16 x 3/4” 2
54 BFH-50220 Shaft Collar 2
55 BFP-52400 SHCS 1/2”-13 x 4 1/4” 1
56 BFH-51201 SHCS1/2”-13 x 3 1/2 ” 1
57 BFP-51747 SHCS 3/8”-16 x 3” 2
58 BFH-50251 1/2” Flat Washer 2
ITEM NO. PART NUMBER DESCRIPTION QTY
60 BFP-51653 SHCS 3/8”-16 x 1-1/4” 4
61 BFH-50173 3-1/2” Pulley 16
62 BFH-50174 4 1/2” Pulley 6
63 BFH-50250 1-1/4” Shoulder Bolt 3
64 BFH-50267 5/16” Nylock 3
65 BFP-51752 SHCS 3/8”-16 x 2-1/4” 2
66 BFH-50204 3/8” Curved Washer 4
67 BFH-50203 1/2” Curved Pulley Spacer 8
68 BFP-51759 SHCS 3/8”-16 x 2” 4
69 BFP-51750 SHCS 3/8”-16 x 2-3/4” 8
70 BFP-51753 SHCS 3/8”-16 x 4-3/4” 6
71 BFH-50622 Roller End Cap 2
72 BFP-52430 BHSCS 3/8”-16 x 3/4” 2
73 BFP-52398 SHCS 3/8”-16 x 7” 1
74 BFP-52397 SHCS 1/2”-13 x 3” 1
87 BFH-50192 Weight Stack Decals 1
88 BFH-50262 Silicon Gel Pack 1
90 BFH-50620 BHSCS 3/8” x 1” 2
91 BFM-52421 1 1/2” Aluminum Cap 2
Cables
ITEM
NO. PART NO. DESCRIPTION QTY
38 CAB-13022 Weight Stack to Cable Tie Out 1
39 CAB-13030 Fusion Floating Pulley Cable 1
40 CAB-13031 Fusion Lat Pull to Cable Lockout 2
86 CAB-13032 Fusion Lat Pull to Functional
Arm
2
Frame Components

Batca Fitness Systems 4 Fusion 4 Upper Body Station
Functional Arm 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
Functional Arm Hardware
ITEM NO. PART NUMBER DESCRIPTION Qty
74 BFM-10573 Functional Arm Mount 1
75 BFM-10571 User Right Functional Arm 1
76 BFM-10572 User Left Functional Arm 1
77 BFM-10582 Functional Arm Swivel Pulley 2
ITEM NO. PART NUMBER DESCRIPTION Qty
79 BFH-50146 3/8” Flat Washer 16
80 BFH-50157 3/8” Nylock 14
81 BFH-50173 3-1/2” Pulley 8
82 BFP-51752 SHCS 3/8”-16 x 2-1/4” 8
83 BFP-51759 SHCS 3/8”-16 x 2” 6
Functional Arm Accessories
ITEM NO. PART NUMBER DESCRIPTION Qty
84 BFH-10103 Strap Handle 2
Cables
ITEM NO. PART NUMBER DESCRIPTION Qty
85 CAB-13032 Fusion Lat Pull to Functional Arm 2

www.batcafitness.com 5 Fusion 4 Upper Body Station
Bolt Length Note: Bolt length is
measured from the underside
of the head of the bolt.

Batca Fitness Systems 6 Fusion 4 Upper Body Station

www.batcafitness.com 7 Fusion 4 Upper Body Station

Batca Fitness Systems 8 Fusion 4 Upper Body Station

www.batcafitness.com 9 Fusion 4 Upper Body Station
Step 1:
 All Flat Washers and Nylocks are
3/8” unless otherwise noted.
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
Next Step
Item # Part # Description Qty
44 BFH-50149 3/8” Jam Nut 2
45 BFP-52394 SHCS 3/8”-16 x 2 1/2” 1
46 BFP-551799 SHCS 3/8”-16 x 5” 1
47 BFP-51756 SHCS 3/8”-16 x 5 1/4” 6
48 BFH-50146 3/8” Flat Washer 15
49 BFH-50147 3/8” Lock Washer 1
50 BFH-50157 3/8” Nylock 7
Item # Part # Description Qty
1 BFM-10566 Right Vertical Support 1
2 BFM-10593 Rear Base 1
3 BFM-10753 Middle Frame Assembly 1
4 BFM-10770 Front Base Support 1
5 BFM-10583 Top Swivel Pulley Holder 1
30 BFL-50197 Middle Frame Connector Plate 2
41 BFH-50253 Beveled Leveler 2
42 BFH-50337 Wavy Washer 1
43 BFH-50165 1” Snap Ring 2

Batca Fitness Systems 10 Fusion 4 Upper Body Station
Figure 2
Step 2:
Item # Part # Description Qty
5 BFM-10583 Top Swivel Pulley Holder 1
6 BFM-10567 Left Vertical Support 1
7 BFM-10299 Top Weight Plate 1
8 BFM-51082 Shroud 2
89 BFM-52410 Front Shroud with Logo 1
9 BFM-51487 Guide Rod Holder 1
10 BFM-51051 Guide Rod 2
11 BFM-50256 Weight Stack Plate 19
12 BFM-50529 Rubber Donut 2
31 BFM-51173 Weight Stack Pull Pin 1
42 BFH-50337 Wavy Washer 1
43 BFH-50165 1” Snap Ring 2
45 BFP-52394 SHCS 3/8”-16 x 2 1/2” 1
46 BFP-51799 SHCS 3/8”-16 x 5” 3
48 BFH-50146 3/8” Flat Washer 13
All Flat Washers and Nylocks are 3/8” unless
Item # Part # Description Qty
49 BFH-50147 3/8” Lock Washer 7
50 BFH-50157 3/8” Nylock 3
51 BFP-52340 SHCS 3/8”-16 x 3/4” 2
52 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
53 BFH-50144 FHSCS 3/8”-16 x 3/4” 2
This 3/8” Nylock
and Flat Washer
are from step 1.
DO NOT remove the ny-
lock or install the Left
Vertical Support until
the Weight Stack and
the Shrouds have been
completely assembled.
Assemble Last
(see note below)
Do Not Tighten
Hardware Until
Next Step
BHSCS
3/8” X 1/2”
(Qty=4)

www.batcafitness.com 11 Fusion 4 Upper Body Station
Figure 3
Item # Part # Description Qty
13 BFM-10733 Right Swing Arm Assembly 1
14 BFM-10737 Left Swing Arm Assembly 1
15 BFM-10735 Right Press Arm Assembly 1
16 BFM-10736 Left Press Arm Assembly 1
17 BFM-51148 1” Arm Shaft 1
18 BFM-51080 Spacer 1
Step 3:
Item # Part # Description Qty
32 BFM-10771
Press Arm Lock
(Optional) 1
42 BFH-50337 Wavy Washer 2
90 BFH-50620 BHSCS 3/8” x 1” 2
54 BFH-50220 Shaft Collar 2
91 BFM-52421 1 1/2” Aluminum Cap 2
Make Sure All
Hardware Is
Tightened Before
Next Step.
*
* See the sheet pack-
aged with the Press Arm
Lock for instructions if
you wish to lock the
Press Arms together.
Press Arm Lock*
(Optional)
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 12 Fusion 4 Upper Body Station
Figure 4
Step 4:
All Flat Washers and Nylocks
are 3/8” unless otherwise noted.
Item # Part # Description Qty
34 BFU-50118 Bottom Pad 1
19 BFM-10741 Seat Frame Assembly 1
20 BFM-10580 Back Chrome Adjustment 1
21 BFM-10577 8” Adjustment Sleeve 1
22 BFM-10579 10” Chrome Adjustment 1
23 BFM-50931 Threaded Axle 1
48 BFH-50146 3/8” Flat Washer 2
49 BFH-50147 3/8” Lock Washer 2
55 BFP-52400 SHCS 1/2”-13 x 4 1/4” 1
56 BFH-51201 SHCS1/2”-13 x 3 1/2 ” 1
57 BFP-52397 SHCS 3/8”-16 x 3” 2
58 BFH-50251 1/2” Flat Washer 2
50 BFH-50157 3/8” Nylock 2
74 BFH-50136 SHCS 1/2”-13 x 3” 1
Note: Make sure the
Bottom Pad is bolted
on before the Seat Frame
Assembly is installed.

www.batcafitness.com 13 Fusion 4 Upper Body Station
Step 5:
Figure 5
Item # Part # Description Qty
24 BFM-10755 Press Arm Cable Lockout 1
48 BFM-50146 3/8” Flat Washer 4
50 BFM-50157 3/8” Nylock 2
60 BFP-51653 SHCS 3/8”-16 x 1 1/4” 2
NOTE: If Functional Arm Option
is purchased then skip this step
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 14 Fusion 4 Upper Body Station
Figure 6
Item # Part # Description Qty
25 BFM-10611 Criss-Cross Free Floater 1
38 CAB-13022 Weight Stack to Cable Tie Out 1
48 BFH-50146 3/8” Flat Washer 6
50 BFH-50157 3/8” Nylock 3
61 BFH-50173 3 1/2” Pulley 2
62 BFH-50174 4 1/2” Pulley 1
63 BFH-50250 1 1/4” Shoulder Bolt 1
64 BFH-50267 5/16” Nylock 1
65 BFP-51752 SHCS 3/8”-16 x 2 1/4” 3
Step 6:
Note: Each Cable with
a threaded bolt on
either end must be
threaded at least 1/2” into
its attachment.
Cable Routing
71 5/8”
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
CAB-13022

www.batcafitness.com 15 Fusion 4 Upper Body Station
Step 7:
Figure 7
Item # Part # Description Qty
26 BFM-10133 Free Floater 2
27 BFM-50345 4 1/2” Pulley Cover 2
39 CAB-13030 Fusion Floating Pulley Cable 1
45 BFP-51653 SHCS 3/8”-16 x 2 1/4” 3
48 BFH-50146 3/8” Flat Washer 8
50 BFH-50157 3/8” Nylock 4
62 BFH-50174 4 1/2” Pulley 5
73 BFP-52398 SHCS 3/8”-16 x 7” 1
96 9/16”
CAB-13030
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 16 Fusion 4 Upper Body Station
Step 8:
Figure 12
Item
# Part # Description Qty
40 CAB-13031
Fusion Lat Pull to Cable
Lockout 1
28 BFM-51022 1 1/4” Pulley Spacer 3
29 BFM-50505 3 1/2” Pulley Cover 4
48 BFH-50146 3/8” Flat Washer 10
50 BFH-50157 3/8” Nylock 9
61 BFH-50173 3 1/2” Pulley 7
63 BFH-50250 1 1/4” Shoulder Bolt 1
Note: Each Cable with a
threaded bolt on either end must
be threaded at least 1/2” into its
attachment.
Note: If Functional Arm
Option is purchased
Item
# Part # Description Qty
64 BFH-50267 5/16” Nylock 1
66 BFH-50204 3/8” Curved Washer 2
67 BFH-50203 3/8” Curved Pulley Spacer 4
68 BFP-51759 SHCS 3/8”-16 x 2” 2
69 BFP-51750 SHCS 3/8”-16 x 2 3/4” 3
65 BFP-51752 SHCS 3/8”-16 x 2 1/4” 1
70 BFP-51753 SHCS 3/8”-16 x 4 3/4” 3
163 13/16”
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
CAB-13031

www.batcafitness.com 17 Fusion 4 Upper Body Station
Step 8 Continued:
A
A
B
B
C
C
Step 9: Repeat for alternate side of Fusion. Use same Bill of
Materials from Step 8 for Step 9. Use CAB-13031, Fusion Lat Pull to
Cable Lockout.
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 18 Fusion 4 Upper Body Station
Figure 10
Item # Part # Description Qty
33 BFC-10103 Strap Handle 2
35 BFU-10119 Head Pad 1
36 BFU-10120 Back Pad With Lumbar 1
37 BFU-50189 7” Upholstery Roller 2
48 BFH-50146 3/8” Flat Washer 4
Step 10:
Item # Part # Description Qty
49 BFH-50147 3/8” Lock Washer 4
60 BFP-51653 SHCS 3/8”-16 x 1 1/4” 2
69 BFP-51750 SHCS 3/8”-16 x 2 3/4” 2
71 BFH-50622 Roller End Cap 2
72 BFH-50620 BHSCS 3/8”-16 x 3/4” 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

www.batcafitness.com 19 Fusion 4 Upper Body Station
Figure 11
Item # Part # Description Qty
74 BFM-10573 Functional Arm Mount 1
75 BFM-10571 User Right Functional Arm 1
76 BFM-10572 User Left Functional Arm 1
77 BFM-10582 Functional Arm Swivel Pulley 2
48 BFH-50146 3/8” Flat Washer 8
50 BFH-50157 3/8” Nylock 4
60 BFP-51653 SHCS 3/8”-16 x 1 1/4” 2
65 BFH-51752 SHCS 3/8” x 2 1/4” 2
92 BFM-52416 Swivel Pulley Counter Weight 2
Step 11:
Functional Arm Option
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 20 Fusion 4 Upper Body Station
Step 12:
Figure 12
Note: Each Cable with a
threaded bolt on either end
must be threaded at least 1/2”
into its attachment.
Item # Part # Description Qty
28 BFM-51022 1 1/4” Spacer 3
29 BFM-50505 3 1/2" Pulley Cover 4
33 BFC-10103 Strap Handle 2
86 CAB-13032 Fusion Lat Pull to Functional Arm 1
48 BFH-50146 3/8" Flat Washer 18
50 BFH-50157 3/8" Nylock 16
61 BFH-50173 3 1/2" Pulley 11
65 BFP-51752 SHCS 3/8"-16 X 2 1/4" 5
66 BFH-50204 3/8" Curved Washer 2
67 BFH-50203 1/2" Curved Pulley Spacer 4
68 BFP-51759 SHCS 3/8"-16 X 2" 5
69 BFP-51750 SHCS-3/8”-16 x 2-3/4” 3
70 BFP-51753 SHCS 3/8"-16 X 4 3/4" 3
200”
CAB-13032
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.