Batca FUSION4 User manual

www.batcafitness.com Fusion 4 Lower Body Station
July 2014
Revision 3
Serial Number Here
Date of Purchase
Owner’s Manual
Lower Body Unit
1207 New Hope Road, Raleigh, NC - 919.255.1233 - www.batcafitness.com

Batca Fitness Systems 2Fusion 4 Lower Body Station
__________ Page
Instructions 2
Parts Listing 3-5
Hardware Comparison 6-9
Main Frame Assembly 10-14
Cable Routing 15-18
Upholstery 19-20
Leg Press Option 21-25
Congratulations on the purchase of your new Fusion 4 Lower 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.
__________ Page
Leg Press Cable Routing 24-25
Weight Stack Decals and Serial Number 26
Cable Tension, Adjustment, and Comparison 27-29
Final Assembly and Troubleshooting 30
Maintenance 31
Warranty 32
Floor plan Layout 33-34
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 (919)
255-1233. www.batcafitness.com
Instructions
Warning

www.batcafitness.com 3 Fusion 4 Lower Body Station
Frame Components
ITEM NO. PART NO. DESCRIPTION QTY
36 BFP-52130 Large Bottom Pad 1
37 BFP-52137 Head Pad 1
38 BFP-52136 Back Pad With Lumbar 1
39 BFU-10122 Large Roller 1
40 BFU-10121 7" Roller 4
ITEM NO. PART NO. DESCRIPTION QTY
1 BFM-10747 Right and Left Vertical Sup-
port
2
2 BFM-10765 Middle Base 1
3 BFM-10593 Rear Base 1
4 BFM-10744 Upper Frame 1
5 BFM-10769 Large Flat Leveler 2
6 BFM-51490 Guide Rod Holder 1
7 BFM-51082 Shroud 1
8 BFM-51051 Guide Rod 2
9 BFM-50256 Weight Plate 19
10 BFM-50529 Rubber Donut 2
11 BFM-10299 Top Weight Plate 1
12 BFM-10581 Leg Extension Curl Frame 1
13 BFM-51143 8” Anti Deflection Plate 1
14 BFM-10141 Knee Alignment Roller 1
15 BFM-10584 Leg Extension Shaft 1
16 BFM-10585 Leg Extension Cam Assembly 1
17 BFM-50222 Axle 1
ITEM NO. PART NO. DESCRIPTION QTY
18 BFM-10742 Leg Extension Arm Assembly 1
19 BFM-10587 Knee Hold Down Assembly 1
20 BFM-51094 Axle 1
21 BFM-10611 Criss-Cross Free Floater 1
22 BFM-10610 Lower Pulley Holder 2
23 BFM-10612 Cable Tie Out Plate 1
24 BFM-50505 3-1/2 Pulley Cover 1
25 BFM-51158 Spacer 1
26 BFM-10588 Knee Hold Down Handle 1
27 BFM-51382 6” Counter Weight 1
28 BFM-10768 Right Handle 1
29 BFM-10767 Left Handle 1
30 BFM-10580 Back Chrome Adjustment 1
31 BFL-50274 Knee Hold Down Adjustment Plate 1
32 BFL-50211 T-Shaped Plate 1
33 BFL-50203 Pulley Holder Connector Plate 1
34 BFL-50221 3-1/2” Double Pulley
Cover
1
125 BFM-52410 Front Shroud 1
Upholstery
Cables
ITEM NO. PART NO. DESCRIPTION QTY
41 CAB-13022 Weight Stack to Cable Tie Out 1
42 CAB-13028 Fusion Free Floater Cable 1
43 CAB-13026 Fusion Tie Out Cable 1
44 CAB-13029 Fusion Leg Extension Cable 1
Accessories
ITEM NO. PART NO. DESCRIPTION QTY
35 BFM-51173 Weight Stack Pin 1

Batca Fitness Systems 4Fusion 4 Lower Body Station
Hardware
ITEM NO. PART NUMBER DESCRIPTION QTY
45 BFP-52394 SHCS 3/8”-16 x 2-1/2” 3
46 BFP-51653 SHCS 3/8”-16 x 1-1/4” 4
47 BFP-51799 SHCS 3/8”-16 x 5” 4
48 BFP-51756 SHCS 3/8”-16 x 5-1/4” 4
49 BFH-50630 FHSCS 3/8”-16 x 3/4” 2
50 BFP-52420 BHSCS 3/8” x 2” 1
51 BFP-52340 SHCS 3/8”-16 x 3/4” 2
52 BFH-50144 FHSCS 3/8”-16 x 1” 2
53 BFP-52396 SHCS 3/8”-16 x 5-1/2” 2
54 BFH-50165 1” Snap Ring 2
55 BFH-50337 Wavy Washer 3
56 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
57 BFH-50245 FHSCS 5/16”-18 x 1” 2
58 BFP-51747 SHCS 3/8”-16 x 3” 5
59 BFH-50174 4-1/2” Pulley 4
60 BFH-50173 3-1/2 Pulley 7
61 BFH-50267 5/16” Nylock 2
62 BFP-51752 SHCS 3/8”-16 x 2-1/4” 9
63 BFH-50250 1-1/4” Shoulder Bolt 2
64 BFP-52397 SHCS 3/8”-16 x 1-3/4” 2
65 BFH-50605 3/8” Pulley Spacer 2
66 BFH-50622 Upholstery Cap 4
67 BFH-50221 3” Plastic Washer 4
68 BFP-51759 HCS 3/8”-16 x 2” 1
69 BFH-50204 Curved Washer 4
70 BFP-52524 SHCS 3/8”-16 x 6 1/4” 1
71 BFP-51750 SHCS 3/8”-16 x 2-3/4” 2
72 BFP-51748 SHCS 3/8”-16 x 3-1/4” 2
73 BFH-50146 3/8” Flat Washer 70
74 BFH-50157 3/8” Nylock 31
75 BFH-50147 3/8” Lock Washer 17
76 BFH-50192 Weight Stack Decals 1
77 BFH-50262 Silicon gel Pack 1
99 BFP-52430 BHSCS 3/8-16 x 3/4” 4
126 BMF-52422 Red Pivot Point Cap 1
127 BFH-50620 BHSCS 3/8” x 1” 1

www.batcafitness.com 5 Fusion 4 Lower Body Station
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
87 BFP-51696 Small Aluminum End Cap 2
88 BFH-50173 3 1/2” Pulley 5
89 BFH-50605 3/8” Pulley Spacer 5
90 BFP-51700 BHSCS 3/8” x 1” 4
91 BFH-50351 1 3/8” Shoulder Bolt 1
92 BFP-51653 SHCS 3/8” x 1 1/4” 2
93 BFP-52397 SHCS 3/8” x 1 3/4” 1
94 BFP-51759 SHCS 3/8” x 2” 2
ITEM NO. PART NUMBER DESCRIPTION Qty
95 BFP-52394 SHCS 3/8” x 2 1/2” 2
96 BFP-51750 SHCS 3/8” x 2 3/4” 2
97 BFP-51756 SHCS 3/8"-16 X 5 1/4" 4
98 BFM-50267 5/16 Nylock 1
99 BFH-50147 3/8” Lock Washer 4
100 BFH-50146 3/8" Flat Washer (Black) 24
101 BFH-50157 3/8"-16 Nylock (Black) 10
105 BFP-51747 3/8”-16 x 3” 2
ITEM NO. PART NUMBER DESCRIPTION Qty
84 BFM-11040 Right Handel 1
85 BFM-11041 Left Handle 1
86 BFM-10106 Back Adjustment Tube 1
ITEM NO. PART NUMBER DESCRIPTION Qty
76 BFM-10575 Leg Press Connector 1
77 BFM-11042 Leg Press Frame 1
78 BFM-11034 Four Bar 2
79 BFM-52449 Four Bar Spacer 2
80 BFM-11035 Leg Press Pivot Arm 1
81 BFP-51844 1” Shaft 2
82 BFP-51846 3/4” Shaft 2
83 BFM-11036 Leg Press Foot Plate 1
ITEM NO. PART NUMBER DESCRIPTION Qty
103 BFP-52130 Large Bottom Pad 1
104 BFP-52136 Back Pad With Lumbar 1

Batca Fitness Systems 6Fusion 4 Lower Body Station
Bolt Length Note: Bolt length is measured from
the underside of the head of the bolt.

www.batcafitness.com 7 Fusion 4 Lower Body Station
Beveled Leveler
BFH-50253
Upholstery
Cap
3” Plastic
Washer
Large Flat Leveler
BFH-50339
3 1/2” Pulley
BFH-50173
Threaded
Bearing
BFH-10002
Pin
BFH-50238
4 1/2” Pulley
BFH-50174
Cable Strap
BFH-50227
Strap Handle
BFC-10103
Snap Hook
BFH-50188

Batca Fitness Systems 8Fusion 4 Lower Body Station

www.batcafitness.com 9 Fusion 4 Lower Body Station

Batca Fitness Systems 10 Fusion 4 Lower Body Station
Step 1:
Item # Part # Description Qty
1 BFM-10747 Right Vertical Support 1
2 BFM-10765 Middle Base 1
3 BFM-10593 Rear Base 1
4 BFM-10744 Upper Frame 1
5 BFM-10769 Large Flat Leveler 2
45 BFP-52394 SHCS 3/8”-16 x 2 1/2 1
46 BFP-51653 SHCS 3/8”-16 x 1 1/4 2
47 BFP-51799 SHCS 3/8”-16 x 5” 1
48 BFP-51756 SHCS 3/8"-16 X 5 1/4" 2
73 BFH-50146 3/8” Flat Washer 11
74 BFH-50157 3/8” Nylock 5
75 BFH-50147 3/8” Lock Washer 1
PLEASE FOLLOW ALL DIRECTIONS VERY CAREFULLY FOR
PROPER INSTALLATION.
Note: For a more consistent
appearance, position all bolts in
the direction shown in each
 All Flat Washers and Nylocks are
3/8” unless otherwise noted.
Figure 1
Do Not Tighten
Hardware Until
Next Step

www.batcafitness.com 11 Fusion 4 Lower Body Station
Figure 2
Step 2:
Item # Part # Description Qty
1 BFM-10747 Left Vertical Support 1
6 BFM-51490 Guide Rod Holder 1
7 BFM-51082 Shroud 1
125 BFM-52410 Front Shroud 1
8 BFM-51051 Guide Rod 2
9 BFM-50256 Weight Plate 19
10 BFM-50529 Rubber Donut 2
11 BFM-10299 Top Weight Plate 1
35 BFM-51173 Weight Stack Pin 1
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Make Sure All
Hardware Is
Tightened Before
Next Step.
Item # Part # Description Qty
45 BFP-52394 SHCS 3/8”-16 x 2-1/2” 1
47 BFP-51799 SHCS 3/8”-16 x 5” 3
49 BFH-50630 FHSCS 3/8"-16 x 3/4” 2
56 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
51 BFH-52340 SHCS 3/8”-16 x 3/4” 2
73 BFH-50146 3/8” Flat Washer 13
74 BFH-50157 3/8” Nylock 3
75 BFH-50147 3/8” Lock Washer 7
This 3/8” Nylock and
Flat Washer are
from step 1. DO NOT
remove the nylock
or install the Left
Vertical Support until the
Weight Stack and the
Shrouds have been
completely assembled.
Assemble Last
(see note)
BHSCS
3/8” X 1/2”
(Qty=4)

Batca Fitness Systems 12 Fusion 4 Lower Body Station
Figure 3
Item # Part # Description Qty
12 BFM-10581 Leg Extension Curl Frame 1
13 BFM-51143 8” Anti Deflection Plate 1
52 BFH-50144 FHSCS 3/8”-16 x 1” 2
53 BFP-52396 SHCS 3/8”-16 x 5 1/2” 2
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 4
Step 3:
All Flat Washers and Nylocks are 3/8” unless
otherwise noted.

www.batcafitness.com 13 Fusion 4 Lower Body Station
Figure 4
Step 4:
Item # Part # Description Qty
14 BFM-10141 Knee Alignment Roller 1
15 BFM-10584 Leg Extension Shaft 1
16 BFM-10585 Leg Extension Cam Assembly 1
17 BFM-50222 Axle 1
54 BFH-50165 1” Snap Ring 1
55 BFH-50337 Wavy Washer 2
68 BFP-52420 BHSCS 3/8"-16 x 2” 1
57 BFM-50245 FHSCS 5/16” x 1” 2
74 BFH-50157 3/8" Nylock 1
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
BHSCS 3/8” x2”

Batca Fitness Systems 14 Fusion 4 Lower Body Station
Step 5:
Figure 5
Item # Part # Description Qty
18 BFM-10742 Leg Extension Arm Assembly 1
19 BFM-10587 Knee Hold Down Assembly 1
20 BFM-51094 Axle 1
31 BFL-50274
Knee Hold Down Adjustment
Plate 1
32 BFL-50211 T-Shaped Plate 1
54 BFH-50165 1” Snap Ring 1
55 BFH-50337 Wavy Washer 1
58 BFP-51747 SHCS 3/8”-16 x 3” 3
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 3
126 BFM-52422 Red Pivot Point Cap 1
127 BFH-50620 BHSCS 3/8” x 1” 1
T-Shaped
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

www.batcafitness.com 15 Fusion 4 Lower Body Station
Figure 6
Item # Part # Description Qty
21 BFM-10611
Criss-Cross Free
Floater 1
41 CAB-13022
Weight Stack to Cable Tie
Out 1
59 BFH-50174 4 1/2” Pulley 1
60 BFH-50173 3 1/2” Pulley 2
61 BFH-50267 5/16” Nylock 1
62 BFP-51752 SHCS 3/8”-16 x 2 1/4 3
63 BFH-50250 1-1/4” Shoulder Bolt 1
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 3
Step 6:
Note: Each Cable with a threaded
bolt on either end must be
threaded at least 1/2” into its
attachment.
71 5/8”
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
CAB-13022

Batca Fitness Systems 16 Fusion 4 Lower Body Station
Step 7:
Figure 7
Item # Part # Description Qty
22 BFM-10610 Lower Pulley Holder 2
42 CAB-13028
Fusion Free Floater Ca-
ble 1
59 BFH-50174 4 1/2” Pulley 3
62 BFP-51752 SHCS 3/8”-16 x 2 1/4” 3
73 BFH-50146 3/8” Flat Washer 6
74 BFH-50157 3/8” Nylock 3
86 5/16”
CAB-13028
All Flat Washers and Nylocks are 3/8” unless
otherwise noted.

www.batcafitness.com 17 Fusion 4 Lower Body Station
Step 8:
Figure 8
Item # Part # Description Qty
23 BFM-10612 Cable Tie Out Plate 1
33 BFL-50203
Pulley Holder Connector
Plate 1
43 CAB-13026 Fusion Cable Tie Out 1
48 BFP-51756 SHCS 3/8”-16 x 5 1/4” 2
73 BFH-50146 3/8” Flat Washer 4
74 BFH-50157 3/8” Nylock 2
22 5/8”
Note: Each Cable with a threaded
bolt on either end must be
threaded at least 1/2” into its
attachment.
Note: If Leg Press Option is purchased
skip this step and continue to step 9.
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
CAB-13026

Batca Fitness Systems 18 Fusion 4 Lower Body Station
Step 9:
Figure 9
Item # Part # Description Qty
24 BFM-50505 3 1/2” Pulley Cover 1
25 BFM-51158 Spacer 1
34 BFL-50221
3 1/2” Double Pulley
Cover 1
44 CAB-13029
Fusion Leg Extension
Cable 1
45 BFP- SHCS 3/8”-16 x 2 1/2” 1
60 BFH-50173 3 1/2” Pulley 5
61 BFM-50267 5/16” Nylock 1
62 BFP-51752 SHCS 3/8”-16 x 2 1/4 3
63 BFH-50250 1 1/4 Shoulder Bolt 1
64 BFP-52397 SHCS 3/8”-16 x 1 3/4” 1
65 BFH-50605 3/8” Pulley Spacer 2
73 BFH-50146 3/8” Flat Washer 7
74 BFH-50157 3/8” Nylock 5
75 BFH-50147 3/8” Lock Washer 4
91 1/4”
CAB-13029
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

www.batcafitness.com 19 Fusion 4 Lower Body Station
Step 10:
Figure 10
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
Item # Part # Description Qty
26 BFM-10588 Knee Hold Down Handle 1
27 BFM-51382 6” Counter Weight 1
36 BFU-10121 7” Upholstery Roller 4
39 BFU-10122 Large Upholstery Roller 1
64 BFP-52397 SHCS 3/8”-16 x 1-3/4 1
66 BFH-50622 Upholstery Cap 4
67 BFH-50221 3” Plastic Washer 4
99 BFP-52430 BHSCS 3/8”-16 x 3/4” 4
69 BFH-50204 Curved Washer 4
70 BFP-52524 SHCS 3/8”-16 x 6 1/4” 1
73 BFH-50146 3/8” Flat Washer 1
74 BFH-50157 3/8” Nylock 1
75 BFH-50147 3/8” Lock Washer 2

Batca Fitness Systems 20 Fusion 4 Lower Body Station
Item # Part # Description Qty
28 BFM-10768 Right Handle 1
29 BFM-10767 Left Handle 1
30 BFM-10580 Back Chrome Adjusment 1
36 BFP-52130 Large Bottom Pad 1
37 BFP-52137 Head Pad 1
38 BFP-52136 Back Pad With Lumbar 1
46 BFP-51653 SHCS 3/8"-16 X 1 1/4” 2
58 BFP-51747 SHCS 3/8”-16 x 3” 2
71 BFP-51750 SHCS 3/8"-16 X 2 3/4” 2
72 BFP-51748 SHCS 3/8"-16 X 3 1/4” 2
73 BFH-50146 3/8” Flat Washer 10
74 BFH-50157 3/8” Nylock 2
75 BFH-50147 3/8” Lock Washer 6
Step 11:
Figure 11