Batca Fusion 3 User manual

www.batcafitness.com Fusion 3 Owner's Manual
JULY 2020
Serial Number Here
Date of Purchase
Owner’s Manual

Batca Fitness Systems 2Fusion 3 Owner's Manual
Page
Instructions 2
Hardware Blister Packs 3-6
Main Frame Assembly 7-16
Cable Routing 17-21
Upholstery 22-23
Leg Press Option 24-30
Leg Press Cable Routing 28
Page
Leg Press Attachment 30
Cable Tension and Adjustments 31-32
Weight Stack Decals and Serial Number 33
Final Assembly and Troubleshooting 34
Maintenance 35
Warranty 36
Floor plan Layout 37-38
Congratulations on the purchase of your new Batca Fusion 3 Personal Gym. 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 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 rst 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 reect total quantities for your gym and may not reect 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.
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 rst 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
Table of Contents
Instructions
Warning

www.batcafitness.com 3Fusion 3 Owner's Manual
Tools Required
• 9/16” Wrench/Ratchet
• 1/2” Wrench/Rachet
• Metric Allen Wrench Set (M10, M8, M6,
M4)
• Utility Knife
• 3/4” Wrench
• Tape Measure
• Snap Ring Pliers
Hardware Blister Packs

Batca Fitness Systems 4Fusion 3 Owner's Manual
Hardware Blister Packs

www.batcafitness.com 5Fusion 3 Owner's Manual
Hardware Blister Packs

Batca Fitness Systems 6Fusion 3 Owner's Manual
Hardware Blister Packs

www.batcafitness.com 7Fusion 3 Owner's Manual
Part # Description Qty
BFM-10593 Rear Base 1
BFM-10566 Left Vertical Support 1
BFM-10567 Right Vertical Support 1
BFM-10568 Middle Base 1
BFM-10583 Top Swivel Pulley 2
BFH-50165 1” Snap Ring 4
BFH-50146 3/8" Flat Washer (Black) 8
BFH-50157 3/8"-16 Nylock (Black) 4
BFP-51756 SHCS 3/8"-16 X 5 1/4" P5 2
BFP-51799 SHCS 3/8-16 X 5" P5 2
BFH-50337 Wavy Washer 2
BFM-11038 Short Bar Holder 1
Step 1:
Note: Please Position Hardware in the same direction as shown in the figure. This will
make future steps easier to assemble
PLEASE READ AND FOLLOW ALL DIRECTIONS VERY CAREFULLY FOR PROPER INSTALLATION.
All Flat Washers and Nylocks are 3/8” unless otherwise noted. Anywhere a washer is against the
round side of a tube there is to be a 3/8” CURVED WASHER instead of a 3/8” FLAT WASHER.
DO NOT TIGHTEN BOLTS UNTIL STEP 4

Batca Fitness Systems 8Fusion 3 Owner's Manual
Part # Description Qty
BFM-10569 Middle Pole Assembly 1
BFL-50197 Middle Pole Connector Plate 2
BFH-50146 3/8" Flat Washer (Black) 10
BFH-50157 3/8"-16 Nylock (Black) 4
BFP-51756 SHCS 3/8"-16 X 5 1/4" P5 4
BFH-50147 3/8” Lock Washer (Black) 2
BFP-52394 SHCS 3/8"-16 X 2 1/2" P5 2
BFH-50253 Beveled Leveler 2
BFH-50149 3/8"-16 Jam Nut (Zinc) 4
BFH-50339 Large Flat Leveler 2
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 2: DO NOT TIGHTEN BOLTS UNTIL STEP 4

www.batcafitness.com 9Fusion 3 Owner's Manual
Part # Description Qty
BFM-10771 Press Arm Lock (Optional) 1
BFM-10736 Right Press Arm Assembly 1
BFM-10737rev1 Right Swing Arm Assembly 1
BFM-10733rev1 Left Swing Arm Assembly 1
BFM-10735 Left Press Arm Assembly 1
BFM-51080 .45” Spacer 1
BFM-51148 1" Arm Shaft 1
BFH-50337 Wavy Washer 2
BFH-50620 BHSCS 3/8” x 1” 2
BFM-52421 1 1/2” Aluminum Cap 2
BFH-50220 1” Shaft Collar 2
Step 3: DO NOT TIGHTEN BOLTS UNTIL STEP 4
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
The Press Arm Lock is an *optional
component that allows the user to
connect both press arms so they are
engaged at the same time. If the user
would rather have each press arm
operate independently then do not
install the Press Arm Lock.
It is crucial to make sure the Small
Beveled Levelers behind the press
arms are adjusted equally so there is
the same amount of thread showing
on each side. This ensures the
starting position of each press arm is
exactly the same. This will help
prolong the life of the cables and
machine when adjusted properly

Batca Fitness Systems 10 Fusion 3 Owner's Manual
Part # Description Qty
BFM-52467 Free Floater Guide Rod 2
BFM-11177 Free Floater Assembly 2
BFP-52376 SHCS 3/8” x 1” 2
BFH-50144 FHSCS 3/8” x 1” 2
BFH-50147 3/8” Lock Washer 2
BFH-50146 3/8” Flat Washer 2
Step 4: DO NOT TIGHTEN BOLTS UNTIL STEP 5
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Note: Each Guide Rod must
be properly Lubed with a
Silicone Based Teon Gel to
ensure smooth operation and
optimal performance.

www.batcafitness.com 11 Fusion 3 Owner's Manual
Part # Description Qty
BFM-52410 Weight Stack Shroud w/Logo 1
BFM-50258 Selector Shaft 1
BFH-50192 Weight Stack Decals 2
BFP-52340 SHCS 3/8”-16 X 3/4” 2
BFP-51799 SHCS 3/8"-16 X 5" P5 2
BFM-51173 Weight Stack Pull Pin 1
BFH-50630 FHSCS 3/8"-16 X 3/4" 2
BFP-52401 BHSCS 3/8"-16 X 1/2" 4
Part # Description Qty
BFM-51044 Guide Rod Holder 1
BFM-50529 Rubber Donut 2
BFM-50256 Weight Plate 19
BFM-51051 Guide Rod 2
BFM-51082 Weight Stack Shroud 1
BFH-50146 3/8" Flat Washer (Black) 10
BFH-50157 3/8"-16 Nylock (Black) 2
BFH-50147 3/8" Lock Washer (Black) 6
BFM-10299 Top Plate 1
Step 5:
All Flat Washers and Nylocks are
3/8” unless otherwise noted.
NOTE: It is important to install the front shroud BEFORE installing the weight stack on the machine. The Front Shroud has
the Fusion Logo decal on it. If this is not installed BEFORE the weight stack on this step, the weight stack will have to be
completely removed later in order to install the Front Shroud. THERE IS NO OTHER WAY to install the front shroud once the
weight stack has been put on the machine. DO NOT wait until the end of assembly to install the Front Shroud.
Tighten all bolts before moving on

Batca Fitness Systems 12 Fusion 3 Owner's Manual
Part # Description Qty
BFM-10573 Functional Arm Mount 1
BFM-10571 User Right Functional Arm 1
BFM-10572 User Left Functional Arm 1
BFM-10582rev1 Functional Arm Swivel Pulley 2
BFH-50146 3/8" Flat Washer (Black) 4
BFH-50157 3/8"-16 Nylock (Black) 2
BFP-51653 SHCS 3/8"-16 1 1/4" P5 2
Step 6:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

www.batcafitness.com 13 Fusion 3 Owner's Manual
Part # Description Qty
BFM-10577 8" Telespar 1
BFM-10579 10" Chrome Adjustment 1
BFM-10581 Leg Extension/ Curl Frame 1
BFM-51143 8” Anti-Deection Plate 1
BFH-50146 3/8" Flat Washer (Black) 6
BFH-50157 3/8"-16 Nylock (Black) 4
BFH-50251 1/2" Flat Washer Black 2
BFP-51884 SHCS 1/2-13 X 4 1/4 P5 1
BFH-50155 1/2"-13 Nylock (Black) 1
BFP-52396 SHCS 3/8"-16 X 5 1/2" 2
BFH-50144 FHSCS 3/8"-16 X 1" 2
BFM-50931 3” Axle 1
8” Anti-Deflection Plate
Step 7:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

Batca Fitness Systems 14 Fusion 3 Owner's Manual
Part # Description Qty
BFM-10578 Seat Frame Assembly 1
BFM-10580 Back Chrome Adjustment 1
BFP-50130 Large Bottom Pad 1
BFH-50251 1/2" Flat Washer (Black) 4
BFP-51747 SHCS 3/8” x 3” 2
BFP-51760 SHCS 1/2”-13 X 3 1/2” 1
BFP-51747 SHCS 1/2”-13 X 3” P5 1
BFH-50155 1/2"-13 Nylock (Black) 2
BFH-50146 3/8” Flat Washer 2
BFH-50147 3/8” Lock Washer 2
Step 8:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Install the Large Bottom Pad before
Installing the 1-2” x 3” Bolt.

www.batcafitness.com 15 Fusion 3 Owner's Manual
Part # Description Qty
BFM-10141 Knee Alignment Roller 1
BFM-10584 Leg Extension Shaft 1
BFM-10585 Leg Extension Cam Assembly 1
BFH-50165 1" Snap Ring 1
BFH-50157 3/8"-16 Nylock (Black) 1
BFP-51759 SHCS 3/8"-16 X 2" 1
BFH-50245 FHSCS 5/16"-18 X 1" 2
BFM-50222 2 9/16” Axle 1
BFH-50337 Wavy Washer 2
Step 9:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

Batca Fitness Systems 16 Fusion 3 Owner's Manual
Part # Description Qty
BFM-10586 Leg Extension Arm Assembly 1
BFL-50207 Hold Down Adjustment Plate 1
BFL-50211 Plate 1
BFM-10587 Knee Hold Down Assembly 1
BFM-51094 2” Axle 1
BFH-50165 1" Snap Ring 2
BFH-50146 3/8" Flat Washer (Black) 6
BFH-50157 3/8"-16 Nylock (Black) 3
BFP-51747 SHCS 3/8"-16 X 3" P5 3
BFH-50337 Wavy Washer 1
BFH-50620 BHSCS 3/8” x 1” 1
BFM-52422 Red Pivot Point Cap 1
Step 10:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

www.batcafitness.com 17 Fusion 3 Owner's Manual
Part # Description Qty
BFH-50173 3 1/2" Pulley 2
BFH-50146 3/8" Flat Washer (Black) 6
BFP-51752 SHCS 3/8"-16 X 2 1/4" P5 3
BFH-50157 3/8"-16 Nylock (Black) 3
BFH-50256 1/2” Jam Nut 1
BFM-10611 Criss-Cross Free Floater 1
BFH-50174 4 1/2" Pulley 1
CAB-13022 Fusion Weight Stack to Cable Tie Out 1
BFH-50351 1 3/8" Shoulder Bolt 1
BFH-50267 5/16"-18 Nylock (Zinc) 1
71 5/8”
Cable Routing
Note: Each Cable with a threaded
bolt on either end must be
threaded at least 1/2” into its
attachment.
CAB-13022
1 3/8”
Step 11:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

Batca Fitness Systems 18 Fusion 3 Owner's Manual
Item # Part # Description Qty
56 BFH-50146 3/8" Flat Washer (Black) 6
57 BFP-51752 SHCS 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 2
93 BFM-10609rev1 Pulley Holder 2
95 BFH-50174 4 1/2" Pulley 3
96 BFM-10610rev1 Lower Pulley Holder 2
103 CAB-13024 Fusion Floating Pulley Cable 1
85 1/4”
Note: Each Cable with a threaded bolt on either
end must be threaded at least 1/2” into its
attachment.
CAB-13024
Step 12:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.

www.batcafitness.com 19 Fusion 3 Owner's Manual
Part # Description Qty
BFL-50203 Pulley Holder Connector Plate 1
BFH-50146 3/8" Flat Washer (Black) 4
BFH-50157 3/8"-16 Nylock (Black) 2
BFP-51756 SHCS 3/8"-16 X 5 1/4" P5 2
BFH-50256 1/2” Jam Nut 2
BFM-10612 Cable Tie Out Plate 1
CAB-13026 Fusion Tie Out Cable 1
22 5/8”
Note: If Leg Press Option is purchased, skip this step and install the Pulley Holder
Connector Plate (from this step) and CAB-13025 Leg Extension Cable (from next step) when
the Leg Press is attached to the machine on page 30. The Cable Tie Out Plate and Tie Out
Cable from this step should not be installed if the Leg Press has been purchased.
Note: The Orientation of the Pulley
Holder Connector Plate should
reect this drawing. If not installed
correctly, the machine will not
function properly.
Step 13:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Note: Each Cable with a threaded bolt on either
end must be threaded at least 1/2” into its
attachment.

Batca Fitness Systems 20 Fusion 3 Owner's Manual
Part # Description Qty
BFH-50605 3/8" Pulley Spacer 1
BFP-52394 SHCS 3/8"-16 X 2 1/2" 1
BFM-50505 3 1/2" Pulley Cover 2
BFH-50256 1/2” Jam Nut 1
CAB-13025 Fusion Leg Extension Cable 1
BFH-50351 1 3/8" Shoulder Bolt 1
BFH-50267 5/16"-18 Nylock (Zinc) 1
BFH-52553 5/16” Pulley Spacer 1
90 1/2”
Part # Description Qty
BFH-50173 3 1/2" Pulley 5
BFH-50147 3/8” Lock Washer (Black) 1
BFL-50221 Pulley Plate 1
BFH-50146 3/8" Flat Washer (Black) 7
BFP-51752 SHCS 3/8"-16 X 2 1/4" P5 1
BFH-50157 3/8"-16 Nylock (Black) 4
BFP-51759 SHCS 3/8”-16 X 2” P5 2
BFP-52397 SHCS 3/8"-16 1 3/4" P5 1
1 3/8”
Step 14:
If you have adjusted the cable system and it
appears your cable may be too short or the
Free Floating Pulleys directly behind the
back pad of the chest press station are not
at the same level (one appears much lower
than the other), please double check the
orientation of the Pulley Holder Connector
Plate from step 13. It should reect this
drawing. There is a spacer welded to the
Pulley Holder Connector Plate. The spacer
should be facing away from the machine if
installed properly.
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
Note: Each Cable with a threaded bolt on either
end must be threaded at least 1/2” into its
attachment.