Batca FUSION 4 FZ-5 User manual
www.batcatness.com Fusion 4 Functional Trainer
May 2021
Serial Number Here
Date of Purchase
FZ-5 Functional Trainer
Batca Fitness Systems 2Fusion 4 Functional Trainer
Page
Instructions 2
Hardware Blister Packs 3-4
Pre-Assembling Instructions 5
Main Frame Assembly 6-9, 12
Cable Routing 10-11
Page
Cable Tension and Adjustments 13
Final Assembly and Troubleshooting 14
Maintenance 15
Warranty 16
Floor plan Layout 17-18
Congratulations on the purchase of your new Batca Fusion 4 Functional Trainer. 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 reect total quantities for your gym and may not reect 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
your local BATCA FITNESS SYSTEMS distributor or BATCA FITNESS SYSTEMS at (919) 255-
1233. www.batcatness.com
Table of Contents
Instructions
Warning
www.batcatness.com 3Fusion 4 Functional Trainer
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 4 Functional Trainer
Hardware Blister Packs
www.batcatness.com 5Fusion 4 Functional Trainer
Pre-Assembling Instructions
NOTE: It is important to position the Upper Body and the Lower Body Stations accordingly. Make sure they are
approximately 5 foot 1 inch apart by measuring from the inside of the rear base on each machine. Also Make sure
the rear base on each machine are in line with each other across the back. This is important for connecting the two
machines via the Functional Trainer as seen in step 3. This will help to insure all of the components on the Fusion 4
Functional Trainer line up smoothly and will help to make the installation process effortless.
Approx. 5’ 1”
Fusion Lower Body Station Fusion Upper Body Station
Batca Fitness Systems 6Fusion 4 Functional Trainer
Item # Part # Description Qty
1BFM-11051 Right Side Height Adjustment 1
2BFM-10400 Swivel Pulley Holder 1
3BFM-10758 Short Base Frame (Right Side) 1
4BFM-52519 Selector Tube 1
5BFM-10760 Long Base Frame (Left Side) 1
6BFM-10772 Right Side Height Adjustment 1
25 BFH-50220 Threaded Collar 1
26 BFH-50279 SHCS 3/8”-16 x 5” 2
27 BFP-52394 SHCS 3/8”-16x 2-1/2” 1
33 BFH-50173 3 1/2” Pulley 2
36 BFP-51752 SHCS 3/8”-16 x 2 1/4” 2
40 BFH-50146 3/8” Flat Washer 10
41 BFH-50157 3/8” Nylock 5
Selector Tube
Step 1a:
Repeat step 1 for
opposite (Left) side
Long Base
Frame
(BFM-10760)
Left Side
Height
Adjustment
(BFM-11052)
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.
NOTE: The numbers
and the holes on the
Selector Tube should
be installed facing the
FRONT of the
machine.
DO NOT TIGHTEN BOLTS UNTIL STEP 3
• Wrench Tighten the set screws on
all Threaded Collars using an allen
wrench, so that the set screws
tighten against the shaft.
Threaded Collar
BFH-50220
www.batcatness.com 7Fusion 4 Functional Trainer
Item # Part # Description Qty
7BFM-51456 PulleyHolder/Support Plate 2
8BFM-10757 Upper Support Brace (Right) 1
9BFM-10756 Extended Upper Support Brace (Left Side) 1
27 BFP-52394 SHCS 3/8”-16 x 2 1/2 4
28 BFP-51756 SHCS 3/8”-16 x 5 1/4 2
40 BFH-50146 3/8” Flat Washer 12
41 BFH-50157 3/8” Nylock 6
Step 2a:
Repeat step 2 for
opposite (Left) side
Extended Upper
Support Brace
(BFM-10756)
NOTE: Attach the Pulley Holder/
Support Plates to the Upper
Support Brace loosely BEFORE
installing the Upper Support Brace.
this will help continue to make the
installation process effortless.
Note: Be sure to remove the 3/8” x
5” bolts from the top of the Lower
Body Station and the Upper Body
Station and use the 3/8” x 5 1/4” bolts
provided with the Functional Trainer.
All Flat Washers and Nylocks are 3/8” unless otherwise
noted.
Step 2: Do Not Tightened Bolts Until Next Step
Batca Fitness Systems 8Fusion 4 Functional Trainer
Item # Part # Description Qty
10 BFM-10751 Front Angle Bracket 1
11 BFM-51457 Rear Angle Bracket 1
29 BFH-50323 FHSCS 3/8”-16 x 3” 2
30 BFH-51184 FHSCS 3/8”-16 x 5 1/4 2
40 BFH-50146 3/8” Flat Washer 4
41 BFH-50157 3/8” Nylock 4
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 3: Make Sure All Bolts are Tightened Before Moving on
www.batcatness.com 9Fusion 4 Functional Trainer
Item # Part # Description Qty
12 BFM-10752 Guide Rod Holder 1
13 BFM-10299 Top Plate 1
14 BFM-51493 Guide Rod 2
15 BFM-50256 Weight Stack Plate 19
16 BFM-50529 Rubber Donut 2
22 BFM-51173 Weight Stack Pull Pin 1
31 BFP-51747 SHCS 3/8”-16 x 3” 2
40 BFH-50146 3/8” Flat Washer 4
41 BFH-50157 3/8” Nylock 2
Step 4a:
Repeat step 4 for
opposite (Left) side
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 4: Make Sure All Bolts are Tightened Before Moving on
Batca Fitness Systems 10 Fusion 4 Functional Trainer
Item # Part # Description Qty
17 BFM-10425 Free Floater (Male) 1
23 BFC-10103 Strap Handle 1
24 CAB-13033 Functinal Trainer Cable 1
27 BFP-52394 SHCS 3/8”-16x 2-1/2” 3
32 BFH-50174 4 1/2” Pulley 4
33 BFH-50173 3 1/2” Pulley 2
34 BFH-51187 3/8” Pulley Spacers 6
35 BFP-51759 SHCS 3/8”-16 x 2” 5
37 BFP-52398 SHCS 3/8”-16 x 1 3/4 1
40 BFH-50146 3/8” Flat Washer 6
41 BFH-50157 3/8” Nylock 9
Step 5a:
Repeat step 5 for
opposite (Left) side
Note: Make Sure Cable is
not pinched in between the
tube and the pulley support
plate. Further cable routing
instructions are on the next
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 5: Make Sure All Bolts are Tightened Before Moving on
www.batcatness.com 11 Fusion 4 Functional Trainer
Start
Here
269 11/16”
CAB-13033
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Note: Cables CAB-13033 has a removable Cable Strap (BFH–50227) end to make cable routing
easier. The Cable Strap ends can be found packaged with the hardware.
Step 5 Continued: Make Sure All Bolts are Tightened Before Moving on
Batca Fitness Systems 12 Fusion 4 Functional Trainer
Item # Part # Description Qty
18 BFM-10762 Short Bar/Ankle Strap Holder 1
19 BFM-51494 Front Shroud 1
20 BFM-51082 Rear Shroud 1
21 BFM-10763 Rope/Long Bar Holder 1
36 BFP-51752 SHCS 3/8”-16 x 2 1/4” 1
38 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
39 BFH-50147 3/8” Lock Washer 5
41 BFH-50146 3/8” Flat Washer 5
Step 6a:
Repeat step 6 for
opposite (Left) side
BHSCS
3/8” X 1/2”
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 6: Make Sure All Bolts are Tightened Before Moving on
BHSCS
3/8” X 1/2”
BHSCS
3/8” X 1/2”
BHSCS
3/8” X 1/2”
www.batcatness.com 13 Fusion 4 Functional Trainer
• Adjust cables to proper tension from any of the locations shown below.
Note: All cables with threaded adjustable ends must have at least 1/2” of the threads threaded in to its counterpart.
It is very important that the 1/2” Jam Nut be wrench tightened to the counterpart to ensure that the threaded adjust-
able end of the cable does not back out of its counterpart.
• Note: If the top plate raises off of the second plate in the weight stack, then the cable tension is too tight. You will need
to take some of the tension out to lower the Top plate ush with the second plate.
Cable Adjustments
This bolt can be
positioned in any one of
the three optional holes
to account for any slack
in the cable.
Fine adjustments to cable
tension can be made here. At
least 1/2” of the threads
should be threaded in to the
top weight plate. It is very
important to tighten the jam
nut after adjustments.
• Verify that all cables lie in between
the guide bolts, tubes and the pulleys.
Routing the cables over the guide
bolts causes premature cable wear
and will void your warranty.
Make Sure Cable is not pinched in between
the tube and the pulley support plate.
Guide Bolts
Batca Fitness Systems 14 Fusion 4 Functional Trainer
Weight Stack Decals:
Final Assembly and Troubleshooting
200lb Stack
Weight Stack Decals:
IMPORTANT - Check These Components Before Using Gym:
• Each Free Floater must be threaded at
least 1/2” into the Top Plate of the weight
stack. Each must also be secured with a
1/2” Jam Nut to ensure a safe and proper
connection.
• Record your serial number on the front of this manual and keep
for your records. The serial number can be found on the side of the
cage as seen in the gure to the left.
Guide Rod
• Clean guide rods with a lint-free cloth and apply a thin layer of silicone lubricant (Part # BFH-50262) to each guide rod.
This will ensure a glass smooth performance from your weight stack.
The weight stack decals should be installed with a gap of 1/2” between the edge of the decals and the side of the
holes for the weight stack pin. This spacing is critical because a larger gap between the decal and the center pin hole
could result in the weight stack decals being covered by shrouds. It is helpful to use a 1” strip of painters tape to in-
stall the decals straight by lining up the edge of the piece of tape with the center of the hole in the plates and use the other
side of the tape as a guide for applying the decals. The stacks shown in the diagram above are our standard 200 lb weight
stacks where all 20 plates are 10lbs. The decals used for the standard weight stack should be labeled 10-200. If the medi-
cal 175 lb weight stacks were purchased, the top ve plates will be 5 lbs. The decals used for the medical weight stacks
should be labeled 5-175 and are typically packaged with the weight stacks themselves.
Serial Number
• Wrench Tighten the set screws on all
Threaded Collars using an allen
wrench, so that the set screws
tighten against the shaft.
Threaded Collar
BFH-50220
www.batcatness.com 15 Fusion 4 Functional Trainer
Daily Weekly Monthly Quarterly Years
Clean
Upholstery X
Hand Grips X
Roller Pads X
Guide Rods X
Chrome Slides X
Frame X
Inspect
Overall X
Safety Decals X
Cables X
Cable Tension X
Pulleys X
Hardware X
Stops X
Upholstery X
Hand Grips X
Frame X
Bushings X
Bearings X
Lubricate
Guide Rods X
Replace
Cables 3
Batca Fitness Systems strives to give you the very best in quality, performance and safety through carefully engineered
designs and excellent workmanship. In order to maintain this high level of quality the preventative maintenance schedule
below should be followed.
Clean upholstery, grips, and roller pads with mild soap and water generally after every use. The guide rods, chrome slides
and frame should be cleaned with a cotton cloth. Upon cleaning the guide rods, a thin layer of Silicone or Teon gel should
be applied to each rod to ensure a glass smooth performance.
An overall inspection should be done before each workout. If the warning and safety decals are worn or have been
removed they should be replaced immediately. The cables and cable systems should be inspected for signs of wear and
proper tension. In order to check cables properly you should carefully run the cable through your ngertips, checking for
signs of wear, cracks, burs and thinning spots. Replace any part at rst signs of wear. Cables should be adjusted for
proper tension. See assembly instructions for this detail. All hardware, stops, and adjustments should be checked and
tightened as required.
The guide rods on your machine should be cleaned and lubricated regularly. This will ensure a glass smooth performance
from your weight stack. A thin layer of either Silicone or Teon gel should applied to each rod.
Although cables should be inspected daily, it is important that ALL cables be replaced as directed in the schedule below.
Please note that at any rst sign of wear the cable should be replaced immediately.
If there are any questions concerning maintenance, please contact your local Batca dealer or contact Batca Fitness
Systems directly at:
Batca Fitness Systems
(919) 255-1233
www.batcatness.com
Preventive Maintenance
Batca Fitness Systems 16 Fusion 4 Functional Trainer
What is covered
For Residential Use:
Batca Fitness Systems warrants all of its products against defects in manufacturing, materials and workmanship
under normal use and service for one year from date of purchase including paint, chrome, upholstery and grips.
Batca Fitness Systems also warrants all cables, belts, bolts, nuts, caps, plugs, bumpers, washers, levelers, decals,
gas springs and other hardware for three years after date of purchase; all moving parts, including pulleys, bushings,
bearings and pull pins for ve years after date of purchase and warrants the frame and all welded parts for the
lifetime of the original purchaser.
For Commercial Use:
Batca Fitness Systems warrants all of its products against defects in manufacturing, materials and workmanship
under normal use and service for six months from date of purchase including paint, chrome, upholstery and grips.
Batca Fitness Systems also warrants all cables, belts, bolts, nuts, caps, plugs, bumpers, washers, levelers, decals,
gas springs and other hardware for one year after date of purchase; all moving parts, including pulleys, bushings,
bearings and pull pins for three years after date of purchase and warrants the frame and all welded parts for ten
years after date of purchase.
What is not covered
This warranty does not cover damage, which results from shipping, misuse, abuse, neglect, carelessness,
modication or alteration, accident, re, ood, “acts of God” or other contingencies beyond the control of Batca
Fitness Systems. This warranty also does not cover deterioration from wear and tear or exposure or any defect,
which would not have happened if instructions in the owner’s manual had been followed. Improper installation,
improper assembly or follow-up maintenance along with installation of parts or accessories not originally intended
for products of Batca Fitness Systems are also not covered by this warranty. Only genuine Batca parts should be
used for replacement, repair, and maintenance for this warranty to apply.
Defective parts will be repaired or replaced at Batca Fitness Systems option, without parts charge to the purchaser.
All returns require a return authorization prior to acceptance of repair work. Batca Fitness Systems reserves the right
to make design changes without any prior notication and shall not be responsible for incidental or consequential
damages.
The purchaser is responsible for shipping the defective part back to the factory. Repair or replacement is the
exclusive and sole remedy of the purchaser. Labor charges associated with parts changeovers are not covered by
this warranty. Proof of purchase, serial number, model number and date of purchase will be required along with all
pertinent information of the alleged damage.
This warranty applies only to the original purchaser and is not transferable. Claims under this warranty must be
made directly to Batca Fitness Systems.
Batca Fitness Systems
1207 N. New Hope Road
Raleigh, NC 27610
(919) 255-1233
www.batcatness.com
Please keep this for your records.
Limited Lifetime Warranty
Scan the QR Code to
register your new
BATCA Product online!
www.batcatness.com 17 Fusion 4 Functional Trainer
The Fusion without Leg Press has a layout dimension of 12’-11” (width) x 6’-7” (length) x 7’-2” (height). There should be a
minimum of 18”, preferably 24”, of working space around the entire unit.
Layout Diagram without Leg Press
Batca Fitness Systems 18 Fusion 4 Functional Trainer
The Fusion with Leg Press has a layout dimension of 14’-4” (width) x 6’-7” (length) x 7’-2” (height). There should be a mini-
mum of 18”, preferably 24”, of working space around the entire unit.
Layout Diagram with Leg Press
Table of contents
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