Batca fusion 4 User manual

www.batcafitness.com Fusion 4 Functional Trainer
June 2014
Revision 2
Serial Number Here
Date of Purchase
Owner’s Manual
Functional Trainer
1207 New Hope Road, Raleigh, NC - 919.255.1233 - www.batcafitness.com

Batca Fitness Systems 2 Fusion 4 Functional Trainer
__________ Page
Instructions 2
Parts Listing 3
Hardware Comparison 4-7
Pre-Assembly Instructions 8
Main Frame Assembly 9-12
Cable Routing 13-14
Accessories Holders and Shrouds 15
__________ Page
Cable Tension and Adjustments 16
Weight Stack Decals and Serial Number 17
Final Assembly and Troubleshooting 18
Maintenance 19
Warranty 20
Floor plan Layout 21-22
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 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 multi-station gyms and to package these gyms in such a way to avoid any damage dur-
ing 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 en-
sure 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 sta-
tion 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 Functional Trainer
Frame Components Accessories
ITEM NO. PART NO. DESCRIPTION QTY
22 BFM-51173 Weight Stack Pull
Pin
2
23 BFC-10103 Strap Handle 2
ITEM
NO. PART NO. DESCRIPTION QTY
1 BFM-11052 Right Side Height Adjustment 1
2 BFM-10400 Swivel Pulley Holder 2
3 BFM-10758 Short Base Frame 1
4 BFM-51438 Selector Tube 2
5 BFM-10760 Long Base Frame 1
6 BFM-11052 Left Side Height Adjustment 1
7 BFM-51456 Pulley Holder/Support Plate 4
8 BFM-10757 Upper Support Brace (Right Side) 1
9 BFM-10756 Extended Upper Support Brace
(Left Side)
1
10 BFM-10751 Front Angle Bracket 1
11 BFM-51457 Rear Angle Bracket 1
12 BFM-10752 Guide Rod Holder 2
13 BFM-10299 Top Weight Plate 2
14 BFM-51493 Guide Rod 4
15 BFM-50256 Weight Plate 38
16 BFM-50529 Rubber Donut 4
17 BFM-10425 Free Floater (Male) 2
18 BFM-10762 Short Bar/Ankle Strap Holder 1
19 BFM-51494 Front Shroud 2
20 BFM-51082 Rear Shroud 2
21 BFM-10763 Rope/Long Bar Holder 1
Hardware
ITEM NO. PART NUMBER DESCRIPTION QTY
25 BFH-50220 Threaded Collar 2
26 BFP-51799 SHCS 3/8”-16x 5” 4
27 BFP-52394 SHCS 3/8”-16x 2-1/2” 16
28 BFP-51756 SHCS 3/8”-16x 5-1/4” 4
29 BFH-50323 FHSCS 3/8”-16x 3” 2
30 BFH-51184 FHSCS 3/8”-16x 5-1/4” 2
31 BFP-51747 SHCS 3/8”-16x 3” 4
32 BFH-50174 4-1/2” Pulley 8
33 BFH-50173 3-1/2” Pulley 8
34 BFH-51187 3/8” Pulley Spacers 12
35 BFP-51759 SHCS 3/8”-16x 2” 10
36 BFP-51752 SHCS 3/8”-16x 2-1/4” 6
37 BFP-52399 SHCS 3/8”-16x 1-3/4” 2
38 BFP-52401 BHSCS 3/8”-16 x 1/2” 4
39 BFH-50147 3/8” Lock Washer 10
40 BFH-50146 3/8” Flat Washer 78
41 BFH-50157 3/8” Nylock 48
42 BFH-50192 Weight Stack Decals 2
43 BFH-50262 Guide Rod Lubricant 2
Cables
ITEM NO. PART NO. DESCRIPTION QTY
24 CAB-13033
Functional Trainer
Cable 2
Tools Required
 1/2” Wrench
 9/16” Wrench
 9/16” Ratchet
 Allen Wrench Set
 Tape Measure
 Snap Ring Pliers

Batca Fitness Systems 4 Fusion 4 Functional Trainer
Bolt Length Note: Bolt length is measured from
the underside of the head of the bolt.

www.batcafitness.com 5 Fusion 4 Functional Trainer

Batca Fitness Systems 6 Fusion 4 Functional Trainer

www.batcafitness.com 7 Fusion 4 Functional Trainer

Batca Fitness Systems 8 Fusion 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

www.batcafitness.com 9 Fusion 4 Functional Trainer
Step 1:
Item # Part # Description Qty
1 BFM-11051 Right Side Height Adjustment 1
2 BFM-10400 Swivel Pulley Holder 1
3 BFM-10758 Short Base Frame (Right Side) 1
4 BFM-52519 Selector Tube 1
5 BFM-10760 Long Base Frame (Left Side) 1
6 BFM-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
 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
Step 3
Selector Tube
Step 1a:
Repeat step 1 for
opposite (Left) side
Long Base
Frame
(BFM-10760)
Left Side
Height
Adjustment
(BFM-11052)
NOTE: The numbers and the
holes on the Selector Tube
should be installed facing
the FRONT of the machine.

Batca Fitness Systems 10 Fusion 4 Functional Trainer
Figure 2
Step 2:
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
Do Not Tighten
Hardware Until
Next Step.
Item # Part # Description Qty
7 BFM-51456 PulleyHolder/Support Plate 2
8 BFM-10757 Upper Support Brace (Right) 1
9 BFM-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)
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.

www.batcafitness.com 11 Fusion 4 Functional Trainer
Figure 3
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
Step 3:
Make Sure to
Tighten All
Hardware Before
Moving to the Next
Step.
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 12 Fusion 4 Functional Trainer
Figure 4
Step 4:
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.

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Step 5:
Figure 5
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 page.
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

Batca Fitness Systems 14 Fusion 4 Functional Trainer
Start
Here
269 11/16”
CAB-13033
Step 5 Continued:
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.

www.batcafitness.com 15 Fusion 4 Functional Trainer
Figure 6
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 6:
Step 6a:
Repeat step 6 for
opposite (Left) side
All Flat Washers and Nylocks are 3/8”
unless otherwise noted.
BHSCS
3/8” X 1/2”
BHSCS
3/8” X 1/2”
BHSCS
3/8” X 1/2”

Batca Fitness Systems 16 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 ad-
justable 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 flush 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. Refer to
Step 5.
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.

www.batcafitness.com 17 Fusion 4 Functional Trainer
 Clean guide rods with a lint-free cloth and apply a thin layer of silicon lubricant
(Part # BFH-50262) to each guide rod. This will ensure a glass smooth performance
from your weight stack.
Weight Stack Decals:
Guide Rod Lubrication:
200lb Stack
(Standard)
Final Assembly and Troubleshooting

Batca Fitness Systems 18 Fusion 4 Functional Trainer
Step 25:
IMPORTANT - Check These Components Before Using Gym:
Final Assembly and Troubleshooting
 Wrench Tighten the set screws on all
Threaded Collars using an allen wrench, so
that the set screws tighten against the
shaft. Refer to Step 1.
Threaded
Collar
BFH-50220
 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.
 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

www.batcafitness.com 19 Fusion 4 Functional Trainer
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 Teflon 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 fingertips, checking for signs of wear, cracks, burs and thinning spots. Replace any
part at first 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 Teflon 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 first 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
[phone]
www.batcafitness.com
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
Preventive Maintenance

Batca Fitness Systems 20 Fusion 4 Functional Trainer
What is covered
For Residential Use:
Batca Fitness Systems warrants all of its products against defects in manufac-
turing, materials and workmanship under normal use and service for one year
from date of purchase including paint, chrome, upholstery and grips. Batca Fit-
ness Systems also warrants all cables, belts, bolts, nuts, caps, plugs, bump-
ers, 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 five years after date of purchase and warrants the frame and
all welded parts for the lifetime of the original purchaser.
What is not covered
This warranty does not cover damage, which results from shipping, misuse,
abuse, neglect, carelessness, modification or alteration, accident, fire, flood,
“acts of God” or other contingencies beyond the control of Batca Fitness Sys-
tems. This warranty also does not cover deterioration from wear and tear or ex-
posure or any defect, which would not have happened if instructions in the own-
er’s manual had been followed. Improper installation, improper assembly or fol-
low-up maintenance along with installation of parts or accessories not origi-
nally intended for products of Batca Fitness Systems are also not covered by
this warranty. Only genuine Batca parts should be used for replacement, re-
pair, 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 authoriza-
tion prior to acceptance of repair work. Batca Fitness Systems reserves the
right to make design changes without any prior notification and shall not be re-
sponsible for incidental or consequential damages.
The purchaser is responsible for shipping the defective part back to the facto-
ry. Repair or replacement is the exclusive and sole remedy of the purchaser. La-
bor charges associated with parts changeovers are not covered by this warran-
ty. 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
[phone]
www.batcafitness.com
Please keep this for your records.
Limited Lifetime Warranty