Batca S-10 User manual

www.batcafitness.com S-10 Owner’s Manual
S-10
January 2006
Revision 1
January 2006January 2006
Revision 1
Record Serial Number Here
Batca Fitness Systems
Tel. [phone]
www.batcafitness.com
Date of Purchase
Owner’s Manual
Ab Crunch

Batca Fitness Systems 2 S-10 Owner's Manual
__________ Page
Instructions 2
Parts Listing 3
Hardware Comparison 4-7
Main Assembly 8-12
Upholstery 13
Cable Routing 14-15
Congratulations on the purchase of your new Batca S-10. 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 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 perform-
ance, 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 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
__________ Page
Final Assembly and Troubleshooting 16
Cable Tension and Adjustments 17
Maintenance 18
Warranty 19
Floor Plan Layout 20
Table of Contents
Instructions
Warning

www.batcafitness.com 3 S-10 Owner’s Manual
Frame Components Accessories
Upholstery
Hardware
Cables
Tools Required
• 9/16” Wrench
• 3/4” Wrench
• 9/16” Ratchet
• Allen Wrench Set
• Tape Measure
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 BFM-10354 Ab Crunch Frame 1
2 BFM-10437 Base Connector 1
3 BFM-10355 Short Cage 1
4 BFM-10358 Ab/Back Bent Connector 1
5 BFM-10357 Pillow Support 1
7 BFM-10332 Ab/Back Pivot Arm 1
8 BFM-50564 Counter Weight 1
9 BFM-50527 Guide Rod 2
10 BFM-50615 Guide Rod Plate 1
12 BFM-50531 Shroud 1
13 BFM-10359 Pulley Holder with Lockout 1
14 BFM-10334 Ab/Back Pivot Roller 1
17 BFM-50150 Anti-Deflection Plate 1
18 BFM-10430 Weight Plate 19
19 BFM-10413 3/4" 10lb Top Plate 1
24 BFM-10420 Ab Crunch Cam 1
25 BFM-50484 Diamond Plate 2
26 BFM-50126 Anti-Deflection Plate 4
27 BFM-50653 Anti-Deflection Plate 1
53 BFM-10133 Free Floater 1
60 BFM-50635 Selector Shaft 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
49 BFC-50127 Magnetic Weight Stack Pin 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
54 CAB-12009 Ab Crunch to Free Floater Cable 1
55 CAB-12012 Weight Stack to Lockout Cable 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
15 BFU-10122 Large Upholstery Roller 1
16 BFU-10121 7" Upholstery Roller 2
20 BFU-10117 Large Bottom Pad 1
ITEM NO. PART NUMBER DESCRIPTION QTY.
6 BFH-50172 Pillow Block Bearing 2
11 BFM-50529 Rubber Donut 2
21 BFH-50220 Threaded Collar 2
22 BFH-50252 Plastic Collar 3
23 BFH-50221 3" Plastic Washer 5
28 BFH-50146 3/8" Flat Washer (Black) 54
29 BFH-50157 3/8"-16 Nylock (Black) 27
30 BFH-50126 HCS 3/8"-16 X 3 1/4" P5 6
31 BFH-50202 3/4" Pulley Spacer 2
32 BFH-50130 HCS 3/8"-16 X 4 1/4" P5 6
33 BFH-50147 3/8" Lock Washer (Black) 8
34 BFH-50119 HCS 3/8"-16 X 1 1/4" P5 2
35 BFH-50118 HCS 3/8"-16 X 1" P5 2
36 BFH-50120 HCS 3/8"-16 1 1/2" P5 4
37 BFH-50201 1/2" Pulley Spacer 2
38 BFH-50124 HCS 3/8"-16 X 2 3/4" P5 1
39 BFH-50174 4 1/2" Pulley 5
40 BFH-50121 HCS 3/8"-16 X 2" P5 2
41 BFH-50145 FHSCS 3/8"-16 X 2 1/4" 4
42 BFH-50199 Rubber Grommet 2
43 BFH-50122 HCS 3/8"-16 X 2 1/4" P5 1
44 BFH-50276 HCS 3/8"-16 X 5 1/4" P5 1
45 BFH-50254 HCS 3/8-16 X 3/4 P5 4
47 BFH-50530 5" Pulley 1
48 BFH-50255 Rubber Foot 5
50 BFM-50345 Pulley Cover 2
51 BFH-50250 1 1/4" Shoulder Bolt 2
52 BFH-50267 5/16"-18 Nylock (Black) 2
59 BFH-50127 HCS 3/8"-16 X 3 1/2" P5 2
61 BFH-50227 Cable Strap 1
62 BFH-50151 5/16” Flat Washer (Zinc) 4

Batca Fitness Systems 4 S-10 Owner's Manual
Bolt Length Note: Bolt length is measured from
the underside of the head of the bolt.

www.batcafitness.com 5 S-10 Owner’s Manual

Batca Fitness Systems 6 S-10 Owner's Manual

www.batcafitness.com 7 S-10 Owner’s Manual

Batca Fitness Systems 8 S-10 Owner's Manual
Figure 1
Step 1:
Note: For a more consistent appearance, position all bolts
in the direction shown in each figure.
PLEASE FOLLOW ALL DIRECTIONS VERY CAREFULLY FOR PROPER
INSTALLATION.
Item # Part # Description Qty
1 BFM-10354 Ab Crunch Frame 1
2 BFM-10347 Base Connector 1
3 BFM-10355 Short Cage 1
17 BFM-50150 Anti-Deflection Plate 1
25 BFM-50484 Diamond Plate 2
26 BFM-50126 Anti-Deflection Plate 1
28 BFH-50146 3/8" Flat Washer (Black) 12
29 BFH-50157 3/8"-16 Nylock (Black) 8
30 BFH-50126 HCS 3/8"-16 x 3 1/4" P5 2
32 BFH-50130 HCS 3/8"-16 x 4 1/4" P5 2
41 BFH-50145 FHSCS 3/8"-16 x 2 1/4" 4
48 BFH-50255 Rubber Foot 5
• All Flat Washers and Nylocks are 3/8”
unless otherwise noted.

www.batcafitness.com 9 S-10 Owner’s Manual
Figure 2
Step 2:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Figure 2A
Item # Part # Description Qty
9 BFM-50527 Guide Rod 2
10 BFM-50615 Guide Rod Plate 1
11 BFM-50529 Rubber Donut 2
13 BFM-10359 Pulley Holder with Lockout 1
18 BFM-10430 Weight Plate 19
19 BFM-10413 3/4” 10lb Top Plate 1
28 BFH-50146 3/8" Flat Washer (Black) 6
29 BFH-50157 3/8"-16 Nylock (Black) 3
43 BFH-50122 HCS 3/8"-16 x 2 1/4" P5 1
47 BFH-50530 5" Pulley 1
49 BFC-50127 Magnetic Weight Stack Pin 1
59 BFH-50127 HCS 3/8"-16 x 3 1/2" P5 2
60 BFM-50635 Selector Shaft 1

Batca Fitness Systems 10 S-10 Owner's Manual
Step 3:
Figure 3
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Item # Part # Description Qty
4 BFM-10358 Ab/Back Bent Connector 1
5 BFM-10357 Pillow Support 1
26 BFM-50126 Anti-Deflection Plate 3
27 BFM-50653 Anti-Deflection Plate 1
28 BFH-50146 3/8" Flat Washer (Black) 14
29 BFH-50157 3/8"-16 Nylock (Black) 7
30 BFH-50126 HCS 3/8"-16 x 3 1/4" P5 3
32 BFH-50130 HCS 3/8"-16 x 4 1/4" P5 4

www.batcafitness.com 11 S-10 Owner’s Manual
Figure 4
Step 4:
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Item # Part # Description Qty
6 BFH-50172 Pillow Block Bearing 2
24 BFM-10420 Ab Crunch Cam 1
28 BFH-50146 3/8" Flat Washer (Black) 8
29 BFH-50157 3/8"-16 Nylock (Black) 4
36 BFH-50120 HCS 3/8"-16 x 1 1/2" P5 4
62 BFH-50151 5/16” Flat Washer (Zinc) 4

Batca Fitness Systems 12 S-10 Owner's Manual
Step 5:
Figure 5
All Flat Washers and Nylocks are 3/8” unless otherwise
Item # Part # Description Qty
7 BFM-10332 Ab/Back Pivot Arm 1
8 BFM-50564 Counter Weight 1
14 BFM-10334 Ab/Back Pivot Roller 1
21 BFH-50220 Threaded Collar 2
28 BFH-50146 3/8" Flat Washer (Black) 2
33 BFH-50147 3/8" Lock Washer (Black) 2
35 BFH-50118 HCS 3/8"-16 x 1" P5 2

www.batcafitness.com 13 S-10 Owner’s Manual
Figure 6
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Step 6:
Item # Part # Description Qty
12 BFM-50531 Shroud 1
15 BFU-10122 Large Upholstery Roller 1
16 BFU-10121 7" Upholstery Roller 2
22 BFH-50252 Plastic Collar 3
23 BFH-50221 3" Plastic Washer 5
28 BFH-50146 3/8" Flat Washer (Black) 6
33 BFH-50147 3/8" Lock Washer (Black) 6
45 BFH-50254 HCS 3/8"-16 x 3/4" P5 4
20 BFU-10117 Large Bottom Pad 1
30 BFH-50126 HCS 3/8"-16 x 1 1/4" P5 2

Batca Fitness Systems 14 S-10 Owner's Manual
Step 7:
Figure 7
All Flat Washers and Nylocks are 3/8” unless otherwise noted.
Note: Shroud was removed from drawing for
Item # Part # Description Qty
28 BFH-50146 3/8" Flat Washer (Black) 2
29 BFH-50157 3/8"-16 Nylock (Black) 1
39 BFH-50174 4 1/2" Pulley 1
40 BFH-50121 HCS 3/8"-16 x 2" P5 1
51 BFH-50250 1 1/4" Shoulder Bolt 1
52 BFH-50267 5/16"-18 Nylock (Black) 1
53 BFM-10133 Free Floater 1
55 CAB-12012 Weight Stack to Lockout Cable 1

www.batcafitness.com 15 S-10 Owner’s Manual
All Flat Washers and Nylocks are 3/8” unless otherwise
Step 8:
Figure 8
Item # Part # Description Qty
28 BFH-50146 3/8" Flat Washer (Black) 4
29 BFH-50157 3/8"-16 Nylock (Black) 4
30 BFH-50126 HCS 3/8"-16 x 3 1/4" P5 1
31 BFH-50202 3/4" Pulley Spacer 2
37 BFH-50201 1/2" Pulley Spacer 2
38 BFH-50124 HCS 3/8"-16 x 2 3/4" P5 1
39 BFH-50174 4 1/2" Pulley 4
40 BFH-50121 HCS 3/8"-16 x 2" P5 1
44 BFH-50276 HCS 3/8"-16 x 5 1/4" P5 1
50 BFM-50345 Pulley Cover 2
51 BFH-50250 1 1/4" Shoulder Bolt 1
52 BFH-50267 5/16"-18 Nylock (Black) 1
54 CAB-12009 Ab Crunch to Free Floater Cable 1
61 BFH-50227 Cable Strap 1

Batca Fitness Systems 16 S-10 Owner's Manual
Final Assembly and Troubleshooting
• Wrench Tighten the two set
screws on all Pillow Block Bearings
with an Allen Wrench.
Pillow Block Bearing
BFH-50172
Free Floater Top Plate
200lb Stack (Standard) 175lb Stack (Optional)
Weight Stack Decals:
IMPORTANT - Check These Components Before Using Gym:
• Each Cable with a threaded bolt on either end must be
threaded at least 1/2” into its attachment, whether it be a Free
Floater, Lockout Free Floater, or 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 figure to the left..
Pulley Cover
BFM-50345
• Position the cable guard tab on the
Pulley Cover so that the tab prevents the
cable from coming out of it’s track on the
4 1/2” Pulley. An example of this
positioning can be seen in the figure to
the right. The cable guard tab should be
positioned so that it is in the middle of the
cable wrap on the 4 1/2” Pulley, between
points “A” and “B”. This will allow better
protection and prevent the cable from
rubbing the cable guard tab.

www.batcafitness.com 17 S-10 Owner’s Manual
• 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 en-
sure that the threaded adjustable 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
1
2

Batca Fitness Systems 18 S-10 Owner's Manual
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. Each pillow block bearing and flange bearing
has a grease fittings that must be lubricated regularly. Use general purpose bearing grease and follow the schedule below.
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
Commercial Home Commercial Home Commercial Home Commercial Home Commercial Home
Clean
Upholstery X X
Hand Grips X X
Roller Pads X X
Guide Rods X X
Chrome Slides X X
Frame X X
Inspect
Overall X X
Safety Decals X X
Cables X X
Cable Tension X X
Pulleys X X
Hardware X X
Stops X X
Upholstery X X
Hand Grips X X
Frame X X
Bushings X X
Bearings X X
Lubricate
Guide Rods X X
Bearings As Needed 1
Replace
Cables 1 3
Preventive Maintenance

www.batcafitness.com 19 S-10 Owner’s Manual
What is covered
For Residential Use:
Batca Fitness Systems warrants all of its products against defects in manufacturing, materials and workmanship under nor-
mal use and service for one year from date of purchase including paint, chrome, upholstery and grips. Batca Fitness Sys-
tems 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 five
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 nor-
mal use and service for six months from date of purchase including paint, chrome, upholstery and grips. Batca Fitness Sys-
tems 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, modification or
alteration, accident, fire, flood, “acts of God” or other contingencies beyond the control of Batca Fitness Systems. This war-
ranty 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 cov-
ered 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 re-
turns require a return authorization prior to acceptance of repair work. Batca Fitness Systems reserves the right to make
design changes without any prior notification 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 al-
leged damage.
This warranty applies only to the original purchaser and is not transferable. Claims under this warranty must be made di-
rectly 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

Batca Fitness Systems 20 S-10 Owner's Manual
The S-10 has a layout dimension of 3’-3” (width) x 3’-8” (length) x 5’-5” (height). There should be a minimum
of 18”, preferably 24”, of working space around the entire unit.
Layout Diagram