Life Fitness Club Series User manual

1CLASS - S
PART # 7115401 Revision: 07/18/01 REV. B
CLUB SERIES
CABLE CROSS OVER
ASSEMBLY INSTRUCTIONS

PARTS LIST
KE
Y
PART
#
DESCRIPTION QT
Y
KE
Y
PART
#
DESCRIPTION QT
Y
1 70837xx TOWER 2 11 3102903 3/8 X 2-1/2” BOLT 6
1A 7111401 CABLE 2 12 3102922 3/8 X 2-3/4” BOLT 8
1B 6692601 END CAP 3 X 2 6 13 3102904 3/8 X 3” BOLT 4
1C 6714901 GUIDE ROD BUSHING 4 14 3102905 3/8 X 3-3/4” BOLT 2
1D 3222801 4.5 PULLEY 3 15 3102807 3/8” LOW HEIGHT LOCK NUT 28
1E 6866601 CAP, RH-20 BLK 4 16 3102514 3/8” SAE WASHER 44
1F 6102903 3/8-16 X 2.5 BOLT 3 17 6866701 3/8” RH WASHER 52
1G 6866701 3/8 WASHER FLAT 4 18 6866601 BLACK RH CAP 12
1H 6480301 3/8 SPACER 6 19 6480301 3/8” FLANGE SPACER 8
1I 6827001 CABLE CLIP 1 20 3103801 SNAP LINK 2
1J 3102807 3/8 NYLOCK NUT 3 21 6714901 GUIDE ROD BUSHING 4
1K 6793001 PRODUCT WARNING LABEL 1 22 7016901 SEWN HANDLE 2
2 7086101 FRONT UPRIGHT 2 23 6827001 CABLE CLIP 2
3 71032xx ASSY TOP CROSS SUPPORT 1 24 3222801 4-1/2” PULLEY 12
3A 3103106 RUBBER GRIPS 2 25 3108001 WEIGHT STACK CUSHION 4
3B 7111301 LF LABEL 1 26 3222001 1” SHAFT COLLAR 4
4 71031xx ASSY REAR CROSS SUPPORT 1 27 6926801 GUIDE ROD 4
4A 7110801 LF LABEL 1 28 7115501 PLACARD LABEL 2
5 70857xx GUIDE ROD SUPPORT 2 29 7115601 LANGUAGE PLACARD LABEL 2
67104802 LEFT SWIVEL PULLEY ASSY 1 30 6887202 10 LB. WEIGHT PLATE 30
6A 7103602 SWIVEL WLDMT BLK 2 31 6888402 15 LB. WEIGHT PLATE (OPT) 20
77103802 RIGHT SWIVEL PULLEY ASSY 132 6971601 WGT STACK LABEL 2
7A 6590901 INSERT 4 33 6866602 WHITE RH CAP 40
7B 7115201 SPRING PIN 2 OR 6866603 PLATINUM RH CAP 40
8 7104002 HEAD PLATE 2 34 6925102 ASSY REAR SHROUD BLK 2
9 3102924 3/8 X 1-3/4” BOLT 4 35 6921207 FRONT SHROUD PLAT 2
10 3102933 3/8 X 2" BOLT 4 36 6862102 FRONT SIDE SHROUDS BLK 4
*OPTION* 6914607 FULL FRONT SHROUD PLAT 78" 2
*For all 5 digit part numbers you need to add the color at the end. **Language placard kit comes with Dutch, French,
For shrouds and weldments please use the following codes: German, Poruguese, Spanish, Japaneese, and
xxxxx07 Denotes Platinum Italian.
xxxxx08 Denotes White
*For upholstery, please use the following codes:
xxxxx12 Denotes Black
xxxxx13 Denotes Hunter Green
xxxxx14 Denotes Regimental Blue
xxxxx15 Denotes Adobe

4
STEP 1
FIGURE 1
• Pull back SPRING PIN on the LEFT and RIGHT SWIVEL PULLEYS (6 &7) and CAREFULLY slide them over the FRONT UPRIGHTS (2) as shown in FIGURE 1.
6 7
2 2
SPRING PIN SPRING PIN
6A
6A
7A
7B

(3X)
(3X)
(4X)
(3X)
(2X)
(6X)
(4X)
(3X)
1C
1
1E
1G
1I
1J
1D
1H
1B
1F
A
90%%d
CABLE ROUTING
1A
DIAGRAM
1"
DETAIL A
SCALE 1 : 4
1K

5
STEP 2
FIGURE 2
• SECURELY assemble the LEFT FRONT UPRIGHT (2) to the top and the bottom of the TOWER (1) using six RH CAPS (33), one 3/8 X 2-1/2” BOLT (11), two 3/8 X 2-3/4”
BOLTS (12), six 3/8” SAE WASHERS (16), six 3/8” RH WASHERS (17) and three 3/8” LOW HEIGHT LOCK NUTS (15) as shown in FIGURE 2.
0
123456
1/2 1/2 1/2 1/2 1/2 1/2
• REPEAT the above step to assemble the RIGHT FRONT UPRIGHT (2) to the TOWER (1)
3/8 X 2-3/4” 12
1
2 LEFT FRONT
UPRIGHT
33
16
15
2 RIGHT FRONT
UPRIGHT
1
3/8 X 2-1/2” 11
33
1716
15
17
• NOTE: Insert one 4-1/2” PULLEY (24) into the bottom slot of both TOWERS (1) as shown. These pulleys will be assembled after the cable is routed.
24
1A
1A

6
STEP 3:
FIGURE 3
• SECURELY assemble the REAR CROSS SUPPORT (4) to the bottom of the LEFT and RIGHT TOWERS (1) using eight RH CAPS (33), four 3/8 X 2-3/4” BOLTS (12),
eight 3/8” SAE WASHERS (16), eight 3/8” RH WASHERS (17) and four 3/8” LOW HEIGHT LOCK NUTS (15) as shown in FIGURE 3.
LEFT TOWER 1
RIGHT TOWER 1
1/2 X 2-3/4” 1216
17
15
4
33
4A
1A

7
STEP 4:
FIGURE 4
• SECURELY assemble the TOP CROSS SUPPORT (3) to the the top of the LEFT and RIGHTTOWERS (1) using four RH CAPS (33), two 3/8 X 3-3/4” BOLTS (14), four 3/8”
SAE WASHERS (16), four 3/8” RH WASHERS (17) and two 3/8” LOW HEIGHT LOCK NUTS (15) as shown in FIGURE 4.
0
123456
1/2 1/2 1/2 1/2 1/2 1/2
14 3/8 X 3-3/4”
15
17
16
33
3
LEFT TOWER 1
RIGHT TOWER 1
3A
1A
3B
1A

8
STEP 5:
FIGURE 5
• Route the threaded end of CABLE through the GUIDE ROD SUPPORT (5) and through the LEFT TOWER (1) as shown in FIGURE 5.
• SECURELY assemble one 4-1/2” PULLEY (24) to the TOWER (1) using one 3/8 X 2-1/2” BOLT (11), two 3/8” FLANGE SPACERS (19), and one 3/8” LOW HEIGHT LOCK
NUT (15) as shown in FIGURE 5.
• Repeat these steps to assemble the 4-1/2” PULLEY (24) and the GUIDE ROD SUPPORT (5) to the RIGHT TOWER (1). (NOTE: The GUIDE ROD SUPPORT (5) is
assembled to the RIGHT TOWER (1) in the opposing direction of the LEFT TOWER (1). See FIGURE 5.)
LEFT TOWER 1
RIGHT TOWER 1
CABLE
5
24
15
19
3/8 X 2-1/2” 11

9
STEP 6:
FIGURE 6
• Route the threaded end of CABLE over one 4-1/2” PULLEY (24) and SECURELY assemble the 4-1/2” PULLEY (24) to the LEFT TOWER (1) using two RH CAPS (33), one
3/8 X 2” BOLT (10), two 3/8” SAE WASHERS (16), two 3/8” RH WASHERS (17) and one 3/8” LOW HEIGHT LOCK NUT (15) as shown in FIGURE 6.
• Repeat this step to assemble one 4-1/2” PULLEY (24) to the RIGHT TOWER (1).
0
123456
1/2 1/2 1/2 1/2 1/2 1/2
LEFT TOWER 1
RIGHT TOWER 1
CABLE
24 15
16
3/8 X 2” 10
17
33

10
STEP 7:
FIGURE 7
• Route the threaded end of CABLE through the LEFT TOWER (1) as shown, then over one 4-1/2” PULLEY (24) and SECURELY assemble the 4-1/2” PULLEY (24) to the
LEFT TOWER (1) using two RH CAPS (33), one 3/8 X 2” BOLT (10), two 3/8” SAE WASHERS (16), two 3/8” RH WASHERS (17) and one 3/8” LOW HEIGHT LOCK NUT
(15) as shown in FIGURE 7.
• Repeat this step to assemble one 4-1/2” PULLEY (24) to the RIGHT TOWER (1).
CABLE
24
15
16
3/8 X 2” 10
17
33
LEFT TOWER 1
RIGHT TOWER 1
1A
1A

11
STEP 8:
FIGURE 8
• Route the threaded end of CABLE through the LEFT TOWER (1) and around the previously inserted 4-1/2” PULLEY (24). SECURELY assemble the 4-1/2” PULLEY (24) to
the LEFT TOWER (1) using two RH CAPS (33), one 3/8 X 2-1/2” BOLT (11), two 3/8” RH WASHERS (17), one CABLE CLIP (23), two 3/8” FLANGE SPACERS (19) and
one 3/8” LOW HEIGHT LOCK NUT (15) as shown in FIGURE 8. (NOTE: Make sure the cable is in the groove of the pulley.)
• Repeat this step to assemble one 4-1/2” PULLEY (24) to the RIGHT TOWER (1).
0
123456
1/2 1/2 1/2 1/2 1/2 1/2
15
24
23
1719
33
3/8 X 2-1/2” 11
LEFT TOWER 1
RIGHT TOWER 1
CABLE
1A

12
STEP 9:
FIGURE 9
• Repeat this step to assemble the CABLE to the RIGHT SWIVEL PULLEY (7) on the RIGHT TOWER (1).
6 7
CABLE
• Screw the threaded end of CABLE approximately 3/4” into the LEFT SWIVEL PULLEY (6) on the LEFT TOWER (1) and snuggly tighten jam nut as shown in FIGURE 9.
LEFT TOWER 1
RIGHT TOWER 1

13
STEP 10:
• Insert the two GUIDE RODS (27) into the base
of the TOWER (1) as shown in FIGURE 10.
Lubricate the GUIDE RODS (27) with a slicon
or teflon spray that is available at most hardware
stores. (NOTE: GUIDE RODS are found in
the SHROUD KIT box.)
• Slide two WEIGHT STACK CUSHIONS (25)
down over the GUIDE RODS (27). See
FIGURE 10.
• Carefully Slide the HEAD PLATE (8) down
over the GUIDE RODS (27) onto the weight
stack as shown in FIGURE 10.
FIGURE 10
• Slide two GUIDE ROD BUSHINGS (21)
over each GUIDE ROD (27).
• Slide two 1” SHAFT COLLARS (26 over
each GUIDE ROD (27) as shown in FIGURE
10.
• Place the GUIDE ROD SUPPORT (5) over
the GUIDE RODS (27) as shown in FIGURE
10.
HEAVYWEIGHTOPTION
• Using EXTREME CARE place fifteen 10 LB.
WEIGHTPLATES(30) overtheGUIDE RODS
(27) as shown in FIGURE 10.(NOTE: If
HEAVY WEIGHT OPTION is being used,
slide ten 15LB. WEIGHT PLATES (31)
over the GUIDE RODS (27) first, then slide
five 10 LB.WEIGHT PLATES (30) over the
GUIDE RODS.)
30
31
25
30
27
8
26
21
5
• Repeat the above steps to assemble the
WEIGHTSTACK onthe oppositeTOWER(1).
1 LEFT TOWER
RIGHT TOWER 1

14
STEP 11:
FIGURE 11
• SECURELY assemble the GUIDE ROD SUPPORT (5) to the the top of the LEFT and RIGHT TOWERS (1) using eight RH CAPS (33), four 3/8 X 3” BOLTS (13), eight 3/8”
SAE WASHERS (16), eight 3/8” RH WASHERS (17) and four 3/8” LOW HEIGHT LOCK NUTS (15) as shown in FIGURE 11.
LEFT TOWER 1
RIGHT TOWER 1
TIGHTEN!
5
15
26
17
16
21
33
3/8 X 3” 13
TIGHTEN!
• Slide GUIDE ROD BUSHINGS (21) into the tubes on the GUIDE ROD SUPPORT (5), slide 1” SHAFT COLLARS (26) underneath the GUIDE ROD BUSHINGS (21) and
SECURELY tighten the set screws.

15
STEP 12:
FIGURE 12
• Place one 4-1/2” PULLEY (24) into the loop of the CABLE and SECURELY assemble the 4-1/2” PULLEY (24) to the HEAD PLATE (8) using two BLACK RH CAPS (18),
one 3/8 X 1-3/4” BOLTS (9), two 3/8” RH WASHERS (17) and one 3/8” LOW HEIGHT LOCK NUT (15) as shown in FIGURE 12.
• Repeat this step to assemble one 4-1/2” PULLEY (24) to the opposing HEAD PLATE (8).
0
123456
1/2 1/2 1/2 1/2 1/2 1/2
18
3/8 X 1-3/4” 9
17
8
24 15

16
STEP 13:
FIGURE 13
• Route the ball end of CABLE under one 4-1/2” PULLEY (24) and SECURELY assemble the 4-1/2” PULLEY (24) to the LEFTSWIVEL PULLEY(6) using two RH CAPS (18),
one 3/8 X 1-3/4” BOLT (9), two 3/8” SAE WASHERS (16), two 3/8” RH WASHERS (17) and one 3/8” LOW HEIGHT LOCK NUT (15) as shown in FIGURE 13.
• Repeat this step to assemble one 4-1/2” PULLEY (24) to the RIGHT SWIVEL PULLEY (7).
24
9 3/8 X 1-3/4”
15 18
6
CABLE
7
16
17
LEFT TOWER 1
RIGHT TOWER 1

• Peel the backing off the WEIGHT STACK LABELS (32), line up sheet to the right of the selector opening and apply labels to the WEIGHT PLATES (30), starting with the
HEAD PLATE (8) as shown in FIGURE 14. (NOTE: The WEIGHT STACK LABEL sheet (32) includes labels for both lbs. and kgs. for both the standard and
optional weight stacks.)
17
STEP 14:
FIGURE 14
32
8
30
• Insert the WEIGHT STACK PIN into the WEIGHT STACK as shown in FIGURE 14.
• If the HEAD PLATE (8) does not sit on top of the first WEIGHT PLATE (30), push the head plate down, insert the WEIGHTSTACK PIN and perform several repetitions on the
machine. This will relax the cable system and prevent the HEAD PLATE (8) from lifting up.
• If after completing previous step the HEAD PLATE (8) still does not sit on top of the first WEIGHT PLATE (30) or if there is excess slack in the cable system, adjust the
threaded end of the CABLE going into the SWIVEL PULLEYS (6 & 7) accordingly and retighten the jam nut.
ADJUST!

18
STEP 16:
FIGURE 16
• Assemble one SEWN HANDLE (22) to the CABLE end using one SNAP LINK (20) as shown in FIGURE 16.
• Repeat this step to assemble one SEWN HANDLE (22) to the opposite side.
CABLE
22
20
• REFERTOSHROUD KITASSEMBLYINSTRUCTIONS.

• Assemble the PLACARD LABEL (28) or the FOREIGN LANGUAGE PLACARD LABEL(29) to the both the SHROUDS as shown in FIGURE 16.
29
28
19
STEP 16:
FIGURE 16
35
34
36