Life Fitness 8235 User manual

8235LEGEXTENSION/LEGCURL
Part # 6869701 Revision:2/21/001
ASSEMBLYINSTRUCTIONS

IMPORTANT NOTES
Please note:
Tools Required for Assembly
* Thank you for purchasing the LIFE FITNESS 8235 LEG EXTENSION/LEG CURL. Please read
these instructions thoroughly and keep them for future reference. This product must be assembled
on a flat, level surface to assure its proper function.
2
NOTE: BOLT LENGTH IS MEASURED FROM THE UNDERSIDE OF THE HEAD OF THE BOLT.
BOLT LENGTH RULER:
* We recommend cleaning your product (pads and frame) on a regular basis, using warm soapy
water. Touch-up paint can be purchased from your LIFE FITNESS customer service representa-
tive at [phone].
Bolt Length Ruler
0123456
1/2 1/2 1/2 1/2 1/2 1/2
BOLT LENGTH
There is a risk assumed by individuals who use this type of equipment. To minimize risk, please
follow these rules:
2. Do not allow minors or children to play on or around this equipment.
1. Inspect equipment daily. Tighten all loose connections and replace worn parts immediately.
Failure to do so may result in serious injury.
3. Exercise with care to avoid injury.
4. If unsure of proper use of equipment, call your local LIFE FITNESS STRENGTH distributor or
call the LIFE FITNESS STRENGTH customer service department at [phone].
* Rubber mallet or hammer
* 3/4” wrench, 9/16” wrench
* Ratchet with 3/4” and 9/16” sockets
* 5/32”, 3/16”, 7/32” Allen wrenches
* Adjustable wrench
* Tape measure
5. Consult your physician before beginning any exercise program.

3
PARTS LIST
PART#
6793303
6662303
6662203
6764901
6782301
6770502
6777403
6780703
6867203
6781303
6698303
6625502
6693502
6780401
6780201
6791102
6427101
6776601
6284501
6714601
3116101
3117305
6782201
3112901
6382301
3108002
6757701
3116001
6140701
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
QTY
1
1
1
6
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
1
4
2
1
2
2
KEY
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
PART #
6692601
6628302
3202107
3102917
3102910
3102915
3102904
3102933
3102901
3202401
3102502
3102501
3114502
3102801
3102802
6406401
6781601
6412001
6214401
3104901
6020601
6695001
3103302
3103304
3102701
6703801
6189501
6214501
DESCRIPTION
3 X 2" END CAP
2 X 8" PLATE
1/2 X 6-1/2” BOLT
1/2 X 4" BOLT
1/2 X 3" BOLT
3/8 X 3-1/4" BOLT
3/8 X 3" BOLT
3/8 X 2" BOLT
3/8 X 1-1/4" BOLT
3/8 X 1" BTN HEAD CAP SCREW
1/2" WASHER
3/8" WASHER
3/8" LOCKWASHER
1/2" LOCK NUT
3/8" LOCK NUT
HINGE TAB
1/2 X 7-7/8" SPRING PIN
3/8" SPRING PIN
SELECTOR PIN
3/4” FLANGE BEARING
1/2" FLANGE BEARING
3/4" DIA TAPPED SHAFT
13/16” SHAFT COLLAR
1-5/16” SHAFT COLLAR
3/8” NUT
WEIGHT STACK LABEL LBS.
WEIGHT STACK LABEL (1-25)
WEIGHT PLATES
QTY
.2
1
1
6
4
2
4
7
5
6
10
13
2
10
9
2
1
2
1
2
2
1
2
6
2
1
1
20
DESCRIPTION
TOWER
LEGEXTHANDLELEFT
LEGEXTHANDLERIGHT
4X7" ROLLER PAD
63-1/2"GUIDEROD
PADSLEEVE
BENCHFRAME
LOWERCROSSSUPPORT
LEGCURL/EXTENSION
TOWERBRACE
UPPERCROSSSUPPORT
PADSUPPORTRIGHT
PADSUPPORTLEFT
BACKPAD
SEAT PAD
SHROUD
KEYHOLECLEVIS
19-1/4”TUBE
20HOLEWEIGHTSTACKSHAFT
HEADPLATE
4-1/2"PULLEY
CLEVISPIN
161-1/2”CABLEASSEMBLY
COTTERPIN
WEIGHTPLATEBUSHING10CT
WEIGHTSTACK CUSHION
2-7/8"CABLECLIP
1-1/4”SQ. RUBBERBUMPER
1X1"GLIDE

STEP 1:
FIGURE 1
• LOOSELYassemble LOWER CROSS SUPPORT (8) to the TOWER (1) using two 1/2 X 4” BOLTS (33), two 1/2” WASHERS (40)
and one 1/2” LOCK NUT (43). See FIGURE 1.
1
33 1/2 X 4”
8
43
4
0123456
1/2 1/2 1/2 1/2 1/2 1/2
• Slide the SHROUD (16) between the TOWER (1) as shown in FIGURE 1.
16
40

STEP 2:
FIGURE 2
• LOOSELY assemble BENCH FRAME (7) to the LOWER CROSS SUPPORT (8) using two 1/2 X 4” BOLTS (33), two 1/2”
WASHERS (40) and two 1/2” LOCK NUTS (43). See FIGURE 2.
• LOOSELY assemble UPPER CROSS SUPPORT (11) to the TOWER (1) with SHROUD (16), and BENCH FRAME (7) using four
1/2 X 3” BOLTS (34), four 1/2” WASHERS (40) and four 1/2” LOCK NUTS (43). See FIGURE 2.
40
1
43
1/2 X 3” 34
34 1/2 X 3”
8
43
11
43
40
7
33 1/2 X 4”
40
5
3/8 X 1”
BUTTON
HEAD
CAP SCREW
39 16
• SECURELYassemble the other side of the SHROUD (16) to the TOWER (1) using two 3/8 X 1” BUTTON HEAD CAP SCREWS
(39) as shown in FIGURE 2.
• SECURELYTIGHTENTHEFRAMECONNECTIONSINTHEFOLLOWINGORDER:
1.LOWERCROSS SUPPORT(8) tothe TOWER (1)and BENCHFRAME (7).
2.UPPERCROSS SUPPORT(11) to theTOWER (1) andBENCH FRAME (7).

STEP 3:
FIGURE 3
6
STEP 4:
• SECURELY assemble the LEFT (2) and RIGHT (3) LEG EXT. HANDLES to the BENCH FRAME (7) using two 3/8 X 3-1/4”
BOLTS (35), four 3/8” WASHERS (41), and two 3/8” LOCK NUTS (44). See FIGURE 3.
• Slide two HINGE TABS (45) onto the BENCH FRAME (7) as shown in FIGURE 3.
3
• SECURELY assemble one 2 X 8” PLATE (31) to the SEAT
PAD (15) using two 3/8 X 1-1/4” BOLTS (38) and two 3/8”
WASHERS (41). See FIGURE 4.
41
35 3/8 X 3-1/4”
7
44
2
45
45
0123456
1/2 1/2 1/2 1/2 1/2 1/2
FIGURE 4
41
31
15
38 3/8 X 1-1/4”
28
• Apply one 1-1/4” RUBBER BUMPER (28) to the 2 X 8”
PLATE (31) as shown in FIGURE 4.

STEP 5:
FIGURE 5
7
STEP 6:
FIGURE 6
• SECURELY assemble SEAT PAD (15) to HINGE TABS (45) using two 3/8 X 1-1/4” BOLTS (38) and two 3/8” WASHERS (41).
See FIGURE 5.
• SECURELYassemble one1/2 X 7-7/8” SPRING PIN (46) to the BENCH FRAME (7) as shown in FIGURE 5.(NOTE: IMPORTANT!
TightenSPRINGPINcompletely.)
• Assemble RIGHT (12) & LEFT (13) PAD
SUPPORTS to the BENCH FRAME (7) using one
1/2 X 6-1/2” BOLT (32), two 1/2” FLANGE
BEARINGS (50), and one 1/2” LOCK NUT (43)
as shown in FIGURE 6. (NOTE: Securely tighten,
then back nut off 1/4 turn to allow the two parts
to rotate freely.)
15
46
7
3/8 X 1-1/4” 38
41
45
50
1/2 X 6-1/2” 32
7
43
13
12

FIGURE 7
8
STEP 7:
FIGURE 8
• SECURELY assemble BACK PAD (14) to the RIGHT & LEFT PAD SUPPORTS (12) (13) using four 3/8 X 3” BOLTS (36) and
four 3/8” WASHERS (41) as shown in FIGURE 7.
STEP 8:
4
7
• Assemble one 1-1/4” RUBBER BUMPER (28) to the middle of the plate on the BENCH FRAME (7) as shown on FIGURE 8.
• Inserttwo 3/4” FLANGE BEARINGS (49)intothebushing of theLEGCURL/EXTENSION(9), then slidethe3/4”DIA TAPPED SHAFT
(51) into the 3/4”FLANGEBEARINGS (49) as showninFIGURE 8.
13 12
41
36 3/8 X 3”
14
7
53
4
49
9
51
49
28 18
53
0123456
1/2 1/2 1/2 1/2 1/2 1/2
• SECURELYassemble two ROLLER PADS (4) to theBENCH FRAME (7)using one 19-1/4” TUBE (18) and two 1-5/16” SHAFT
COLLARS (53). SECURELY tighten set screws on SHAFT COLLARS (53). See FIGURE 8.

STEP 10:
9
• SECURELYassembletwo 3/8” SPRING PINS(47)tothePAD SLEEVES (6) as shown in FIGURE 10. (NOTE:IMPORTANT!Tighten
SPRINGPINcompletely.)
• Assemble four ROLLER PADS (4) to the PAD SLEEVES (6) using four 1-5/16” SHAFT COLLARS (53). SECURELY tighten
set screws on SHAFT COLLARS (53). See FIGURE 10.
• SlidePADSLEEVES (6)over LEG CURL/EXTENSION(9) untilthe spring pinpops intothe holes. SeeFIGURE 10.
• SECURELYassemble two 3/8 X 1” BUTTON HEAD CAP SCREWS (39) and two 3/8” HEX NUTS (54) to the last holes in the LEG
CURL/EXTENSION asshowninFIGURE 10.
• Insert two 3 X 2” END CAPS (30) into the ends of the LEG CURL/EXTENSION (9) as shown in FIGURE 10.
FIGURE 9
STEP 9:
• Attach LEG PEDESTAL (9) to the BENCH FRAME
(7) using two 3/8 X 1” BUTTON HEAD CAP
SCREWS (39) and two 3/8” LOCKWASHERS (42) as
shown in FIGURE 9.
(NOTE: Both button head cap screws must be
tightened at the same time using two allen
wrenches.)
3/8 X 1” BTN HEAD 39
7
FIGURE 10
6
30
4
53 HEX 54
NUT
39 3/8 X 1” BTN HD 9
47
9
42

10
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1/2 1/2 1/2 1/2 1/2 1/2
FIGURE 12
STEP 12:
STEP 11:
FIGURE 11
• Snap two WEIGHT PLATE BUSHINGS (25) into the
top of all twenty WEIGHT PLATES (57) as shown in
FIGURE 11.
25
57
5
3/8 X 1-1/4” 38
20
41
19
57
26
1
5655
52
• Insert the two GUIDE RODS (5) into the base of
the TOWER (1) as shown in FIGURE 12. Lubricate
the GUIDE RODS (5) with a slicon or teflon spray
that is available at most hardware stores.
• Slide two WEIGHT STACK CUSHIONS (26) down
over the GUIDE RODS (5). See FIGURE 12.
• Using EXTREME CARE slide twenty WEIGHT
PLATES(57) downover the GUIDE RODS (5)with
the key-hole facing as shown in FIGURE 12.
• Securely assemble the WEIGHT STACK SHAFT
(19) to the HEAD PLATE (20) using one 3/8 X 1-
1/4” BOLT (38) and one 3/8” WASHER (41).
(Note: The bolt hole in the HEAD PLATE (20)
should be on top.)
• Carefully Slide the HEAD PLATE ASSEMBLY
(19 & 20) down over the GUIDE RODS (5) onto
the weight stack as shown in FIGURE 12.
• Apply one set of WEIGHT STACK LABELS - LBS.
OR 1-25 (55) (56) to each WEIGHT PLATE (57)
as shown in FIGURE 12.
• Slide two 13/16” SHAFT COLLARS (52) over the
GUIDE RODS (5) as shown in FIGURE 12.

FIGURE 14
11
STEP 14:
• SECURELY assemble two 4-1/2” PULLEYS (21) to the TOWER BRACE (10) using two 3/8 X 2” BOLTS (37), and two 3/8”
LOCK NUTS (44). See FIGURE 14.
44
37 3/8 X 2”
21
10
29
FIGURE 13
STEP 13:
• Attach two 1 X 1” GLIDES (29) to the LEFT & RIGHT PAD SUPPORTS approximately where shown in FIGURE 13.

0123456
1/2 1/2 1/2 1/2 1/2 1/2
12
FIGURE 15
• Place TOWER BRACE (10) over the GUIDE RODS (5) and SECURELY assemble TOWER BRACE (10) to TOWER (1) using
two 1/2 X 4” BOLTS (33), two 1/2” WASHERS (40), and two 1/2” LOCK NUTS (43) as shown in FIGURE 15.
STEP 15:
40
43
10
33 1/2 X 4”
5
1
52
• Slide the 13/16” SHAFT COLLARS (52) to the top of the GUIDE RODS (5) and SECURELY tighten the SHAFT COLLAR
(52) set screws. See FIGURE 15. FIGURE 16
• Loop the ball end of the CABLE (23) through the holes and around
the pulleys in the TOWER BRACE (10) as shown in FIGURE 16.
23
10
STEP 16:

13
FIGURE 18
STEP 18:
• Attach the to the KEYHOLE CLEVIS(17) to the CABLE (23) as
shown in FIGURE 18.
FIGURE 17
STEP 17:
• SECURELYassemble three 4-1/2” PULLEYS (21) to the brackets on the BENCH FRAME (7) and LOWER CROSS SUPPORT (8), us-
ingfour 3/8 X2”BOLTS (37), one2-7/8”CABLE CLIP (27),and four 3/8” LOCK NUTS (44) as shown in FIGURE 17.(NOTE:Posi-
tionthe2-7/8”CABLE CLIPbeforetighteningand makesuretheCABLEis runningoverthe3/8X 2”retainingbolt.)
23
• Make sure the CABLE (23) is routed around all pulleys as shown in FIGURE 17.
7
44
27
37 3/8 X 2”
21
17
23
8

14
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1/2 1/2 1/2 1/2 1/2 1/2
FIGURE 19
STEP 19:
• Assemble the KEYHOLE CLEVIS (17) to the tab on the cam of the LEG PEDESTAL (9) using one CLEVIS PIN (22) and one
COTTER PIN (24) as shown in FIGURE 19.
• Insert ball end of CABLE (23) through slot of the BENCH FRAME (7) and around LEG PEDESTAL (9) as shown in FIGURE 19.
17
23
22
24
7
9

FIGURE 20
15
STEP 20:
• Screw the treaded end of the CABLE (23) approximately 3/4” into the end of the WEIGHT STACK SHAFT (19) and tighten jam
nut securely. See FIGURE 20.
• If the HEAD PLATE (20) does not sit on top of the first WEIGHT PLATE (57), push the head plate down, insert the SELECTOR
PIN (48) and perform several repetitions on the machine. This will relax the cable system and prevent the HEAD PLATE (20) from
lifting up.
• If after completing the previous step the HEAD PLATE (20) still does not sit on top of the first WEIGHT PLATE (57) or if there
is excess slack in the cable system, adjust the threaded end of the CABLE accordingly and retighten the jam nut.
23
19
48
20
57
1
Thank you for purchasing the LifeFitness 8235 LEG EXTENSION/LEG CURL. If unsure of proper use of equipment, call
your local LifeFitness distributor or call the LifeFitness customer service department at [phone].