Powerline P1 User manual

P1
OWNER’S MANUAL

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Reference Drawings
Note: Due to continuing product improvements, specifications
and designs are subject to change without notice.
Even though we have prepared this manual with extreme care,
neither the publisher nor the author can accept responsibility
for any errors in, or omission from, the information given.

Thank you for purchasing the Powerline P1. This gym is part of the Powerline line of quality strength
training machines, which let you target specific muscle groups to achieve better muscle tone and overall
body conditioning. To maximize your use of the equipment please study this Owner’s Manual thoroughly.
Unpacking the Equipment
The P1 is carefully tested and inspected before
shipment. We have shipped the unit in several
pieces that require assembly. Ask for assistance
during the assembly process.
Carefully unpack the boxes and lay the pieces
on the floor near the area where you plan to use
the equipment.
Be careful to assemble all components in the
sequence presented in this guide.
If any items are missing, contact the dealer from
whom you purchased the unit or call:
Customer Service 1-800-556-3113.
Before You Begin
3

Before beginning any fitness program, you should obtain a complete physical examination from your
physician.
Il est conseille de subir un examen medical complet avant d’entreprendre tout programme d’exercise.
Si vous avez des etourdissements ou des faiblesses, arretez les exercices immediatement.
Antes de comenzar cualquier programma de ejercicios, deberias tener un examen fisico con su doctor.
When using exercise equipment, you should always
take basic precautions, including the following:
Read all instructions before using the P1. This manual
is written to ensure your safety and to protect the
unit.
Do not allow children on or near the equipment.
Use the equipment only for its intended purpose as
described in this guide. Do not use accessory
attachments that are not recommended by the
manufacturer. Such attachments might cause injuries.
Wear proper exercise clothing and shoes for your
workout, no loose clothing.
Use care when getting on or off the unit.
Do not overexert yourself or work to exhaustion.
If you feel any pain or abnormal symptoms,
stop your workout immediately and consult your
physician.
Never operate unit when it has been dropped or
damaged. Return the equipment to a service center
for examination and repair.
Never drop or insert objects into any opening in the
equipment.
Always check the unit and its cables before each use.
Make sure that all fasteners and cables are secure
and in good working condition.
Do not use the equipment outdoors or near water.
Personal Safety During Assembly
It is strongly recommended that a qualified dealer
assemble the equipment. Assistance is required.
Before beginning assembly, please take the time to
read the instructions thoroughly. Read each step in
the assembly instructions and follow the steps in
sequence. Do not skip ahead. If you skip ahead, you
may learn later that you have to disassemble
components and that you may have damaged the
equipment.
Assemble and operate the P1 gym on a solid, level
surface. Locate the unit a few feet from the walls or
furniture to provide easy access.
The P1 is designed for your enjoyment. By following
these precautions and using common sense, you will
have many safe and pleasurable hours of healthful
exercise with your gym.
After assembly, you should check all functions to
ensure correct operation. If you experience problems,
first recheck the assembly instructions to locate any
possible errors made during assembly. If you are
unable to correct the problem, call the dealer from
whom you purchased the machine or call:
1-800-556-3113.
Obtaining Service
Please use this Owner’s Manual to make sure that
all parts have been included in your shipment. When
ordering parts, you must use the part number, key
number, and description from this Owner’s Manual.
Use only Powerline replacement parts when servicing
this machine. Failure to do so will void your warranty
and could result in personal injury.
For information about product operation or service,
go to Powerline Equipment at www.bodysolid.com or
contact an authorized Powerline dealer or a
Powerline factory-authorized service company or
contact Body-Solid customer service at one of the
following:
Toll Free:1-800-556-3113
Phone: [phone] ext. 2
Fax: [phone]
E-mail: [email protected]
Or write to: Body-Solid, Inc.
Service Department
1900 S. Des Plaines Ave.
Forest Park, IL 60130 USA
Retain this Owner’s Manual for future reference. Part
numbers, key numbers, and description are required
when ordering parts.
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Important Safety Instructions
4

Successful resistance training programs have one prominent feature in common...safety. Resistance
training has some inherent dangers, as do all physical activities. The chance of injury can be greatly
reduced or completely removed by using correct lifting techniques, proper breathing, maintaining
equipment in good working condition, and by wearing the appropriate clothing.
1. It is highly recommended that you consult your physician before beginning any exercise program.
This is especially important for individuals over the age of 35, or persons with pre-existing health
problems.
2. Always warm up before starting a workout. Try to do a total body warm up before you start. It is
especially important to warm up the specific muscle groups you are going to be using. This can
be as simple as performing a warm up set of high repetitions and light weight for each exercise.
3. Use proper form. Focus on only working the muscle groups intended for the exercise you are doing.
If there is strain elsewhere, you may need to re-evaluate the amount of weight that is involved with
the lift. Keeping proper form also includes maintaining control through an entire range of motion.
4. Breath properly. Inhale during the eccentric phase of the exercise, and exhale during the lifting, or
concentric phase. Never hold your breath during any part of an exercise.
5. Always wear the appropriate clothing and shoes when exercising. Wearing comfortable athletic
shoes with good support and suitable, breathable clothing will reduce the risk of injury.
6. Maintaining equipment in proper operating condition is of utmost importance for a safe resistance
training program. Pulleys and cables should be checked for wear frequently and replaced as
needed.
Equipment should be lubricated as indicated by the manufacturer.
7. Read and study all warning labels on this machine. It is absolutely necessary that you familiarize
yourself and all others with the proper operation of this machine prior to use.
8. Keep hands, limbs, loose clothing and long hair well out of the way of all moving parts.
9. Do not attempt to lift more weight than you can control safely.
10. Inspect the machine daily for loose or worn parts. If a problem is found do not allow the machine to
be used until all parts are tightened or worn or defective parts are repaired or replaced.
Safety Guidelines
5

CAUTION: To set up this unit, you will need assistance. Do not attempt assembly by yourself.
You must review and follow the instructions in this Owner’s Manual. If you do not assemble and use the
P1 gym according to these guidelines, you could void the warranty.
Required Tools
The tools that you should obtain before assembling
the P1 gym include:
Rubber Mallet
4mm Allen Key
5mm Allen Key
6mm Allen Key
8mm Allen Key
9/16” Open-End Wrench
11/16” Open-End Wrench
13/16” Open-End Wrench
3/4” Open-End Wrench
9/16” Box Wrench
11/16” Box Wrench
13/16” Box Wrench
3/4” Box Wrench
Screwdriver (standard or phillips)
Installation Requirements
Follow these installation requirements when
assembling the P1:
Set up the P1 on a solid, flat surface. A smooth, flat
surface under the machine helps keep it level. A
level machine has fewer malfunctions.
Provide ample space around the machine. Open
space around the machine allows for easier access.
Insert all bolts in the same direction. For aesthetic
purposes, insert all bolts in the same direction
unless specified (in text or illustrations) to do
otherwise.
Leave room for adjustments. Tighten fasteners such
as bolts, nuts, and screws so the unit is stable, but
leave room for adjustments. Do not fully tighten
fasteners until instructed in the assembly steps to
do so.
Fill out and mail warranty card.
CAUTION: Obtain assistance! Do not attempt
to assemble the P1 by yourself. Review the
Installation Requirements before proceeding
with the following steps.
The P1 unit comes in separate boxes.
Be careful to assemble components in the sequence
presented in this guide.
NOTE: With so many assembled parts, proper
alignment and adjustment is critical. While tightening
the nuts and bolts, be sure to leave room for
adjustments.
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Preparations
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Assembly of the P1 gym takes professional installers about 3 hours to complete. If this is the first time
you have assembled this type of equipment, plan on significantly more time.
Professional installers are highly recommended!
However, if you acquire the appropriate tools, obtain assistance, and follow the assembly steps
sequentially, the process will take time, but is fairly easy.
IMPORTANT!
Before you begin you should fold-out pages 58,
59 and 60.
This is a quick reference guide that shows all
hardware parts (in actual size) along with the
corresponding key numbers on the assembly
instructions.
Assembly Tips
Read all “Notes” on each page before beginning
each step.
While you may be able to assemble the P1 gym
using the illustrations only, important safety
notes and other tips are included in the text.
Some pieces may have extra holes that you will
not use. Use only those holes indicated in the
instructions and illustrations.
NOTE: To find out the length of a particular bolt,
measure its shank (the long, narrow part
beneath the head). Refer to the following
diagram:
Do not fully tighten bolts until
instructed to do so.
Note: After assembly, you should check all
functions to ensure correct operation. If you
experience problems, first recheck the assembly
instructions to locate any possible errors made
during assembly. If you are unable to correct the
problem, call the dealer from whom you
purchased the machine or call Customer
Service 1-800-556-3113.
Assembly Instructions
7

8
Be careful to assemble all components in the
sequence they are presented.
STEP
1
Inch
MM
NOTE:
Finger tighten all hardware in this step. Do NOT wrench tighten until the end of step 2.
A. Attach Stabilizing Leg (P) to the Lower Main Frame (A) as shown using:
One 58 (3/8” x 4” hex head bolt)
Two 60 (3/8” washer)
Two 14 (pulley spacer)*
One 70 (3/8” nylon lock nut)
*NOTE:
The Pulley Spacers fit into Lower Main Frame. Finger tighten all
hardware in this step, you will be installing a pulley in Step 9 here.
B. Attach Lower Main Frame (A) to Rear Leg (B) and Rear Upright (C) using:
Two 55 (3/8” x 2 1/2” hex head bolts)
Two 70 (3/8” nylon lock nut)
C. Attach Upper Main Frame (D) to Lower Main Frame (A) using:
Two 58 (3/8” x 4” hex head bolt)
Four 60 (3/8” flat washer)
Two 70 (3/8” nylon lock nut)
D. Attach Flat Plate (H) as shown using:
Two 55 (3/8” x 2 1/2” hex head bolt)
Four 60 (3/8” flat washer)
Two 70 (3/8” nylon lock nut)
E. Attach two End Caps (17)* to Upper Main Frame (D) as shown.
Attach two Foot Caps (46)* to Stabilizing Leg (P) as shown.
Attach 2 Foot Caps (46)* to Rear Leg (B) as shown.
*NOTE:
These parts might be pre-installed.

STEP
1
9

10
STEP
2
Be careful to assemble all components in the
sequence they are presented.
Inch
MM
NOTE:
At this point you must make sure that the gym is level, stable and in the right location.
A. Place two Weight Stack Risers (F)* and two Rubber Donuts (29) onto Rear Leg (B) as shown.
Slide two Guide Rods (G) through the Rubber Donuts (29), through the two Weight Stack
Risers (F), and into the Rear Leg (B).
*NOTE:
Use Weight Stack Risers (F) for a 160lb. weight stack.
Do NOT use Weight Stack Risers (F) for a 210lb. weight stack.
B. Slide Weight Stack Plates (36)* onto Guide Rods (G). Make sure the opening in each Weight
Stack Plate (36), for the Weight Stack Pin (30), is facing outward.
*NOTE:
Use fifteen 10lb. plates for a 160lb. weight stack.
Use twenty 10lb. plates for a 210lb. weight stack.
C. Connect Top Plate (37) to the Selector Rod (31) using:
One 35 (3/8” x 2” socket head bolt)
One 64 (3/8” spring lock washer)
Slide Top Plate (37) and Selector Rod (31) onto Guide Rods (G).
D. Slide two Shaft Collars (32) onto the two Guide Rods (G) as shown.
E. Insert Guide Rods (G) into Rear Upper Beam (E), and attach Rear Upper Beam (E) to The
Upper Main Frame (D) and Rear Upright (C) using:
Two 55 (3/8” x 2 1/2” hex head bolt)
Two 70 (3/8” nylon lock nut)
Attach End Caps (17) to Rear Upper Beam (E) as shown.
F. Slide Shaft Collars (32) up into Rear Upper Beam (E) and turn the Shaft Collar, so it locks onto
Rear Upper Beam (E), Now tighten each Allen Screw (8) in Shaft Collars (32).
G. You can now wrench tighten all bolts and nuts on the main frame unit.
Leave all pulley bolts hand tight until cable installation in step 10 is completed.

STEP
2
11

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STEP
3
Be careful to assemble all components in the
sequence they are presented.
Inch
MM
A. Insert Plastic Bushing (93) into the Lower Main Frame (A) as shown.
Insert Front Foot Plate (J) into the Plastic Bushing (93) in the Lower Main Frame (A) as shown and attach
using:
Two 52 (3/8” x 3 3/4” hex head bolt)
Four 60 (3/8” washer)
Two 70 (3/8” washer)
B. Attach End Cap (50)* to Front Foot Plate (J) as shown.
*NOTE:
These parts might be pre-installed.
C. Attach Leg Extension Arm (K) to the Lower Main Frame (A) as shown using:
Two 38 (5/16” x 1/2” allen head bolt)
Two 61 (5/16” washer)
D. Attach two End Caps (17)* to the top and bottom of Leg Extension Arm (K) as shown.
*NOTE:
These parts might be pre-installed.
E. Attach End Cap (17)* to Lower Main Frame (A) as shown.
*NOTE:
These parts might be pre-installed.
G. You can now wrench tighten all bolts and nuts in this step.
Leave all pulley bolts hand tight until cable installation in step 10 is completed.

STEP
3
13

Be careful to assemble all components in the
sequence they are presented.
STEP
4
Inch
MM
14
A. Attach Seat Pad (AA) to the Seat Pad Frame (L) as shown using:
Two 56 (5/16” x 1 5/8” hex head bolt)*
Two 62 (5/16” spring lock washer)
Two 61 (5/16” washer)
Attach two End Caps (23) to the front and back of Seat Pad Frame (L) as shown.
*NOTE:
Do NOT over-tighten these bolts. Tighten these bolts until spring lock washer is flat.
Over-tighten these bolts will cause T-nuts in pads to strip out.
B. Slide two Plastic Bushings (20)* into the opening in the Lower Main Frame (A) as shown.
Slide the Seat Pad Frame (L) into the two Plastic Bushings (20).
Hold the Seat Pad Frame (L) in place with T-shapped Pop Pin (21).
To stop the Seat Pad Frame (L) from slidding all the way out insert:
One 57 (5/16” x 1/2” socket head bolt)
One 61 (5/16” washer)
*NOTE:
These parts might be pre-installed.
C. Attach Back Pad (AA) to the Back Pad Frame (M) as shown using:
Two 56 (5/16” x 1 5/8” hex head bolt)*
Two 62 (5/16” spring lock washer)
Two 61 (5/16” washer)
Attach two End Caps (23) to the top and bottom of Back Pad Frame (M) as shown.
*NOTE:
Do NOT over-tighten these bolts. Tighten these bolts until spring lock washer is flat.
Over-tighten these bolts will cause T-nuts in pads to strip out.
D. Attach Back Pad Frame (M)* onto Back Pad Adjustment (N)* using:
One 95 (1/2” x 5 1/4” hex head bolt)
Two 97 (1/2” washer)
One 96 (1/2” nylon lock nut)
*NOTE:
These two parts might be pre-installed.
E. Slide two Plastic Bushings (20) into the opening in the Upper Main Frame (D) as shown.
Slide the Back Pad Adjustment (N) into the two Plastic Bushings (20).
Hold the Back Pad Adjustment (N) in place with T-shapped Pop Pin (21).
Attach End Cap (2) to Back Pad Adjustment (N) as shown.
Insert T-shapped Pop Pin (26) as shown.
To stop the Back Pad Adjustment (N) from slidding all the way out insert:
One 57 (5/16” x 1/2” socket head bolt)
One 61 (5/16” washer)
F. You can now wrench tighten all bolts and nuts in this step. Do NOT re-tighten any of the pad bolts.
Leave all pulley bolts hand tight until cable installation in step 10 is completed.

STEP
4
15

Be careful to assemble all components in the
sequence they are presented.
STEP
5
Inch
MM
16
A. Attach Press Arm Pivot (Q) to Upper Main Frame (D) as shown using Shaft (16) and:
Two 99 (3/8” x 3/4” allen head bolt)
Two 60 (3/8” washer)
Tighten the two Allen Screws (8) in the Upper Main Frame (D).
B. Attach Press Arm (R) to the Press Arm Pivot (Q) as shown using Shaft (5).
Install Round Pop Pin (13).*
Tighten the two Allen Screws (8) in the Press Arm (R).
Attach Rubber Stop (94)* and Jam Nut (47)* as shown into Upper Main Frame (D).
*NOTE:
These three parts might be pre-installed.
C. Attach Right Handle (S)* and Left Handle (T)* to Press Arm (R) as shown using for each handle:
One 51 (3/8” x 2 1/4” hex head bolt)
One 70 (3/8” nylon lock nut)
*NOTE:
To identify the difference between left and right: notice in the picture in
Step 5 the horizontal grips point outward, and the smaller grip is angled
toward the front of the gym.
D. Install two 4 1/4” diameter Pulley (4) into Press Arm Pivot (Q) as shown using:
Two 50 (3/8” x 7 1/4” threaded rod)*
Four 3 (pulley spacer)
Four 60 (3/8” washer)
Four 70 (3/8” nylon lock nut)
*NOTE:
Leave the two threaded rods (50) hand tight.
You will install a shroud after cable installation in Step 7.
G. You can now wrench tighten all bolts and nuts in this step. Do NOT re-tighten any of the pad bolts.
Leave all pulley bolts hand tight until cable installation in step 10 is completed.

STEP
5
17
smaller
grip
horizontal
grip

Be careful to assemble all components in the
sequence they are presented.
STEP
6
Inch
MM
A. Slide Long Foam Roller Bar (86) into the opening in Lower Main Frame (A) as shown.
Slide two Plastic Washer (25) and two Foam Rollers (22) onto Long Foam Roller Bar (86) as shown.
Hold Foam Rollers (22) in place with two Plastic Roller End Cap (24) as shown.
B. Slide Foam Roller Bar (39) into the Seat Pad Frame (L) as shown.
Slide two Plastic Washer (25) and two Foam Rollers (22) onto Foam Roller Bar (39) as shown.
Hold Foam Rollers (22) in place with two Plastic Roller End Cap (24) as shown.
C. Slide Foam Roller Bar (86) into the Leg Extension Arm (K) as shown.
Slide two Plastic Washer (25) and two Foam Rollers (22) onto Foam Roller Bar (39) as shown.
Hold Foam Rollers (22) in place with two Plastic Roller End Cap (24) as shown.
D. You can now go through the main frame unit and double check all bolts and nuts are wrench tight.
Do NOT re-tighten any of the pad bolts.
Leave all pulley bolts hand tight until cable installation in step 10 is completed.
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STEP
6
19

Be careful to assemble all components in the
sequence they are presented.
STEP
7
Inch
MM
High Pulley Cable (90)
Ball Stop End Metal Ball End
Note:
All Pulleys in this step are 4 1/4” diameter, except where noted in step 7B and 7C.
Leave all pulley bolts hand tight until step 10 is completed.
A. See diagram 1. Begin at the high pulley station. Route the metal ball end of the High Pulley Cable (90)
up and through the opening where Pulley (A1) will be installed and then down through the next
opening where Pulley (A2) will be installed.
B. See diagram 2. Install 3 1/2” diameter Pulley (A1) under Cable (90) and into Upper Main Frame (D) as
shown using:
One 52 (3/8” x 3 3/4” hex head bolt)
Two 14 (pulley spacer)
One 70 (3/8” nylon lock nut)
C. See diagram 2. Install 3 1/2” diameter Pulley (A2) under Cable (90) and into Upper Main Frame (D) as
shown using:
One 52 (3/8” x 3 3/4” hex head bolt)
Two 14 (pulley spacer)
One 70 (3/8” nylon lock nut)
D. See diagram 1. Route Cable (90) over the top and around pre-installed Pulley (A3) as shown.
Route Cable (90) around Pulley (A4) and install Pulley (A4) into Upper Main Frame (D) as shown in
diagram 2 using:
One 52 (3/8” x 3 3/4” hex head bolt)
Two 14 (pulley spacer)
One 70 (3/8” nylon lock nut)
E. See diagram 1. Route Cable (90) between Pulley (A3) and pre-installed Pulley (A5).
Route Cable (90) over the top and around Pulley (A5) and back through Frame (D).
Route Cable (90) down through the small arm sticking out of the Upper Main Frame (D).
And pull entire length of Cable through.
F. See Diagram 2. Install Pulley (A6) under Cable (90) and into arm sticking out of the Upper Main
Frame (D) using:
One 54 (3/8” x 2” hex head bolt)
Two 84 (pulley spacer)
One 70 (3/8” nylon lock nut)
Cable (90) should be hanging down through the bottom of the small arm sticking out of the
Upper Main Frame (D).
G. See Diagram 2. Attach Press Arm Pulley Shroud (U) to Press Arm Pivot (Q) as shown and tighten.
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