Trojan CONCEPT 200 Installation guide

HOME GYM CARE INSTRUCTIONS
AND ASSEMBLY MANUAL
TROJAN
MY SPACE MY TIME
®
#1
HOME
FITNESS
SOUTH AFRICA’S
SINCE
1981
CAUTION
READ ALL PRECAUTIONS AND
INSTRUCTIONS IN THIS MANUAL
BEFORE USING THIS EQUIPMENT
KEEP THIS MANUAL FOR
FUTURE REFERENCE
1 YEAR
warranty
CALL
0861 876526
0861 TROJAN
CONCEPT 200
HOME GYM
11485

1. SAFETY INSTRUCTIONS 3
2. PRE ASSEMBLY CHECK LIST 4
3. HARDWARE LIST 5
4. ASSEMBLY STEPS (GYM) 6
5. FITNESS TIPS AND TECHNIQUES 11
6. EXERCISE PROGRAM 12
7. CONDITIONING GUIDELINES 14
8. WARM-UP AND COOL-DOWN 15
9. PARTS LIST 16
10. EXPLODED DRAWING (GYM) 18
11. FREQUENTLY ASKED QUESTIONS 19
12. TROJAN 1YEAR LIMITED WARRANTY 20
13. TROJAN REPAIRS PROCEDURE 22
INDEX PAGE

11485-3
1.SAFETYINSTRUCTION
WARNING:
To reduce the risk of serious injury, read the following safety instruction before using the TROJAN CONCEPT 200 GYM.
1. Use the TROJAN CONCEPT 200 GYM only on a level surface.
2. Keep children and pets away from this equipment at all times.
3.The TROJAN CONCEPT 200 GYM should not be used by persons weighing more than 120kgs.
4.The TROJAN CONCEPT 200 GYM should be used by only one person at a time.
5. Be careful to maintain your balance while using, mounting, dismounting, folding, unfolding or assembling theTROJAN
CONCEPT 200 GYM, loss of balance may result in a fall and serious bodily injury.
6. Use the TROJAN CONCEPT 200 GYM only as described in the manual.
7. Do not attempt to adjust the seat position while you are on the TROJAN CONCEPT 200 GYM.
8. Before using this equipment to exercise, do stretching exercises to properly warm up.
9. Always make sure all bolts and nuts are tightened prior to each use.
WARNING
Before starting any exercise or conditioning program you should consult with your personal physician to see if you
require a complete physical exam.This is especially important if you are over the age of 35, have never exercised before,
are pregnant, or suffer from any illness.

11485-4
2.PREASSEMBLYCHECKLIST
Thank you for choosing the TROJAN CONCEPT 200 GYM.We take great pride in producing this quality product and
hope it will provide many hours of quality exercise to make you feel better, look better and enjoy life to its fullest.
Yes, it’s a proven fact that a regular exercise program can improve your physical and mental health.Too often, our busy
lifestyles limit our time and opportunity to exercise.TROJAN CONCEPT 200 GYM provides a convenient and simple
method to begin your assault on getting your body in shape and achieving a healthier lifestyle.
Before reading further, please review the drawing below and familiarize yourself with the parts that are labeled.
s2EADTHISMANUALCAREFULLYBEFOREUSINGTHE42/*!.#/.#%04'9-
Butterfly Arms
Top Lat Bar
Seat Cushion
Leg Beam
Back Cushion
Weight Stack
Ridge Tube
Support Tube
Short Lat Bar
Seat Adjuster Knob

11485-5
3.HARDWARELIST
No.48 No.49
1/2”
1/2”
1/2”
No.50
3/8”
No.51 No.52 No.54
No.53 No.56 No.57 No.59 No.75 No.60
No.61 No.65 No.66 No.67 No.69
1/2” x 26mm 3/8” x 19mm
4pcs pre-assemble to No.4
3/8” x 1”
1pc pre-assemble to No.58 and No.44
2pcs
1/2” x 47mm
pack in weight plate
1pc
No.64 No.76 No.62 No.68
5/16” 3/8” (w/o Nylon) 1/2” 5/16” x 16mm
No.63
3/8”(w/ Nylon)
pre-assemble to No.4
4pcs
1pc
1pc
2pcs 4pcs
4pcs 2pcs
2pcs
14pcs 1pc
1pc
2pcs
8pcs
52pcs
12pcs4pcs2pcs3pcs24pcs
4pcs
5/16”

11485-6
4.ASSEMBLYSTEPS
STEP01 Assembly of the base frame and weight stack
s  *OIN44UBEAND(ORIZONTAL"EAMSECURINGTHEMWITHTWOvXv"OLTSFOURvXMM 
Washer (66) and two 3/8” Nut (63).
Note: Two 3/8”x19mm Washer (66) and two 3/8” x 1” Bolt (59) have been attached on the
Guiding Tubes, so please separate them, then follow Step 1.2 to assemble.
s  3LIDEBOTH'UIDE4UBEINTOTHETWO2UBBER2INGSANDTHROUGHTHE(ORIZONTAL"EAMSECURE 
them with two 3/8” x 19mm Washer (66) and two 3/8” x 1” Bolts (59).
s  0LACETHENINE7EIGHT3TACKONTOTHETWO'UIDING4UBES
s  )NSTALL"LACK&IXING"USHINGINTO3ELECTOR"AR,ET&IXING0INGOTHROUGHTHEHOLEOF"LACK&IXING
Bushing (74) and the first hole of Selector Bar (32), then attach to the bottom part in the hook of Top Plate
(30).
s  4HENPUT3ELECTOR"ARINTOTHE7EIGHT3TACK!TTACHTHE"LACK7ASHERONTHEMIDDLEHOLE
of Top Plate (30).
s  #ONNECTTHE2EVOLVING0ARTWITH44UBESECURETHEMWITHONEvXv"OLTANDONE
3/8” x 1”Washer (67).

11485-7
ASSEMBLYSTEPS
STEP02 Assembly of the Base Frame and Back Cushion
s  Join the Support Tube (1) with T-Tube (2), securing them with two 3/8” x 4” Bolts (51), two 3/8” Nuts (63) and
four 3/8” x 19mm Washers (66).
s  &ASTENTHE"ACK#USHIONTOTHE3UPPORT4UBESECUREITWITHTWOvXv"OLTSANDTWO
5/16” x 16mm Washers (68).
s  0UTTHE2IDGE4UBEONTOTOPOFTHE3UPPORT4UBE
s  4HENPUTTHE&ITTING0LATEONTOTOPOFTHE2IDGE4UBESECURINGTHEMWITHTWOvXv"OLTS
two 3/8” Nuts (63) and four 3/8” x 19mm Washers (66).
Caution:
The direction of the Bolts should be from Support Tube (1) through the Fitting Plate (27).
Incorrect direction of the bolts will affect the cables.
s  &IRMLYCONNECTTHE2IDGE4UBEANDTHETWO'UIDING4UBESSECURINGTHEMWITHTWOvXv"OLTS
and two 3/8” x 19mm Washers (66).
Note:
Two 3/8” x 1” Bolts (59) and two 3/8” x
19mm Washer (66) have been attached on
the Guiding Tube (4), so please separate
them, then follow Step 2.5 to assemble.
s  !TTACHTWO0ULLEY"RACKETSTO3UPPORT
Tube (1), secure them with two 5/16” x 2 3/4”
Bolts (53), four 5/16” x 16mm Washer (68)
and two 5/16” Nut (64).
s  !TTACH0RESS0INTO3UPPORT4UBE
with one 5/16” x 1 3/4” Bolt (57), two
5/16” x 16mm Washer (68) and one Nut
(64).
s  !TTACH+NOBANDvXv7ASHER
(67) to the Press Pin (58).

47
11485-8
ASSEMBLYSTEPS
STEP03 Assembly of the Butterfly Set
Note: Rubber Sticker (28) has been attached on the back of Connecting Part (11) to protect
Connecting Part (11) from Butterfly Arm (12,13).
s  !TTACHTHE#ONNECTING0ARTTO2IDGE4UBESECURETHEMWITHONEvXv"OLTTWOvXMM
Washers (65), two Brass Colour Bushings (71) and two 1/2” Nuts (62).
s  4HENATTACH"UTTERmY!RMSECURINGTHEMWITHFOUR"RASS#OLOUR"USHINGSTWOvXv"OLTS
four 1/2” x 26mm Washers (65) and two 1/2” Nuts (62).
Note:
The Grip of the two Butterfly Arms (47) and two Arm foam Rollers (19) have been attached on the
Butterfly Arms (12,13).

11485-9
ASSEMBLYSTEPS
STEP04 Assembly of the Seat Cushion and the Leg Curl
s  &IXTHE3EAT"EAMTOTHE3UPPORT4UBESECURETHEMWITHONE&ITTING0LATEFOURvXMM 
Washers (66), two 3/8” x 2 1/2” Bolts (52) and two 3/8” Nuts (63).
s  !TTACHTHE,EG"EAMTOTHE3EAT"EAMSECURETHEMWITHTWO"RASS#OLOUR"USHINGSONEMM
End Cap (72), one 12” Nut (62), two 1/2” x 26mm Washers (65), and one 1/2” x 3” Bolt (48).
s  4HENATTACHTHE3EAT#USHIONTOTHE3EAT#USHION"EAMSECURETHEMWITHFOURvXMM
Washers (68) and four 5/16” x 3/4” Bolts (75).
s  0UTTHE2OLLER4UBEINTOTHEHOLEOF,EG"EAM
s  0OURALITTLEBITOFWATERONTOTHE2OLLERTUBEANDATTACHTWO,EGFOAMROLLERSONEITHERSIDEOFTHE
Roller Tube (33).

11485-10
ASSEMBLYSTEPS
STEP05
5.1 How to assemble the Pulleys
s#ONNECTALLFOURTEEN0ULLEYSONTOTHEWELDED0ULLEY"RACKETSLTWO0ULLEY#ONNECTING0LATESANDONE
Floating Pulley Bracket (16).
s3ECURETHEMWITHFOURTEENvXLv"OLTSTWENTYEIGHTvXLMM7ASHERANDFOURTEENv.UTS
(63).
5.2 How to assemble the wires cable
Cable 36 (3305mm)
s 3TARTINGATPULLEYTHREADTHECABLEAROUNDPULLEYTHENFOLLOWTHE!22/73AROUNDNOAND
s &INALLYLETTHEFRONTTHREADEDBOLTOFCABLEGOTHROUGHTHE"LACK&IXING7ASHERTHENTHREADITINTOTHEHEADOF
the Selector Bar (32) to lock together.
s 5SE3NAP(OOKTOCONNECTCABLEAND4OP,AT"ARTOGETHER
Cable 35 (3930mm)
s 3TARTAT0ULLEY.OTHREADTHECABLEAROUNDPULLEYTHENFOLLOWTHE!22/73AROUND.OAND))
s 5SE3NAP(OOKTOCONNECTTOEYEENDOFTHECABLE/.,%'"%!-AND,OWER,AT"ARTOGETHER
s 5SE3NAP(OOKTOCONNECTTOTHEOTHERSIDEOFCABLETOJOINTOGETHER#HAIN3NAP(OOKAND
Ankle Strap (41).
Cable 37(2160mm)
s 3TARTAT.OANDATTACHCABLEON2IGHT"UTTERmY!RMSECURINGITWITHONE"OLTvXLvLONEvWO
Nylon Nut (76), one 3/8’ x l9mm Washer (66) and one 3/8” Nut (63).
s !TTACHTHECABLElRSTTHENASSEMBLETHEPULLEYON.OTHENFOLLOWTHE!22/73TOGOAROUND.OUPTO.O
s !TTACHCABLEON,EFT"UTTERmY!RMSECURINGWITHONEvXv"OLTSONEvWO.YLON.UTL 
one 3/8” x 19mm Washer (66) and one 3/8” Nut(63).
Please make sure all pulleys can turn and cable are tight enough.
PS: Please adjust the original two Pulley Connecting Plates (l7) at “A” hole and tighten the
threaded bolt of cable 36 to
Selector Bar (32) if the cables are not tight enough during workout.