Trojan STACK 680 Installation guide

STACK 680
HOME GYM
CARE INSTRUCTIONS AND ASSEMBLY MANUAL
CAUTION
READ ALL PRECAUTIONS AND
INSTRUCTIONS IN THIS MANUAL
BEFORE USING THIS EQUIPMENT
KEEP THIS MANUAL FOR
FUTURE REFERENCE
CALL
08-93015557 www.trojanfitness.com.au
in your own space / in your own time

INDEX
SAFETY INSTRUCTION 3
BEFORE YOU BEGIN 4
PART LIST 5
EXPLODE DRAWING 7
ASSEMBLY STEP 8
WARM-UP AND COOL-DOWN 14
CONDITIONING GUIDELINES 15
TROJAN 1YEAR LIMITED WARRANTY 16
TROJAN REPAIRS PROCEDURE 17
PROOF OF PURCHASE 18

11485AU-3
SAFETY INSTRUCTION
WARNING :
Safety Instruction before using the TROJAN STACK 680.
To reduce the risk of serious injury, read the following.
1. Use the TROJAN STACK 680 only on a level surface.
2. Keep children and pets away from this equipment at all times.
3.The TROJAN STACK 680 should not be used by persons weighing more than 110kgs.
4.The TROJAN STACK 680 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 the TROJAN
STACK 680, loss of balance may result in a fall and serious bodily injury.
6. Use the TROJAN STACK 680 only as described in the manual.
7. Do not attempt to adjust the back rest cushion while you are on the TROJAN STACK 680.
8. Before using this equipment to exercise, always 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.

11485AU-4
BEFORE YOU BEGIN
Thank you for choosing the TROJAN STACK 680.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 STACK 680 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.
• Read this manual carefully before using the TROJAN STACK 680.

11485AU-5
PART LIST
No. Illustrator Description Q’ty
20 End Cap 1” 12
21
End Cap
(40 x 80 mm) 4
22
End Cap
(30 x 70 mm) 4
23 End Cap
(30 x 60 mm) 2
24
End Cap
(40 x 80 mm) 4
25 Plastic Sleeve 1
26 Weight Stack Pin 5” 1
27 Fitting Plate 2
28 Rubber Sticker
(Pre-Assemble to 11) 1
29 Revolving Part 1
30 Top Plate 15LBS 1
31 Weight Stack 15LBS 9
32 Selector Bar 1
33 Roller Tube 2
34 Lower Lat Bar 1
35 Cable
3930 mm/149.2” 1
36 Cable
3305 mm/130.1” 1
37 Cable
2160 mm/85.1” 1
38 Chain 1
39 Leg Foam Roller 7” 2
40 Leg Foam Roller 7-
1/2” 2
41 Ankle Strap 1
42 Snap Hook 4
43 Rubber Ring 2
44
Knob
(Pre-Assemble to
58 & 67)
1
No. Illustrator Description Q’ty
1 Support Tube 1
2 T-Tube 1
3 Horizontal Beam 1
4 Guide Tube 2
5 Ridge tube 1
6 Seat Beam 1
7 Leg Beam 1
8 1
9Back Cushion
(Big) 1
10 Seat Cushion
(Small) 1
11 Connecting Part 1
12 Butterfly Arm
(Left) 1
13 Butterfly Arm
(Right) 1
14 Seat Cushion
Beam 1
15 Pulley Bracket 2
16 Floating Pulley
Bracket 1
17 Pulley
Connecting Plate 2
18 Pulley 14
19
Arm Foam Roller
(Pre-Assemble
to 12&13)
2

11485AU-6
PART LIST
HAERDWARE LIST
No. Illustrator Description Q’ty
46 Grip 13-3/4” for Top Lat
Bar (Pre-Assemble to 8) 2
47
Grip 11” for Butterfly
Arm (Pre-Assemble to
12 &13)
2
55 End Cap
(20 x 40 mm) 2
58 Press Pin 1
70 Fixing Pin
(Pack with Weight Plate) 1
No. Illustrator Description Q’ty
71
Brass Colour Bushing
(Press this Part into the
Steel Tube by Rubber
Hammer)
8
72 End Cap 19mm 2
73 Hand Grip for Lower Lat
Bar (Pre-Assemble to 34) 2
74 Black Fixing Bushing
(Pack with Weight Plate) 1
77 Knob (8 x 41L) 1
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”

11485AU-7
EXPLODED DRAWING

11485AU-8
ASSEMBLY STEP
STEP 01 Assembly of the base frame and weight stack
Step 1 Screw T-Tube (2) and Horizontal Beam (3), secure them with two 3/8”x 4” Bolts (51), four 3/8”x19mm
Washer (66) and two 3/8” Nut (63).
Step 2 Slide both two Guide Tube (4) into the two Rubber Rings (43) and through the Horizontal Beam (3), secure
them with two 3/8”x19mm Washer (66) and two 3/8”x1” Bolts (59).
Two 3/8”x19mm Washer (66) and two 3/8”x1” Bolt (59) have been attached on the Guiding Tubes, so please separate them,
then follow Step 2 to assemble.
Step 3 Place the nine Weight Stack (31) into the two Guiding Tubes (4).
Step 4 Install Black Fixing Bushing (74) into Selector Bar (32). Let Fixing Pin (70) go through the hole of Black Fixing
Bushing (74) and the first hole of Selector Bar (32), then attach to the bottom part in the hook of Top Plate
(30).Then put Selector Bar (32) into the Weight Stack (31). Attach the Black Washer (69) on the middle hole
of Top Plate (30).
Step 5 Connect the Revolving Part (29) with T-Tube (2), secure them with one 3/8”x1/2” Bolt (60) and one 3/8”x1”
Washer (67).

11485AU-9
ASSEMBLY STEP
STEP 02 Assembly of the Base Frame and Back Cushion
Step 1 Screw the Support Tube (1) with T-Tube (2), secure them with two 3/8”x4” Bolt (51), two 3/8” Nut (63) and
four 3/8”x19mm Washer (66).
Step 2 Fasten the Back Cushion (9) to the Support Tube (1), secure them with two 5/16” x 2-1/4” Bolts (54) and two
5/16”x16mm Washer (68).
Step 3 Put the Ridge Tube (5) onto top of the Support Tube (1). Then put the Fitting Plate (27) onto top of the
Ridge Tube (5), secure them with two 3/8” x 2-1/2” Bolt (52), two 3/8” Nut (63) and four 3/8”x19mm Wash-
er(66).
Notice:
The direction of the Bolts should be from Support Tube (1) through the Fitting Plate (27). Incorrect direction of the bolts will af-
fect the cables.
Step 4 Firmly connect the Ridge Tube (5) and the two Guiding Tube (4), secured them with two 3/8”x1” Bolts (59)
and two 3/8”x19mm Washer (66).
Notice:
Two 3/8”x1” Bolts (59) and two 3/8”x19mm Washer
(66) have been attached on the Guiding Tube (4), so
please separate them, then follow Step 5 to assemble.
Step 5 Attach two Pulley Bracket (15) to Support
Tube (1), secure them with two 5/16”x2
3/4” Bolts (53), four 5/16”x16mm Washer
(68) and two 5/16” Nut (64).
Step 6 Attach Press Pin (58) to Support Tube
(1) with one 5/16”x1 3/4” Bolt (57), two
5/16”x16mm Washer (68) and one Nut
(64). Attach Knob (44) and 3/8”x1” Washer
(67) to the Press Pin (58).

11485AU-10
ASSEMBLY STEP
STEP 03 Assembly of the Buttery Set
Rubber Sticker (28) has been attached on the back of Connecting Part (11) to protect Connecting Part (11) from But-
terfly Arm (12,13).
Step Attach the Connecting Part (11) to Ridge Tube (5), secure them with one 1/2”x6” Bolt (49), two 1/2”x26mm
Washer (65), two Brass Colour Bushing (71) and two 1/2” Nut (62).Then attach Butterfly Arm (12,13), secure
them with four Brass Colour Bushing (71), two 1/2”x4” Bolts (50), four 1/2”x26mm Washer (65) and two
1/2” Nut (62).
Notice:
Grip of two Buttery Arm (47) and two Arm foam Roller (19) have been attached on the Buttery Arm (12,13).