426103 ELASTIC CORD CONVERSION KIT Part # 6860801 1 Revision: 10/12/99
PARTS LIST KEY 1 2 3 4 5 PART # 3102903 6122702 3201501 6271801 3118701 DESCRIPTION 3/8 X 2-1/2” BOLT 3/8 X 1/2” SPACER SWIVEL SNAP 22” ELASTIC CORD 2” PULLEY QTY 2 4 4 4 4 KEY 6 7 8 9 10 PART # 3102501 3102802 3102701 6535001 3102909 DESCRIPTION 3/8” WASHER 3/8” LOCK NUT 3/8” HEX NUT 3/8” THREADED SHAFT 3/8” X 1” BOLT QTY 4 7 8 3 1 FIGURE 1 SHROUD 3/8” X 1” BUTTON HEAD CAP SCREW STEP 1 • Remove the top of the front SHROUD & rear SHROUD by removing the four 3/8” X 1” BUTTON HEAD CAP SCREWS.
FIGURE 3 STEP 3 • Remove the three 1/4” CAP NUTS and each TENSION CORD from the TOP BOOM as shown in FIGURE 3. CAP NUT CORD FIGURE 4 STEP 4 CORD • Remove the three TENSION CORDS from the D-RING by removing the three KEYHOLE CLEVIS, CLEVIS PINS, and COTTER PINS as shown in 4.
3/8” LOCK NUT 3/8” WASHER BASE 4-1/2” PULLEY 3/8” WASHER 3/8” X 2” BOLT 2-7/8” L-BRACKET FIGURE 5 STEP 5 • Remove the 3/8 X 2” BOLT, two 3/8” WASHERS, one 2-7/8” L-BRACKETS, one 4-1/2” PULLEY, and one 3/8” LOCK NUT from the upper flat on the BASE as shown in FIGURE 5.
BASE 8 HEX NUT 7 3 9 10 3 7 8 HEX NUT FIGURE 7 STEP 7 • Position two 3/8 X 1/2” SPACERS (2) inside the bracket on the BASE and slide one 3/8” THREADED SHAFT (9) through the bracket. See FIGURE 7. • Assemble two 3/8” HEX NUTS (8), two SWIVEL SNAP (3), and two 3/8” LOCK NUTS (7) to the 3/8” THREADED SHAFT (9) as shown in FIGURE 7.
3/8” LOCK NUT 3/8” WASHER TOP BOOM 3/8” X 2-1/4” FIGURE 8 3-1/2” PULLEY STEP 8 • Remove the 3/8 X 2-1/4” BOLT, two 3/8” WASHERS, one 3/8” LOCK NUT, and 3-1/2” PULLEY from the bracket on the TOP BOOM as shown in FIGURE 8.
5 7 8 3/8” HEX NUT TOP BOOM 6 9 6 2 8 3/8” HEX NUT 5 FIGURE 10 7 STEP 10 • Position two 3/8 X 1/2” SPACERS (2) inside the rear bracket of the TOP BOOM and slide one 3/8” THREAD SHAFT (9) through the bracket. See FIGURE 10. • SECURELY assemble two 2” PULLEYS (5) to the rear bracket on the TOP BOOM using one 3/8” THREADED SHAFT (9), two 3/8” WASHERS, two 3/8” HEX NUTS (8), and two 3/8” LOCK NUTS (7) as shown in FIGURE 10.
5 TOP BOOM 4 LEG EXT CABLE LAT CABLE PRESS CABLE FIGURE 12 STEP 12 • Assemble the 22” ELASTIC CORD (4) from the PRESS CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 12.
TOP BOOM 5 4 LEG EXT CABLE LAT CABLE PRESS CABLE FIGURE 13 STEP 13 • Assemble the 22” ELASTIC CORD (4) from the LEG CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 13.
5 TOP BOOM 4 LEG EXT CABLE PRESS CABLE LAT CABLE FIGURE 14 STEP 14 • Assemble the 22” ELASTIC CORD (4) from the LAT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 14.
4 PRESS CABLE 3 BASE FIGURE 15 STEP 15 • Assemble the ELASTIC CORD (4) from the PRESS CABLE to the SWIVEL SNAP (3) on the BASE as shown in FIGURE 15.
BASE LEG CABLE 4 3 LAT CABLE 4 FIGURE 16 STEP 16 • Assemble the ELASTIC CORDS (4) from the LAT & LEG CABLES to the corresponding SWIVEL SNAPS (3) on the BASE as shown in FIGURE 16.
FIGURE 17 SHROUD 3/8” X 1” BUTTON HEAD CAP SCREW STEP 17 • SECURELY attach the top of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 17. 3/8” X 1” BUTTON HEAD CAP SCREW FIGURE 18 STEP 18 • SECURELY attach the bottom of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 18.
425103 with 832 LEG PRESS OPTION INSTALLED • If the 445 WEIGHT STACK OPTION IS INSTALLED PROCEED TO PAGE 27. • If the 832 LEG PRESS OPTION & 445 WEIGHT STACK OPTION ARE INSTALLED PROCEED TO PAGE 35. FIGURE 3 CAP NUT CORD STEP 3 • Remove the 1/4” CAP NUTS and each TENSION CORD from the TOP BOOM as shown in FIGURE 3.
COTTER PIN KEYHOLE CLEVIS CLEVIS PIN D-RING FIGURE 4 STEP 4 • Remove the TENSION CORDS, CLEVIS PINS and COTTER PINS as shown in FIGURE 4.
3/8” LOCK NUT 3/8” WASHER BASE 4-1/2” PULLEY 2-7/8” L-BRACKET 3/8” WASHER 3/8” X 2” BOLT FIGURE 5 STEP 5 • Remove two 3/8 X 2” BOLTS, four 3/8” WASHERS, two 2-7/8” L-BRACKETS, two 4-1/2” PULLEYS, and two 3/8” LOCK NUTS from the upper flats on the BASE as shown in FIGURE 5.
3-1/2” PULLEY 3/8 X 2” BOLT 3/8” WASHER BASE 3/8” WASHER 3/8” LOCK NUT FIGURE 7 STEP 7 • Remove one 3-1/2” PULLEY, one 3/8 X 2” BOLT, two 3/8” WASHERS and one 3/8” LOCK NUT from the BASE as shown in FIGURE 7. FIGURE 8 BASE 8 HEX NUT 7 3 9 3-1/2” PULLEY 3 3/8” LOCK NUT 8 HEX NUT STEP 8 • Assemble two 3/8” HEX NUTS (8), two SWIVEL SNAP (3), one previously removed 3-1/2” PULLEY, one previously removed 3/8” LOCK NUT, and one 3/8” LOCK NUT (7) to the 3/8” THREADED SHAFT (9) as shown in FIGURE 8.
3/8” LOCK NUT 3/8” WASHER TOP BOOM 3/8” X 2-1/4” FIGURE 9 3-1/2” PULLEY STEP 9 • Remove the 3/8 X 2-1/4” BOLT, two 3/8” WASHERS, one 3/8” LOCK NUT, and 3-1/2” PULLEY from the bracket on the TOP BOOM as shown in FIGURE 9.
5 7 8 3/8” HEX NUT TOP BOOM 6 9 6 2 8 3/8” HEX NUT 5 FIGURE 11 7 STEP 11 • Position two 3/8 X 1/2” SPACERS (2) inside the rear bracket of the TOP BOOM and slide one 3/8” THREAD SHAFT (9) through the bracket. See FIGURE 11. • SECURELY assemble two 2” PULLEYS (5) to the rear bracket on the TOP BOOM using one 3/8” THREADED SHAFT (9), two 3/8” WASHERS, two 3/8” HEX NUTS (8), and two 3/8” LOCK NUTS (7) as shown in FIGURE 11.
STEP 13 • Assemble four 72” ELASTIC CORDS to the KEYHOLE CLEVIS as shown in FIGURE 13. FIGURE 13 ELASTIC CORD KEYHOLE CLEVIS D-RING 5 TOP BOOM 4 LEG PRESS CABLE LEG EXT CABLE LAT CABLE PRESS CABLE FIGURE 14 STEP 14 • Assemble the 72” ELASTIC CORD (4) from the PRESS CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 14.
TOP BOOM 5 4 LEG EXT CABLE LAT CABLE PRESS CABLE LEG PRESS CABLE FIGURE 15 STEP 15 • Assemble the 72” ELASTIC CORD (4) from the LEG PRESS CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 15.
TOP BOOM 5 4 LEG EXT CABLE LAT CABLE PRESS CABLE LEG PRESS CABLE FIGURE 16 STEP 16 • Assemble the 72” ELASTIC CORD (4) from the LEG EXT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 16.
TOP BOOM 5 4 LEG EXT CABLE LAT CABLE PRESS CABLE LEG PRESS CABLE FIGURE 17 STEP 17 • Assemble the 72” ELASTIC CORD (4) from the LAT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 17.
LEG PRESS CABLE PRESS CABLE 3 BASE FIGURE 18 STEP 18 • Assemble the ELASTIC CORDS (4) from the PRESS CABLE and the LEG PRESS CABLE to the corresponding SWIVEL SNAPS (3) on the BASE as shown in FIGURE 18.
BASE LEG CABLE 4 3 LAT CABLE 4 FIGURE 19 STEP 19 • Assemble the ELASTIC CORDS (4) from the LAT & LEG CABLES to the corresponding SWIVEL SNAPS (3) on the BASE as shown in FIGURE 19.
FIGURE 20 SHROUD 3/8” X 1” BUTTON HEAD CAP SCREW STEP 20 • SECURELY attach the top of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 20. 3/8” X 1” BUTTON HEAD CAP SCREW FIGURE 21 STEP 21 • SECURELY attach the bottom of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 20.
425103 with 445 WEIGHT STACK OPTION • If the 832 LEG PRESS OPTION & 445 WEIGHT STACK OPTION ARE INSTALLED PROCEED TO PAGE 35. FIGURE 3 CAP NUT CORD STEP 3 • Remove the 1/4” CAP NUTS and each TENSION CORD from the TOP BOOM as shown in FIGURE 3.
COTTER PIN KEYHOLE CLEVIS CLEVIS PIN LAT CABLE (67248) LEG CURL/EXTENSION CABLE (67247) D-RING FIGURE 4 STEP 4 • CAREFULLY remove the TENSION CORDS by pulling the COTTER PIN and CLEVIS PIN from the KEYHOLE CLEVIS as shown in FIGURE 4. • Please discard the previously removed PRESS TENSION CORDS, COTTER PINS and CLEVIS PINS.
BASE 8 HEX NUT 7 3 9 10 3 7 8 HEX NUT FIGURE 7 STEP 7 • Position two 3/8 X 1/2” SPACERS (2) inside the bracket on the BASE and slide one 3/8” THREADED SHAFT (9) through the bracket. See FIGURE 7. • Assemble two 3/8” HEX NUTS (8), two SWIVEL SNAP (3), and two 3/8” LOCK NUTS (7) to the 3/8” THREADED SHAFT (9) as shown in FIGURE 7.
3/8” LOCK NUT 3/8” WASHER TOP BOOM 3/8” X 2-1/4” FIGURE 8 3-1/2” PULLEY STEP 8 • Remove the 3/8 X 2-1/4” BOLT, two 3/8” WASHERS, one 3/8” LOCK NUT, and 3-1/2” PULLEY from the bracket on the TOP BOOM as shown in FIGURE 8.
STEP 10 • Assemble two 72” ELASTIC CORDS to the KEYHOLE CLEVIS as shown in FIGURE 10. (NOTE: The LAT or LEG CABLE can be moved over one hole on the D-RING so the KEYHOLE CLEVIS are evenly spaced as shown in FIGURE 10.) FIGURE 10 ELASTIC CORD KEYHOLE CLEVIS D-RING TOP BOOM 5 4 LEG EXT CABLE LAT CABLE FIGURE 11 STEP 11 • Assemble the 72” ELASTIC CORD (4) from the LAT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 11.
TOP BOOM 5 4 LAT CABLE LEG EXT CABLE FIGURE 12 STEP 12 • Assemble the 72” ELASTIC CORD (4) from the LEG EXT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 12.
BASE LEG CABLE 4 3 LAT CABLE 4 FIGURE 13 STEP 13 • Assemble the ELASTIC CORDS (4) from the LAT & LEG EXT CABLES to the corresponding SWIVEL SNAPS (3) on the BASE as shown in FIGURE 13.
FIGURE 14 SHROUD 3/8” X 1” BUTTON HEAD CAP SCREW STEP 14 • SECURELY attach the top of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 14. 3/8” X 1” BUTTON HEAD CAP SCREW FIGURE 15 STEP 15 • SECURELY attach the bottom of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 15.
425103 with 832 LEG PRESS OPTION & 445 WEIGHT STACK OPTION INSTALLED • If the 832 LEG PRESS OPTION IS INSTALLED PROCEED TO PAGE 14. • If the 445 WEIGHT STACK OPTION IS INSTALLED PROCEED TO PAGE 27. CAP NUT CORD FIGURE 3 STEP 3 • Remove the 1/4” CAP NUTS and each TENSION CORD from the TOP BOOM as shown in FIGURE 3.
KEYHOLE CLEVIS COTTER PIN CLEVIS PIN D-RING FIGURE 4 STEP 4 • Remove the TENSION CORDS, CLEVIS PINS and COTTER PINS as shown in FIGURE 4.
3/8” LOCK NUT 3/8” WASHER BASE 4-1/2” PULLEY 2-7/8” L-BRACKET 3/8” WASHER FIGURE 5 3/8” X 2” BOLT STEP 5 • Remove two 3/8 X 2” BOLTS, four 3/8” WASHERS, two 2-7/8” L-BRACKETS, two 4-1/2” PULLEYS, and two 3/8” LOCK NUTS from the upper flats on the BASE as shown in FIGURE 5.
3-1/2” PULLEY 3/8 X 2” BOLT 3/8” WASHER BASE 3/8” WASHER 3/8” LOCK NUT FIGURE 7 STEP 7 • Remove one 3-1/2” PULLEY, one 3/8 X 2” BOLT, two 3/8” WASHERS and one 3/8” LOCK NUT from the BASE as shown in FIGURE 7. FIGURE 8 BASE 8 HEX NUT 7 3 9 3-1/2” PULLEY 3 3/8” LOCK NUT 8 HEX NUT STEP 8 • Assemble two 3/8” HEX NUTS (8), two SWIVEL SNAP (3), one previously removed 3-1/2” PULLEY, one previously removed 3/8” LOCK NUT, and one 3/8” LOCK NUT (7) to the 3/8” THREADED SHAFT (9) as shown in FIGURE 8.
3/8” LOCK NUT 3/8” WASHER TOP BOOM 3/8” X 2-1/4” FIGURE 9 3-1/2” PULLEY STEP 9 • Remove the 3/8 X 2-1/4” BOLT, two 3/8” WASHERS, one 3/8” LOCK NUT, and 3-1/2” PULLEY from the bracket on the TOP BOOM as shown in FIGURE 9.
TOP BOOM 3/8” X 1” 10 6 FIGURE 11 5 7 3/8” LOCK NUT STEP 11 • SECURELY assemble one 3/8 X 1” BOLT (10), one 3/8” WASHER (6), one 2” PULLEY (5) and one 3/8” LOCK NUT (7) to the bracket on the TOP BOOM as shown in FIGURE 11. TOP BOOM 5 4 LEG EXT CABLE LAT CABLE LEG PRESS CABLE FIGURE 12 STEP 12 • Assemble the 72” ELASTIC CORD (4) from the LEG PRESS CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 12.
STEP 14 • Assemble three 72” ELASTIC CORDS to the KEYHOLE CLEVIS as shown in FIGURE 14. FIGURE 14 TOP BOOM 4 5 LEG EXT CABLE LAT CABLE LEG PRESS CABLE FIGURE 15 STEP 15 • Assemble the 22” ELASTIC CORD (4) from the LEG EXT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 15.
TOP BOOM 5 4 LEG EXT CABLE LAT CABLE LEG PRESS CABLE FIGURE 16 STEP 16 • Assemble the 72” ELASTIC CORD (4) from the LAT CABLE around the 2” PULLEY (5) in the TOP BOOM as shown in FIGURE 16.
LEG PRESS CABLE 3 BASE FIGURE 17 STEP 17 • Assemble the ELASTIC CORDS (4) from the PRESS CABLEand the LEG PRESS CABLE to the coresponding SWIVEL SNAPS (3) on the BASE as shown in FIGURE 17.
BASE LEG CABLE 4 3 LAT CABLE 4 FIGURE 18 STEP 18 • Assemble the ELASTIC CORDS (4) from the LAT & LEG CABLES to the corresponding SWIVEL SNAPS (3) on the BASE as shown in FIGURE 18.
FIGURE 19 SHROUD 3/8” X 1” BUTTON HEAD CAP SCREW STEP 19 • SECURELY attach the top of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 19. 3/8” X 1” BUTTON HEAD CAP SCREW FIGURE 20 STEP 20 • SECURELY attach the bottom of the front SHROUD (with label) & rear SHROUD to the TOP BOOM using the four previously removed 3/8” X 1” BUTTON HEAD CAP SCREWS. See FIGURE 20.
