Trojan Concept 200 Owner's manual

Brand: Trojan

Model: Concept 200

Category: Fitness, gymnastics & weight training

Type: Owner's manual

HOME GYM CARE INSTRUCTIONS

AND ASSEMBLY MANUAL

TROJAN

MY SPACE MY TIME

HOME

FITNESS

UTH A

CA’

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 1 YEAR LIMITED WARRANTY 20

13. TROJAN REPAIRS PROCEDURE 22

INDEX PAGE

11485-3

1. SAFETY INSTRUCTION

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. PRE ASSEMBLY CHECK LIST

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. HARDWARE LIST

No.48 No.49

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

2pcs

4pcs

2pcs

14pcs 1pc

1pc

2pcs

8pcs

52pcs

12pcs4pcs2pcs3pcs24pcs

4pcs

5/16”

11485-6

4. ASSEMBLY STEPS

STEP 01 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

ASSEMBLY STEPS

STEP 02 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).

11485-8

ASSEMBLY STEPS

STEP 03 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

ASSEMBLY STEPS

STEP 04 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

ASSEMBLY STEPS

STEP 05

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.

AEROBIC EXERCISE

Aerobic exercise is any sustained activity that sends oxygen to your muscles via your heart and lungs.

Aerobic exercise improves the ﬁtness of your lungs and heart - your body’s most important muscle.

Aerobic exercise ﬁtness is promoted by any activity that uses your large muscle -arms, legs, or buttock, for example.

Your heart beats quickly and you breathe deeply. An aerobic exercise should be part of your entire exercise routine.

WEIGHT TRAINING

Along with aerobic exercising which helps get rid of and keep off the excess fat that our bodies can store,

weight training is an essential part of the exercise routine process. Weight training helps tone, build and strengthen

muscle. If you are working above your target zone, you may want to do a less amount of reps.

And as always consult your physician before beginning any exercise program.

MUSCLE CHART

GYM

The exercise routine that is performed on this gym will develop the upper and lower body muscle groups. These muscle

groups are highlighted on the muscle chart below.

5. FITNESS TIPS AND TECHNIQUES

11485-11

SEATED BENCH PRESS

Sit with your back against the

support. Grip the handlebars

under the butterﬂy arms and press

the bars away from your body.

Return the bars in a controlled

manner to the start position

UPRIGHT ROW

Grip the lower lat bar.

Stand upright and using a narrow

grip pull your elbows out high,

bringing the bar under your chin.

Return the bar in a controlled

manner to the start position.

BICEP CURLS

Grip the lower lat bar.

Stand upright and using a narrow

grip, with palms facing up, curl the

bar towards your chest, using only

your biceps.

Return the bar in a controlled man-

ner to the start position.

LAT PULL DOWN (FRONT)

Attach lat bar to high pulley.

In a seated position, facing away

from the machine, pull the lat bar

to the front of your chest.

Return the bar in a controlled man-

ner to the start position.

6. EXERCISE PROGRAM

11485-12

START POSITION FINISH POSITION

LAT PULL DOWN (BACK)

Attach lat bar to high pulley.

In a seated position, facing away from

the machine, pull the lat bar to the

back of your neck.

Return the bar in a controlled manner

to the start position.

PEC DEC

Sit with your back against the support.

Bend your arms 90° and place them

against cushions and pull your arms

together until they touch.

Return the bars in a controlled man-

ner to the start position.

LEG EXTENSION

Sit on bench and hook legs over top roller pads and feet under bottom roller pads.

Extend both legs together and ﬂex thighs at top of movement.

For single leg work, extend one leg at a time and ﬂex thighs at top of movement.

Return the bottom roller pads in a controlled manner to the start position

11485-13

START POSITION FINISH POSITION

7. CONDITIONING GUIDELINES

How you begin your exercise program depends on your physical condition. If you have been inactive for several years, or

are severely overweight, you must start slowly and increase your time on the equipment; a few minutes per workout.

Initially, you may be able to exercise only for a few minutes in your target zone, however, your aerobic ﬁtness will improve

over the next six to eight weeks. Don’t be discouraged if it takes longer. It’s important to work at your own pace. Ulti-

mately, you’ll be able to exercise continuously for 30 minutes. The better your aerobic ﬁtness, the harder you will have to

work to stay in your target zone. Please remember these essentials :

s(AVEYOURDOCTORREVIEWYOURTRAININGANDDIETPROGRAMSTOADVISEYOUOFAWORKOUTROUTINEYOUSHOULDADOPT

s"EGINYOURTRAININGPROGRAMSLOWLYWITHREALISTICGOALSTHATHAVEBEENSETBYYOUANDYOURDOCTOR

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EXERCISE INTENSITY

To maximize the beneﬁts of exercising, it is important to exercise with the

proper intensity. The proper intensity level can be found by using your heart

rate as a guide. For effective aerobic exercise, your heart rate should be

maintained at a level between 65% and 85% of your maximum heart rate

as you exercise. This is known as your target zone. You can ﬁnd your target

zone in the table below.

During the ﬁrst few months of your exercise program, keep your heart rate

near the low end of your target zone as you exercise. After a few months, your heart rate can be increased gradually

until it is near the middle of your target zone as you exercise.

To measure your heart rate, stop exercising but continue moving your legs or walking around and place two ﬁngers on

your wrist. Take a six-second heartbeat count and multiply the results by 10 to ﬁnd your heart rate. For example, if your

six-second heartbeat count is 14, your heart rate is 140 beats per minute. (A six-seconds count is used because your

heart rate will drop rapidly when you stop exercising.) Adjust the intensity of your exercise until your heart rate is at the

proper level.

For more information on dieting and

training visit www.trojanhealth.co.za

11485-14

11485-15

8. WARM-UP AND COOL-DOWN

WORKOUT GUIDELINES

Each workout should include the following three parts:

A warm-up, consisting of 5 to 10 minutes of stretching and light exercise. A proper warm-up increases your body tem-

perature, heart rate, and circulation in preparation for exercise.

Training zone exercise, consisting of 20 to 30 minutes of exercising with your heart rate in your training zone. (Note:

During the ﬁrst few weeks of your exercise program, do not keep your heart rate in your training zone for longer than

20 minutes.)

A cool-down, with 5 to 10 minutes of stretching. This will increase the ﬂexibility of your muscles and will help to prevent

post-exercise problems.

EXERCISE FREQUENCY

To maintain or improve your condition, plan three workouts each week, with at least one day of rest between workouts.

After a few months of regular exercise, you may complete up to ﬁve workouts each

week, if desired. Remember, the key to success is make exercise a regular and enjoy-

able part of your everyday life.

SUGGESTED STRETCHES

The correct form for several basic stretches is shown at the right. Move slowly as you

stretch-never bounce.

1. Toe Touch Stretch

Stand with your knees bent slightly and slowly bend forward from your hips. Allow

your back and shoulders to relax as you reach down toward your toes as far as pos-

sible. Hold for 15 counts, then relax. Repeat 3 times. Stretches: Hamstrings, back of

knees and back.

2. Hamstring Stretch

Sit with one leg extended. Bring the sole of the opposite foot toward you and rest it

against the inner thigh of your extended leg. Reach toward your toes as far as pos-

sible. Hold for 15 counts, then relax. Repeat 3 times for each leg. Stretches: Ham-

strings, lower back and groin.

3. Calf/Achilles Stretch

With one leg in front of the other, reach forward and place your hands against a

wall. Keep your back leg straight and your back foot ﬂat on the ﬂoor. Bend your

front leg, lean forward and move your hips toward the wall. Hold for 15 counts, then

relax. Repeat 3 times for each leg. To cause further stretching of the achilles tendons,

bend your back leg as well. Stretches: Calves, achilles tendons and ankles.

4. Quadriceps Stretch

With one hand against a wall for balance, reach back and grasp one foot with your

other hand. Bring your heel as close to your buttocks as possible. Hold for 15 counts,

then relax. Repeat 3 times for each leg. Stretches: Quadriceps and hip muscles.

5. Inner Thigh Stretch

Sit with the soles of your feet together and your knees outward. Pull your feet

toward your groin area as far as possible. Hold for 15 counts, then relax. Repeat 3

times. Stretches: Quadriceps and hip muscles.

For more information on dieting and

training visit www.trojanhealth.co.za

11485-16

9. PARTS LIST

No. Illustrator Description Q’ty

20 End Cap 1” 12

End Cap

(40 x 80 mm) 4

End Cap

(30 x 70 mm) 4

End Cap

(30 x 60 mm)

End Cap

(40 x 80 mm) 4

25 Plastic Sleeve 1

26 Weight Stack Pin 5” 1

27 Fitting Plate 2

Rubber Sticker

(Pre-Assemble to 11)

29 Revolving Part 1

30 Top Plate 15LBS

31 Weight Stack 15LBS 9

32 Selector Bar 1

33 Roller Tube 2

34 Lower Lat Bar 1

Cable

3930 mm/149.2”

Cable

3305 mm/130.1”

Cable

2160 mm/85.1”

38 Chain 1

39 Leg Foam Roller 7” 2

Leg Foam Roller 7-

1/2”

41 Ankle Strap 1

42 Snap Hook 4

43 Rubber Ring 2

Knob

(Pre-Assemble to

58 & 67)

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

Back Cushion

(Big)

Seat Cushion

(Small)

11 Connecting Part 1

Butterﬂy Arm

(Left)

Butterﬂy Arm

(Right)

Seat Cushion

Beam

Pulley Bracket

Floating Pulley

Bracket

Pulley

Connecting Plate

18 Pulley 14

Arm Foam Roller

(Pre-Assemble

to 12&13)

11485-17

PARTS LIST

No. Illustrator Description Q’ty

Grip 13-3/4” for Top Lat

Bar (Pre-Assemble to 8)

Grip 11” for Butterﬂy

Arm (Pre-Assemble to

12 &13)

End Cap

(20 x 40 mm)

58 Press Pin 1

Fixing Pin

(Pack with Weight Plate)

No. Illustrator Description Q’ty

Brass Colour Bushing

(Press this Part into the

Steel Tube by Rubber

Hammer)

72 End Cap 19mm 2

Hand Grip for Lower Lat

Bar (Pre-Assemble to 34)

Black Fixing Bushing

(Pack with Weight Plate)

77 Knob (8 x 41L) 1

11485-18

10. EXPLODED DRAWING

11. FREQUENTLY ASKED QUESTIONS

Q1. Is it possible to leave my weights on the bench once I have ﬁnished my workout?

1. It is not advisable as this could cause injury or cause the bench to fall over in the case of the weights be-

ing left on the leg developer

Q2. Is it possible to secure my bench to the ground?

1. Yes, provided that the area in which you are going to secure it is going to be in in a permanent location

and that the ﬂoors are not tiled

Q3. My bench is not stable

1. Ensure that all bolts are tightened and that all tha end caps are on legs.

Q4. Is it a good idea to use my bench in a commercial gym?

1. No, as it is for domestic use only.

Q5. My moving parts on my bench don’t move ﬂuidly and are too tight.

1. Make sure not to over tighten the oil bushes as the butterﬂy arms have to move freely.

2. Do not over tighten any bolt or nut which has bushes and moveable parts

Q6. How do I maintain my cables?

1. The cables work in conjunction with the pulleys. When assembling the unit; make sure not to over

tighten the pulleys. The pulleys are meant to move freely.

2. Before your workout; make sure all the cables are lined up correctly on the pulleys.

11485-19

12. TROJAN 1 YEAR LIMITED WARRANTY

Masstores (Pty)Ltd (“the Supplier”) hereby provides a limited warranty to the original purchaser of this product (“the

Consumer”) that this product will be free of manufacturing defects in materials and workmanship which under normal,

personal, family or household use (commercial use expressly excluded) manifest themselves within the following stipu-

lated periods from the date of purchase:

Exclusions

The warranty does not include and will not be construed to cover products damaged as a result of disaster; misuse;

commercial use; use not in accordance with the written instructions included with the product; abuse; and/or any

non-authorized modication of the product. It also does not cover replacement of the light bulbs and other expendables.

All demo models carry a 3 month warranty.

Waiver

The warranty provided herein and the obligations of the Supplier are in lieu of, and the Customer waives, all other war-

ranties, guarantees, conditions or liabilities, express or implied, arising by law or otherwise, including without limitation, any

obligation of the Supplier in respect of any injury , loss or damage (direct, indirect or consequential) arising out of the

use of, or inability to use, this product and whether or not occasioned by the Supplier’s negligence or any act or omission

on its part.

Claims under 1 Year Limited Warranty

Within 7 days of purchase:

The faulty product will be exchanged (provided that the product is in its original packaging with all accessories).

After 7 days but within 3 months of purchase:

The Supplier may in its sole discretion either replace or repair the product.

After 3 months but within 1 year of purchase:

The Supplier may in its sole discretion either replace or repair the product. The following shall not be covered:

r Treadmills: Running Decks, Running Belts, and Rubber Arm covers

r Exercise Bikes/Spinners: Pedals, Cranks, and Rubber Arm covers

r Cross Trainers/ Ellipticals/ Steppers: Foot Rests, Cranks, Shocks, and Rubber/Foam Arm covers

r Home Gyms / Benches: Pulleys, Cables, Seats and Padding

r Trampolines: Springs, Mats, and Covers

r Rowers: Rowing Strap / Rope / Arms, Pulling Handle, Grip, Moveable Seat

Parts not mentioned in the above, are covered under warranty within the 1st year of purchase

11485-20

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Trojan Concept 200 Owner's manual

Brand: Trojan

Model: Concept 200

Category: Fitness, gymnastics & weight training

Type: Owner's manual

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Trojan Concept 200 Owner's manual

Trojan Concept 200 Owner's manual

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