TROJAN
MY SPACE MY TIME
®
CAUTION
READ ALL PRECAUTIONS AND
INSTRUCTIONS IN THIS MANUAL
BEFORE USING THIS EQUIPMENT.
KEEP THIS MANUAL FOR
FUTURE REFERENCE
CHALLENGER 140 HOME GYM CARE, INSTRUCTION
AND ASSEMBLY MANUAL
CHALLENGER 140
HOME GYM
10239-2
INDEX PAGE
1. SAFETY INSTRUCTIONS 3
2. PRE ASSEMBLY CHECK LIST 5
3. HARDWARE LIST 6
4. ASSEMBLY STEPS 9
5. FITNESS TIPS AND TECHNIQUES 20
6. CONDITIONING GUIDELINES 21
7. WARM-UP AND COOL-DOWN 22
8. FREQUENTLY ASKED QUESTIONS 23
9. PARTS LIST 24
10. EXPLODED DRAWING 25
11. TROJAN 1 YEAR LIMITED WARRANTY 26
12. TROJAN REPAIRS PROCEDURE 27
10239-3
1. SAFETY INSTRUCTIONS
It is the sole responsibility of the purchaser of TROJAN products to read the owner’s manual, warning labels and instruct
all individuals, on proper usage of the equipment. Understanding each and every warning to the fullest is important. If any
of these instructions or warnings are unclear please contact Trojan Customer Services on 0861 876 526 (0861 Trojan),
within the Republic of South Africa.
The equipment is only intended for HOME USE and is NOT INTENDED FOR COMMERCIAL, INSTITUTIONAL AND/
OR STUDIO FACILITIES USE.
Contact TROJAN with any questions regarding this classication. It is recommended that all users of TROJAN be informed
of the following information prior to use.
HEALTH 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 inactive, pregnant or suffer from any illness.
• If at any time during exercise you feel faint, dizzy or experience pain, stop exercising immediately and consult your
physician.
• To avoid muscular pain and strain, begin each workout by stretching and warming up and end each session by cooling
down and stretching.
ACCESS CONTROL
TROJAN recommends that all tness equipment be used in a supervised area. It is recommended that the equipment be
located in an access controlled area. Control is the responsibility of the owner. Keep children away from all equipment.
Parents or other adults must provide close supervision of children if the equipment is used in the presence of children.
INSTALLATION
TROJAN recommends that all equipment:
• Be secured to or set up on a solid, level surface to stabilize and eliminate rocking or tipping over during training.
• Be set up inside your home away from moisture and dust (the equipment is not designed for outdoor use).
• Be set up with sufcient ventilation to ensure proper operation.
• Be set up with sufcient space around the equipment so that all exercises can be completed safely. It is recommended
that there should be at least 1m of space around the equipment where access is required to exercise.
• Be installed by our team of installers.
PROPER USAGE
• Do not use the equipment in any way other than as designed or intended by the manufacturer. It is imperative that
TROJAN equipment is used properly to avoid injury.
• Injuries may result from exercising improperly or excessively.
• Your TROJAN equipment should only be used by one person at a time.
• Be careful to maintain your balance while using, mounting, dismounting or assembling your TROJAN equipment to
avoid injury.
• Do not attempt to adjust any pads or pulleys while you are on your TROJAN equipment.
• Servicing other than the procedures in this manual should be performed by an authorized service representative only.
• When adjusting any range of motion limiter, foothold pad, pulley or any other adjustor, make certain the adjusting pin
is fully engaged in the hole to avoid injury.
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INSPECTION
• Do not use or permit use of any equipment that is damaged or has worn or broken parts. For all TROJAN equipment
use only replacement parts supplied by TROJAN.
• Always make sure that all nuts and bolts are tightened prior to each use.
• Cables pose an extreme danger if used when frayed. Always replace any cable at rst sign of wear.
• Routinely inspect all accessory clips that join attachments to the cables and replace at the rst sign of wear.
• Maintain labels and nameplates – do not remove labels for any reason. They contain important information.
• Equipment maintenance – Preventative maintenance is the key to smooth operating equipment. Please ensure that
you follow our maintenance tips to ensure the continued correct function of your TROJAN equipment.
• Before any use, examine all accessories approved for use with the TROJAN equipment for damage or wear.
• Should your Trojan equipment appear damaged or worn, do not attempt to use or repair the equipment yourself.
Please contact our service department on 0861 876526 (0861 Trojan) to arrange a repair.
OPERATING WARNINGS
• It is the purchaser’s responsibility to instruct all users as to the proper operating procedures of all TROJAN
equipment.
• Keep children away from all moving parts and away from all strength equipment. Parents must provide close
supervision of children if the equipment is used in the presence of children.
• Do not wear loose tting clothing or jewellery when using the equipment. It is also recommended that users tie up
long hair to avoid contact with moving parts.
• Ensure that anyone not using the equipment stays clear of the user, accessories and moving parts while the machine is
in operation.
SELECTORIZED WEIGHT STACKS
• Use only weight selector pins supplied by TROJAN. Should you lose or damage your pin, contact our service
department to arrange delivery of a new pin.
• Ensure that weight selector pins are fully inserted as partial insertion can cause weights to fall unexpectedly.
• Never pin the weight stack in an elevated position.
• Never remove a selector pin if any weights are suspended.
• Never attempt to release jammed weights or pins that are suspended.
• When your gym is not in use, place the weight selector pin into the welded loop on the back of the base frame U
bracket. This will lock the selector shaft and all the weight plates.
USER WEIGHT LIMITATIONS
• This TROJAN CHALLENGER 140 may not be used by persons weighing more than 110 kg.
SAVE THIS INSTRUCTION MANUAL FOR FUTURE USE AND REFERENCE
If any of these instructions or warnings are unclear please contact Trojan Customer Services on 0861 876526
(0861 Trojan), within the Republic of South Africa or visit www.trojanhealth.co.za.
1. SAFETY INSTRUCTIONS - Continued
Leg Curl Pad
Seat Cushion
Weight Stack
Back Rest Cushion
Buttery Arm
Pulley
Guide Rod
10239-5
2. PRE ASSEMBLY CHECK LIST
Thank you for choosing the TROJAN CHALLENGER 140 home gym. We take great pride in producing this 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. The TROJAN CHALLENGER 140 home 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.
• Read this manual carefully before using the TROJAN CHALLENGER 140 home gym
10239-6
3. HARDWARE LIST
10239-7
3. HARDWARE LIST
36. Lower Cable (3640 mm) × 1
30. Leg Foam Roller × 4
19. Lat Bar × 1
29. Pothook × 2
18. Handle Tube × 2
42. Chain × 1
21. Single Pulley Block × 2
20. Reverse U × 1
31. Arm Foam Roller × 2
32. Pulley (3.5" X 27 T) × 9
43. Bumper × 1
24. Weight Selector Pin × 1
25. Rubber Ring × 2
22. Pulley U × 1
44. Selector Shaft Bushing × 1
40. Selector Shaft End Cap × 1
28. Tobacco-pipe × 1
38. Oil Bushing(small) × 2
27. Selector Shaft Pin × 1
39. Oil Bushing (big) × 4
17. Foam Tube × 2
37. Butterfly Cable(2750mm) × 1
26. Plastic Washer × 1
35. Upper Cable (2510mm) × 1
23. Plum Blossom Nut × 1
34. Big Pulley (4")× 1
45. 25 mm Round Cap × 1
46. Handle Grip × 6
41. Allen Key x 1
33. Pulley (3.5" X 22 T) × 1
10239-8
3. HARDWARE LIST
54. Pulley Cover × 2 55. Pulley Hook × 18
73. Bolt M10 X × 4
72. Washer ( 30 X 10.3) × 1
50. 20*40 mm Square End Plug × 2
51. Middle-empty Plug
(□3 X
Ø26) × 2
52. 25 mm Round End Plug ×4
48. 40 mm Square End Plug × 2
49. 38mm Square Cap × 3
53. Plastic Cover × 2
71. M8 Nylon Nut × 3
69. M12 Nylon Nut × 3
70. M10 Nylon Nut × 24
66. M12 Washer × 4
67. M10 Washer × 50
68. M8 Washer × 12
57. Hex Bolt M10 X 65 mm × 2
58. Hex Bolt M10 X 60 mm × 11
60. Hex Bolt M10 X 45mm × 1 61. Hex Bolt M10X 20 mm × 2
62. Hex Bolt M8 X 50 mm × 2
63. Hex Bolt M8X40 mm × 2
64. Hex Bolt M8X 25 mm× 1
65. Hex Bolt M8 X15 mm × 4
56. Hex Bolt M12 X 120 mm × 1
59. Hex Bolt M10 X 48 mm× 10
47. 38mm Square End Plug × 8
25 mm
10239-9
4. ASSEMBLY STEPS
STEP 1:
• Remove two M10 x 25 mm Bolts (73) from the two Weight Guide Tubes (3).
• Insert the Weight Guide Tube (3) into the Rear Base Frame (1) using two M10 x 25 mm Bolts (73).
• Attach the Front Base Frame (2) to the Rear Base Frame (1) using two M10 x 60 mm Hex Bolts (58), four
M10 Washers (67) and two M10 Nylon Nuts (70).
• Unpack the carton and place all the parts on the oor, carefully removing all packaging.
• Check that all the required parts are in the box.
• When assembling, rst assemble all nuts and bolts loosely, then tighten them up once the entire gym is
assembled.
10239-10
4. ASSEMBLY STEPS
STEP 2:
• Slide two Rubber Rings (25) onto the two Weight Guide Tubes (3).
• Slide nine Weight Plates (16) down the Weight Guide Tubes (3).
• Slide the Selector Shaft Bushing (44) down the Selector Shaft (5) and secure at the rst hole with the Selector Shaft
Pin (27).
• Insert the Selector Shaft (5) into the hole of Weight Plate (16).
• Slide the Top Weight Plate (15) down the Selector Shaft (5).
• Insert the Weight Selector Pin (24) into the hole of desired Weight.
10239-11
4. ASSEMBLY STEPS
STEP 3:
• Attach the Support Frame (8) to the Front Base Frame (2) using two M10 x 60 mm Hex Bolts (58), four M10
Washers (67) and two M10 Nylon Nuts (70).
• Attach the two Single Pulley Blocks (21) to the Support Frame (8) using two M10 x 65 mm Hex Bolts (57), four
M10 Washers (67) and two M10 Nylon Nuts (70).
10239-12
4. ASSEMBLY STEPS
STEP 4:
• Attach the Front Support Frame (4) to the Front Base Frame (2) using one M10 x 60 mm Hex Bolts (58), two M10
Washers (67) and one M10 Nylon Nut (70).
• Attach the Seat Base Frame (7) to the Front Support Frame (4) and the Support Frame (8) using three M10 x
60 mm Hex Bolts (58), six M10 Washers (67) and three M10 Nylon Nuts (70).
10239-13
4. ASSEMBLY STEPS
STEP 5:
• Remove two M10 x 25 mm Bolts (73) from the two Weight Guide Tubes (3).
• Attach the Upper Cross Beam (9) to the two Weight Guide Tubes (3) using two M10 x 25 mm Bolts (73).
• Attach the Upper Cross Beam (9) to the Support Frame (8) using two M10 x 60 mm Hex Bolts (58), four M10
Washers (67) and two M10 Nylon Nuts (70).
• Attach the Leg Extension Frame (6) and the Seat Base Frame (7) using one M10 x 60 mm Hex Bolt (58), two M10
Washers (67) and one M10 Nylon Nut (70).
10239-14
STEP 6:
• Attach the Back Cushion (14) to the Support Frame (8) using two M8 x 50 mm Hex Bolts (62) and two M8
Washers (68).
• Attach the Seat Cushion (13) to the Seat Base Frame (7) using four M8 x 15 mm Hex Bolts (65) and four M8
Washers (68).
• Insert the Foam Tube (17) into the Leg Extension Frame (6) and the Seat Base Frame (7) then slide the Leg Foam
Rollers (30) onto the Foam Tubes (17).
4. ASSEMBLY STEPS
10239-15
4. ASSEMBLY STEPS
STEP 7:
NOTE: Two small Oil Bushings (38) have been pre-assembled onto the Upper Cross Beam (9).
• Attach the Press Bar (10) to the Upper Cross Beam (9) using one M12 x 120 mm Hex Bolt (56), two M12 Washers
(66) and one M12 Nylon Nut (69).
NOTE: Four big Oil Bushings (39) have been pre-assembled into the Press Bar (10).
• Remove two M12 Nylon Nuts (69) and two M12 Washers (66) from the Left Buttery Arm (11) and the Right
Buttery Arm (12).
• Attach the Right Buttery Arm (12) and the Left Buttery Arm (11) to the Press Bar (10) using two M12 Washers
(66) and two M12 Nylon Nuts (69).
• Slide the Arm Foam Rollers (31) onto the Right Buttery Arm (12) and the Left Buttery Arm (11).
• Remove two M10 x 20 mm Hex Bolts (61) and two M10 Washers (67) from the Handle Tube (18).
• Attach the Handle Tube (18) to the Right Buttery Arm (12) and Left Buttery Arm (11) using two M10 x 20 mm
Hex Bolts (61) and two M10 Washers (67).
• Slide two □38 X Ø26 Middle-empty Plugs (51) and two Handle Grips (46) onto the Right Buttery Arm (12) and
the Left Buttery Arm(11).
• Attach the Tobacco-pipe (28) to the Support Frame (8) using one M8 x 40 mm Hex Bolt (63), two M8 Washers
(68) and one M8 Nylon Nut (71).
• Slide the Ø30 X Ø10.4 Washer (72) and the Plum Blossom Nut (23) onto the Tobacco-pipe (28).
10239-16
4. ASSEMBLY STEPS
STEP 8:
Start with the 2510 mm Upper Cable (35):
• With the Upper Cable (35) in the groove of Pulley No.1(33) thread the cable through Upper Cross Beam (9).
• Install Pulley No.1 (33) onto the Upper Cross Beam (9) using one M10 x 45 mm Hex Bolt (60), two M10 Washers
(67) and one M10 Nylon Nut (70).
• Install Pulley No.2 (32) and two Pulley Hooks (55) onto the Support Frame (8) using one M10 x 48 mm Hex Bolt
(59), two M10 Washers (67) and one M10 Nylon Nut (70).
• Install Big Pulley No.4 (34) and two Pulley Covers (54) onto the Upper Cross Beam (9) using one M10 x 48 mm
Hex Bolt (59), two M10 Washers (67) and one M10 Nylon Nut (70).
• Attach the Bolt End of the Upper Cable (35) to the Selector Shaft (5) with Plastic Washer (26).
• Attach the Ball End of Upper Cable (35) to the Lat Bar (19) using one Pothook (29).
• Install pulley No.3 (32) and two Pulley Hooks (55) to the Pulley U (22) using one M10 x 48 mm Hex Bolt (59), two
M10 Washers (67) and one M10 Nylon Nut (70).
10239-17
4. ASSEMBLY STEPS
STEP 9:
Assembly of the 2750 mm Buttery Cable (37):
• Attach both ends of the Cable (37) to the Left Buttery Arm (11) and the Right Buttery Arm (12) using two Plastic
Covers (53).
• Install Pulley No.5&7 (32) and four Pulley Hooks (55) to the Single Pulley Block (21) using two M10 x 48 mm Hex
Bolts (59), four M10 Washers (67), and two M10 Nylon Nuts (70).
• Install Pulley No.6 (32) and two Pulley Hooks (55) to the Reverse U (20) using one M10 x 48 mm Hex Bolt (59),
two M10 Washers (67) and one M10 Nylon Nut (70).
10239-18
4. ASSEMBLY STEPS
STEP 10:
Assembly of the 3640 mm Lower Cable (36):
• With the Lower Cable (36) in the groove of Pulley (32) thread the cable through Leg Extension Frame (6).
• Attach the end of Lower Cable (36) to the Leg Extension Frame (6) using one M8 x 25 mm Hex Bolt (64), two M8
Washers (68) and one M8 Nylon Nut (71).
• Install Pulley No.8 (32) and two Pulley Hooks (55) to the Support Frame (8) using one M10 x 48 mm Hex Bolt (59),
two M10 Washers (67) and one M10 Nylon Nut (70).
• Install Pulley No.9 (32) and two Pulley Hooks (55) to the Reverse U (20) using one M10 x 48 mm Hex Bolt (59),
two M10 Washers (67) and one M10 Nylon Nut (70).
• Install Pulley No.10 (32) and two Pulley Hooks (55) to the Front Base Frame (2) using one M10 x 48 mm Hex Bolt
(59), two M10 Washers (67) and one M10 Nylon Nut (70).
• Install Pulley No.11 (32) and two Pulley Hooks (55) to the Pulley U (22) using one M10 x 48 mm Hex Bolt (59), two
M10 Washers (67) and one M10 Nylon Nut (70).
• Attach the other end of the Cable (36) to the Front Base Frame (2) using one M8 x 40 mm Hex Bolt (63), two M8
Washers (68), one M8 Nylon Nut (71), one Chain (42) and one Pothook (29).
10239-19
4. ASSEMBLY STEPS
When your home gym is not in use, ensure the Weight Selector Pin (24) is located through
the welded loop on the back of the Base Frame and into the Selector Shaft (5).This will lock
the weights in place.
NOTE:
Recheck
all bolts and nuts are
tightened securely
before using the machine
10239-20
AEROBIC EXERCISE
Aerobic exercise is any sustained activity that sends oxygen to your muscles via your heart and lungs. Aerobic exercise
improves the tness of your lungs and heart - your body’s most important muscle. Aerobic exercise tness 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.
5. FITNESS TIPS AND TECHNIQUES
Tr apezius
Posterior
Tricep
Latissimus Dorsi
Gluteals
Hamstrings
Gastrocnemius
Tr apezius
Anterior
Pectoralis Major
Serratus Anterior
Biceps
Abdominal
Sartorius
Quadriceps
Tibialis
MUSCLE CHART
CHALLENGER 140 home gym
The exercise routine that is performed with the TROJAN CHALLENGER 140 home gym will develop the whole body.
These muscle groups are highlighted on the muscle chart below.
Trojan and the Heart and Stroke Foundation have joined forces to KEEP SOUTH AFRICA MOVING.
The Heart and Stroke Foundation South Africa encourages all South Africans to make heart-healthy
choices that include daily physical activity, exercise and a balanced diet. Use Trojan, SA’s No. 1
selling Home Fitness brand to gives you the ability to boost your tness level and lower your risk of
cardiovascular disease.
Visit www.trojanhealth.co.za for equipment choices and exercise programs, and
www.heartfoundation.co.za for information on how to adopt a healthy lifestyle.
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