Trojan Power Gym 400 User manual

Brand: Trojan

Model: Power Gym 400

Category: Fitness, gymnastics & weight training

Type: User manual

This manual is also suitable for

Recumbent 400

POWER STATION 400

HOME GYM

USER MANUAL

CAUTION

READ ALL PRECAUTIONS AND

INSTRUCTIONS IN THIS MANUAL

BEFORE USING THIS EQUIPMENT.

KEEP THIS MANUAL FOR

FUTURE REFERENCE.

Visit facebook.com/trojanhealth

www.trojanhealth.co.za

10318

INDEX

• SafetyInstructions ______________________________________________ 3

• PreAssemblyCheckList__________________________________________ 5

• Hardware&ToolsList____________________________________________ 6

• PartsList______________________________________________________  10

• ExplodedDrawing_______________________________________________  13

• AssemblySteps_________________________________________________  14

• FitnessTips&Techniques__________________________________________  27

• ConditioningGuidelines __________________________________________  28

• WarmUp&CoolDown _________________________________________  29

• FrequentlyAskedQuestions_______________________________________  30

• 1YearLimitedWarranty __________________________________________  31

• RepairsProcedure_______________________________________________  32

10318

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 our Trojan Call Centre on

0861 TROJAN (0861 876526), within the Republic of South Africa. International Consumers can contact us

on: +27 10 206 4405

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 classication. 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, are 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.

• This equipment is not intended for use by persons (including children) with reduced physical, sensory

or mental capabilities, unless they have been given instruction on the use of this equipment or are

supervised.

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 supervising adults must provide close supervision of

children, if the equipment is used in the presence of children.

INSTALLATION

• Be secured to or set up on a solid, level surface to stabilise and eliminate rocking or tipping over during

training.

• Set up inside your home away from moisture and dust (the equipment is not designed for outdoor use).

• Set up with sufcient 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.

• Have the equipment 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, folding, unfolding or assembling

your Trojan equipment to avoid injury.

10318

SAFETYINSTRUCTIONS

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.

• Maintain labels and nameplates – do not remove labels for any reason, as it contains 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 TROJAN (0861 876526) to arrange a repair.

OPERATING WARNINGS

• It is the purchaser’s responsibility to instruct all users of the proper operating procedures of all Trojan

equipment.

• Keep children away from all moving parts. 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.

SELECTORISED 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 Power Station 400 Home Gym may not be used by persons weighing more than 120 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 TROJAN (0861 876526) within the Republic of South Africa or visit www.trojanhealth.co.za.

10318

PREASSEMBLYCHECKLIST

Thank you for choosing the Trojan Power Station 400 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 Power Station 400 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 Power Station 400 Home Gym.

Lat Bar

Arm Curl Cushion

Leg Press Plate

Leg Extension Bar Curl Bar

Weight Plates

Bench Press Arms

Buttery Arms

35 (minimum)

5 kg to 60 kg

120 kg (maximum)

1650 (l) x 1900 (w) x 2100 (h)

10318

HARDWARE&TOOLSLIST

#20 FOAM ROD

(LONG) 1PC

#21 LAT BAR 1PC

#22 CURL BAR

1PC

#23 SINGLE

PULLEY BRACKET

2PCS

10318

HARDWARE&TOOLSLIST

#31 WEIGHT

PLATE 10PCS

#66 OIL

BUSHING

12PCS

#67 OIL BUSHING

Ø44 X Ø39.4 X Ø19.1 X 12 MM

4PCS

#68 OIL BUSHING

Ø50 X Ø44 X Ø12.8 X 12 MM

2PCS

#69 OIL BUSHING

Ø44 X Ø39.4 X Ø25.6 X 12 MM

4PCS

MM MM MM

10318

HARDWARE&TOOLSLIST

#70 HEX BOLT

3/8” X 3-3/8”

2PCS

#71 HEX BOLT

3/8” X 4-1/4”

2PCS

#72 HEX BOLT

3/8” X 2-1/2”

2PCS

#73 HEX BOLT

3/8” X 1-1/4”

2PCS

#74 HEX BOLT

3/8” X 2”

16PCS

#75 HEX BOLT

3/8 X 2-1/8”

2PCS

#76 HEX BOLT

3/8” X 1”

8PCS

#77 HEX BOLT

1/2” X 3-3/8”

1PC

#78 HEX BOLT

3/8” X 3-3/4”

3PCS

#79 HEX BOLT

3/8” X 3”

1PC

#80 SCREW

M10 X 25 MM

4PCS

#81 SCREW

M8 X 16 MM

12PCS

#82 SCREW

M8 X 42 MM

2PCS

#83 SCREW

M8 X 60 MM

2PCS

#85 LOCK NUT

3/8”

40PCS

#86 LOCK NUT

1/2”

1PC

#87 LOCK NUT

5/8”

4PCS

#88 LOCK NUT

3PCS

#89 WASHER

20PCS

#90

WASHER

3/8”

90PCS

#91 WASHER

1/2”

2PCS

#92 WASHER

5/8”

4PCS

#94 HEX BOLT

3/8” X 4-1/8”

8PCS

#95 WASHER

T3.0 X 13 X 32 MM

1PC

#96 WASHER

T3.0 X 26 X 46 MM

1PC

#84 PIVOT SHAFT

19 X 280 MM

1PC

#93 WASHER

T3.0 X Ø11 X 36 MM

4PCS

#97

ALLEN BOLT

3/8” X 3/4”

2PCS

#98 BUSHING

13 X T1.0 X 11 MM

2PCS

#100 BUSHING

13 X T1.0 X 22 MM

2PCS

#102 ANKLE

STRAP

#103 BIG

PULLEY

GUARD

2PCS

#104

PULLEY

BRACKET

30PCS

#99 BUSHING

13 X T1.0 X 17 MM

2PCS

10318

HARDWARE&TOOLSLIST

#105 BUSHING

1PC

#116 BACKREST

CUSHION (LEG

FRAME) 1PC

#118 HEX

BOLT M8

X 20 MM

2PCS

#121 HEX BOLT

3/8” X 4-3/8”

2PCS

#123 SQUARE

BUMPER 1PC

#124 ALLEN BOLT

M10 X 25 MM

2PCS

#125 BUSHING

13 X T1.0 X 26 MM

2PCS

#119 HEX BOLT

3/8” X 4”

2PCS

#120 HEX BOLT

M8 X 45

1PC

#117 OIL BUSHING

Ø38 MM X 32

X 25.4 X 19 MM

2PCS

10318

PARTSLIST

Part Description Qty Part Description Qty

1 Main Base 1 31 Weight Plate 10

2 Rear Base 1 32 Weight Base Plate 1

3 Vertical Post 1 33 Weight Selection Pin 1

4 Guide Rod 2 34 Pin 1

5 Top Beam 1 35 Elliptical End Cap 30 X 70 mm 1

6 Buttery Extension 1 36 Plastic Bushing 1

7 Left Buttery Arm 1 37 Square End Plug 50 X 50 mm 4

8 Right Buttery Arm 1 38 Oval End Plug 40 X 80 mm 3

9 Seat Cushion Support 1 39 Round End Plug 25 mm 12

10 Seat Support Post 1 40 Round End Plug 50 mm 5

11 Leg Extension 1 41 Round Bushing 3

12 Arm Curl Frame 1 42 Bumper Cap 2

13 Bench Press Arm 1 43 Plastic Dome Cap 5/8" 4

14 Solid Handle 2 44 Plastic Dome Cap 3/8" 2

15 Left Adjustable Plate 1 45 Plastic Dome Cap 1/2" 2

16 Right Adjustable Plate 1 46 Foam Roll 4

17 Adjustable Press Frame (A) 1 47 Round Bumper 2

18 Adjustable Press Frame (B) 1 48 Oval Bumper 3

19 Foam Rod (Short) 1 49 PVC Handle Grip 4

20 Foam Rod (Long) 1 50 Pop Pin 2

21 Lat Bar 1 51 Pop Pin Pt-1B 4

22 Curl Bar 1 52 Hook 4

23 Single Pulley Bracket 2 53 Red Pulley 2

24 Pulley Bracket Piece 2 54 Pulley 19

25 Intersect Pulley Bracket 1 55 Big Pulley 1

26 Arm Curl Cushion 1 56 Chain (Short) 1

27 Seat Cushion 1 57 Chain (Long) 1

28 Backrest Cushion 1 58 Handle Tube (Long) 2

29 Weight Selection Rod 1 59 Handle Tube (Short) 2

30 Top Plate 1 60 Taper End Plug 1

10318

PARTSLIST

Part Description Qty Part Description Qty

61 Taper Bumper 1 89 Washer M8 20

62 Plate 2 90 Washer 3/8" 90

63 Upper Cable 1 91 Washer 1/2" 2

64 Low Cable 1 92 Washer 5/8" 4

65 Buttery Cable 1 93 Washer

T3.0 X Ø11 X Ø36 mm

66 Oil Bushing 12 94 Hex Bolt 3/8" X 4-1/8" 8

67 Oil Bushing Ø44 X Ø39.4

X Ø19.1 X 12 mm

4 95 Washer T3.0 X 13 X 32 mm 1

68 Oil Bushing Ø50 X Ø43.9.4

X Ø12.8 X 12 mm

2 96 Washer T3.0 X 26 X 46 mm 1

69 Oil Bushing Ø44 X Ø39.4

X Ø25.6 X 12 mm

4 97 Allen Bolt 3/8" X 3/4" 2

70 Hex Bolt 3/8" X 3-3/8" 2 98 Bushing 13 X T1.0 X 11 mm 2

71 Hex Bolt 3/8" X 4-1/4" 2 99 Bushing 13 X T1.0 X 17 mm 2

72 Hex Bolt 3/8" X 2-1/2" 2 100 Bushing 13 X T1.0 X 22 mm 2

73 Hex Bolt 3/8" X 1-1/4" 2 101 Pulley Guard 6

74 Hex Bolt 3/8" X 2" 16 102 Ankle Strap 1

75 Hex Bolt 3/8" X 2-1/8" 2 103 Big Pulley Guard 2

76 Hex Bolt 3/8" X 1" 8 104 Pulley Bracket 30

77 Hex Bolt 1/2" X 3-3/8" 1 105 Bushing 1

78 Hex Bolt 3/8" X 3-3/4" 3 106 Leg Frame 1

79 Hex Bolt 3/8" X 3" 1 105 Bushing 1

80 Screw M10 X 25 mm 4 106 Leg Frame 1

81 Hex Bolt M8 X 16 mm 12 107 Arc Base Connect Tube 1

82 Hex Bolt M8 X 42 mm 2 108 Leg Support 1

83 Hex Bolt M8 X 60 mm 2 109 Right Hand Bar 1

84 Pivot Shaft Ø19 X 280 mm 1 110 Left Hand Bar 1

85 Lock Nut 3/8" 40 111 Pattern Plate 1

86 Lock Nut 1/2" 1 112 Shaft Ø19 X 168 mm 1

87 Lock Nut 5/8" 4 113 Shaft Ø25 X 119 mm 1

88 Lock Nut M8 3 114 Back Adjust Tube 1

10318

PARTSLIST

NOTE: The parts mentioned above are all the parts you

need to assemble this equipment. Before you

start to assemble, please check the hardware

packing to make sure all parts are included.

Basic tools, such as spanners will be required

for assembly.

Part Description Qty

115 Seat Cushion (Leg Frame) 1

116 Backrest Cushion (Leg

Frame)

117 Oil Bushing Ø38 X Ø32 X

Ø25.4 X 19 mm

118 Hex Bolt M8 X 20 2

119 Hex Bolt 3/8" X 4" 2

120 Hex Bolt M8 X 45 1

121

Hex Bolt 3/8’ X 4-3/8”

122 Hand Tube 155 mm 2

123 Square Bumper 1

124 Allen Bolt M10 X 25 mm 2

125 Bushing 13 X T1.0 X 26 mm 2

10318

EXPLODEDDRAWING

10318

ASSEMBLYSTEPS

STEP 1:

• Attach Main Base (1) to the Rear Base (2) using two Hex

Bolts 3/8” x 4-1/8” (94), four Washers 3/8” (90) and two

Lock Nuts 3/8” (85).

STEP 2:

• Slide two Round Bumpers (47) onto the two Guide Rods

(4). Insert two Guide Rods (4) into the two holes of the

Rear Base (2) and secure using two Hex Bolts 3/8” x 1”

(76) and two Washers 3/8” (90). Slide the Weight Base

Plate (32) down as shown.

• Place the Plastic Bushing (36) onto the Weight Selection

Rod (29), in line with the 1st hole, and secure using Pin (34).

• Slide Top Plate (30) down as shown.

• Attach Vertical Post (3) to the Main Base (1) using two

Hex Bolts 3/8” x 4-3/8” (121), four Washers 3/8” (90) and

two Lock Nuts 3/8” (85).

(Don’t tighten the Hex Bolts 3/8” x 4-3/8” (121) yet.)

• 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.

10318

ASSEMBLYSTEPS

STEP 3:

• Lift the Top Plate (30) and

Weight Selection Rod (29) up,

and then slide the 10 Weight

Plates (31) into place, one at

a time.

• Insert the Weight Selection

Pin (33) into the desired

Weight Plates.

• Place the Upper Cable (63)

in the groove of the Red

Pulley (53), install the Red

Pulley (53) into the bracket of

the Top Beam (5) using one

Hex Bolt 3/8”x 2” (74), two

Washers 3/8” (90) and one

Lock Nut 3/8” (85).

• Attach the Top Beam (5) to

the top of the Guide Rods (4)

using two Hex Bolts 3/8” X

1” (76) and two Washers 3/8”

(90). Place the Top Beam (5)

onto the Vertical Post (3).

• Attach two Plates (62) to the

Top Beam (5) using two Hex

Bolts 3/8” x 4-1/4” (71), two

Allen Bolts 3/8” X 3/4” (97),

six Washers 3/8” (90) and

two Lock Nuts 3/8” (85).

10318

ASSEMBLYSTEPS

STEP 4:

• Attach the Bench Press Arm (13) to the Main Base

(1) using one Pivot Shaft Ø19 X 280 mm (84), two

Washers 5/8” (92), two Lock Nuts 5/8” (87) and

two Plastic Dome Caps 5/8” (43).

• Insert the Adjustable Press Frame A & B (17,18) into

the Bench Press Arm (13) using Pop Pin Pt-1B (51)

to secure them in place.

STEP 5:

• Attach the Seat Cushion Support (9) to the Seat

Support Post (10) using one Hex Bolt 3/8” x 2-1/2”

(72), two Washers 3/8” (90) and one Lock Nut 3/8” (85).

• Attach the Seat Cushion Support (9) to the Vertical

Post (3) using two Hex Bolts 3/8” x 2-1/8” (75), four

Washers 3/8” (90) and two Lock Nuts 3/8” (85).

• Attach the Seat Support Post (10) to the Main Base (1)

using two Hex Bolts 3/8” x 4-1/8” (94), four Washers

3/8” (90) and two Lock Nuts 3/8” (85).

• Attach the Leg

Extension (11) to

the Seat Support

Post (10) using one

Hex Bolt 1/2” X

3-3/8” (77), two

Washers 1/2” (91)

and one Lock Nut

1/2” (86). Plug two

Plastic Dome Caps

1/2” (45) onto the

Lock Nut 1/2” (86)

and Hex Bolt 1/2” X

3-3/8” (77).

10318

STEP 6:

• Attach the Buttery Extension

(6) to the Vertical Post (3)

using two Hex Bolts 3/8” x

3-3/4” (78), four Washers 3/8”

(90) and two Lock Nuts 3/8”

(85).

• Insert the shaft of the Left

Buttery Arm (7) through

the Left Adjustable Plate (15)

and secure to the Buttery

Extension (6) using one

Washer 5/8” (92) and one

Lock Nut 5/8” (87). Place one

Plastic Dome Cap 5/8” (43)

onto Lock Nut 5/8” (87).

• Insert the Solid Handle (14)

into the Left Buttery Arm (7)

and secure using one Hex Bolt

3/8” x 1” (76), one Washer

3/8” (90) and one Washer T3.0

x Ø11 x Ø36 (93). Place one

Plastic Dome Cap 3/8” (44)

onto Hex Bolt 3/8” x 1” (76).

• Assemble the Right Buttery

Arm (8) as per the steps used

for the Left Buttery Arm (7).

• Attach two Single Pulley

Brackets (23) to the bracket

of Vertical Post (3) using two

Hex Bolts M8 x 60 mm (83),

four Washers M8 (89) and

two Lock Nuts M8 (88).

ASSEMBLYSTEPS

10318

ASSEMBLYSTEPS

STEP 7:

• Thread the Upper Cable (63)

through the pulley brackets of

the unit.

• With the Upper Cable (63)

in the groove of the Pulley

(54), install Pulley B with two

Pulley Brackets (104) into the

bracket of the Top Beam (5)

using one Hex Bolt 3/8” x 2”

(74), two Washers 3/8” (90)

and one Lock Nut 3/8” (85).

• With the Upper Cable (63)

in the groove of Pulley (54),

install Pulley C with two Pulley

Brackets (104) into the top of

Pulley Bracket Piece (24) using

one Hex Bolt 3/8” x 2” (74),

two Washers 3/8” (90) and

one Lock Nut 3/8” (85).

• With the Upper Cable (63)

in the groove of the Big Pulley

(55), install the Pulley D with

two Big Pulley Guards (103)

into the bracket of the Top

Beam (5) using one Hex Bolt

3/8” x 2” (74), two Washers

3/8” (90) and one Lock Nut

3/8” (85).

• Secure the bolt end of Upper

Cable (63) onto the Weight

Selection Rod (29) using one

Washer T3.0 X Ø13 X Ø32

mm (95) and one Washer T3.0 X

Ø26 X Ø46 mm (96).

• Attach the ball end of Upper

Cable (63) onto the Lat Bar

(21) using the Chain (Short)

(56) and two Hooks (52).

10318

STEP 8:

• Thread the Buttery Cable

(65) through the brackets

of unit.

• Attach one end of Buttery

Cable (65) to the Right

Adjustable Plate (16) using

one Hex Bolt 3/8” X 1-1/4”

(73), one Washer 3/8” (90)

and one Lock Nut 3/8”

(85).

• With the Buttery Cable

(65) in the groove of the

Pulley (54), install Pulley E

with two Pulley Brackets

(104) into the Single Pulley

Bracket (23) using one Hex

Bolt 3/8” x 2” (74), two

Washers 3/8” (90) and

one Lock Nut 3/8” (85).

• With the Buttery Cable

(65) in the groove of Pulley

(54), install Pulley F with

two Pulley Brackets (104)

into the top of the Intersect

Pulley Bracket (25) using

one Hex Bolt 3/8” x 2” (74),

two Washers 3/8” (90) and

one Lock Nut 3/8” (85).

ASSEMBLYSTEPS

• With the Buttery Cable (65) in the groove of Pulley (54), install Pulley G with two Pulley Brackets (104)

into the Single Pulley Bracket (23) using one Hex Bolt 3/8” x 2” (74), two Washers 3/8” (90) and one

Lock Nut 3/8” (85).

• Attach the other end of Buttery Cable (65) to the Left Adjustable Plate (15) using one Hex Bolt 3/8” x

1-1/2” (73), one Washer 3/8” (90) and one Lock Nut 3/8” (85).

10318

ASSEMBLYSTEPS

STEP 9:

• First, remove two Hex Bolts 3/8”

X 4-3/8” (121) and four Washers

3/8” (90) and two Lock Nuts

3/8” (85) from the Main Base (1)

and Vertical Post (3).

• Attach the Arc Base Connect

Tube (107) to the Main Base (1)

and Vertical Post (3) using two

Hex Bolts 3/8” X 4-3/8” (121),

four Washers 3/8” (90) and two

Lock Nuts 3/8” (85).

• Attach the Leg Frame (106) to

the Rear Base (2) using two Hex

Bolts 3/8” X 1” (76) and two

Hex Bolts 3/8” X 4” (119), six

Washers 3/8” (90), two Lock

Nuts 3/8” (85).

• Attach the Leg Frame (106)

to the Arc Base Connect Tube

(107) using two Hex Bolts 3/8”

X 4-1/8” (94), three Washers

3/8” (90) and one Lock Nut

3/8” (85).

Page is loading ...

Trojan Power Gym 400 User manual

Brand: Trojan

Model: Power Gym 400

Category: Fitness, gymnastics & weight training

Type: User manual

This manual is also suitable for

Recumbent 400

Download PDF

report

Trojan Power Gym 400 User manual

This manual is also suitable for

Trojan Power Gym 400 User manual

Related papers

Other documents