Trojan Power Gym 400 User manual

Trojan
Brand
Trojan
Model
Power Gym 400
Category
Fitness, gymnastics & weight training
Type
User manual

This manual is also suitable for

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
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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
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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.
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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.
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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)
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HARDWARE&TOOLSLIST
#20 FOAM ROD
(LONG) 1PC
#21 LAT BAR 1PC
#22 CURL BAR
1PC
#23 SINGLE
PULLEY BRACKET
2PCS
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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 MM MM
8
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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
M8
3PCS
#89 WASHER
M8
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
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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
MM
#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
MM
MM
10
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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
11
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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
4
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
12
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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)
1
117 Oil Bushing Ø38 X Ø32 X
Ø25.4 X 19 mm
2
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”
2
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
13
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EXPLODEDDRAWING
14
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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.
2
1
15
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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).
3
16
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).
5
4
17
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
6
18
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ASSEMBLYSTEPS
7
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).
19
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
8
• 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).
20
10318
ASSEMBLYSTEPS
9
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).
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Trojan Power Gym 400 User manual

Trojan
Brand
Trojan
Model
Power Gym 400
Category
Fitness, gymnastics & weight training
Type
User manual
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