10
STEP 5 Cable and Pulley Assembly
When attaching pulleys, make certain the Flat Bolts are completely through both holes
in the pulley bracket. Failure to do so will result in improper alignment and the pulley
will rub on steel. Assemble pulleys and cables simultaneously.
1. Attach two 90mm PULLEYS (229) to the right side REVOLVING CABLE BRACKET (211)
while inserting the CABLE (241) in between these two pulleys so that the Ball End rests
against the outside of these pulleys, as shown in Fig. P1, P2. Secure the pulleys using one
3/8" X 30.5L FLAT BOLT (254) and one M6 X 12L MALE SET SCREW (258) for each
90mm PULLEY (229).
2. Route the Steel Head End of the CABLE (241) up and over 90mm PULLEY (229) P3 that
you will mount into the slot in the TOP FRAME (202) using one 3/8" X 109.5L FLAT BOLT
(251) and one M6 X 12L MALE SET SCREW (258) as shown in Fig P3.
3. Continue routing the Steel Head End of the CABLE (241) down and under 90mm PULLEY
(229) P4 that you will mount into the TOP FRAME (202) through two 3/8" ID BUSHINGS
(239), using one 3/8" X 50.5L FLAT BOLT (252) and one M6 X 12L MALE SET SCREW
(258) as shown in Fig P4.
4. Route the Steel Head End of the CABLE (241) over to the horizontal bracket at the bend in
the TOP FRAME (202). Go ahead and stack two 90mm PULLEYS (229) P5 and P9 here
and route the cable behind the top pulley P5. Loosely secure these pulleys to the TOP
FRAME (202) using one 3/8" X 2-1/2" HEX BOLT (245) as shown in Fig P5, P9.
5. Continue routing the Steel Head End of the CABLE (241) over to 90mm PULLEY (229) P6
as shown in large drawing and Fig P6. Secure this pulley using one 3/8" X 1-3/4" HEX
BOLT (247) and one 3/8" NYLON NUT (267).
6. Continue routing the Steel Head End of the CABLE (241) down and under the inside of
114mm PULLEY (228) P7 that you will mount to the PULLEY BLOCK (215) attached to
Top Plate using one CABLE TENSIONER (218), two 3/8" WASHERS (261), and one 3/8"
NYLON NUT (267). Exit the cable to the outside of Pulley P7 as shown in Fig P7.
7. Route the Steel Head End of the CABLE (241) up and over 90mm PULLEY (229) P8 that
you will mount into the TOP FRAME (202) using one 3/8" X 1-3/4" HEX BOLT (247) and
one 3/8" NYLON NUT (267) as shown in Fig P8.
8. Route the Steel Head End of the CABLE (241) over to the horizontal bracket at the bend in
the TOP FRAME (202), and route the cable behind the bottom pulley P9. Secure these
pulleys to the TOP FRAME (202) using one 3/8" X 2-1/2" HEX BOLT (245) as shown in
Fig P5, P9.
9. Continue routing the Steel Head End of the CABLE (241) over to 90mm PULLEY (229)
P10 which you will mount to the vertical bracket welded to the top of RIGHT FRAME
UPRIGHT (203R) using one 3/8" X 1-3/4" HEX BOLT (247) and one 3/8" NYLON NUT
(267).
10. Route the Steel Head End of the CABLE (241) down through the inside of RIGHT
FRAME UPRIGHT (203R), exiting at the bottom. Continue routing the Steel Head End of
the CABLE (241) around 90mm PULLEY (229) P11 that you will mount to the vertical
bracket welded to the bottom of the RIGHT FRAME UPRIGHT (203R) using one 3/8" X 1-
3/4" HEX BOLT (247) and one 3/8" NYLON NUT (267).
11. Finish routing the cable up to the CABLE ADJUSTER (210) and fix the Steel Head End of
the CABLE (241) to the CABLE ADJUSTER (210) using one 3/8" X 43L DOUBLE FLAT
BOLT (253) and two M6 X 12L MALE SET SCREWS (258).
12. Repeat this fun procedure for the other side!
13. TIGHTEN ALL BOLTS.
0 1/4 1/2 3/4 1" 1/4 1/2 3/4 2" 1/4 1/2 3/4 3" 1/4 1/2 3/4 4" 1/4 1/2 3/4 5" 1/4 1/2 3/4 6"
(inch)