CW-608
CW-608 Assembly Guide
page 3
IMPORTANT SAFETY INSTRUCTIONS
Important Safety Instructions
Important Safety Guidelines
for Owners
Follow these guidelines to maintain proper working
condition of the equipment:
Important: Do not modify the equipment or any of
its parts, or permanently remove any part from the
equipment. Do not use accessory attachments that
are not recommended by Precor, as such attachments
might cause injuries.
• Qualiedtechniciansmustperformallregular
maintenance.
• Makesurethattrainers,facilitypersonnel,and
maintenance technicians understand how to use
theequipment,knowimportantsafetyguidelines,
and can recognize potential problems such as a
worn cable or cracked weld.
• Strengthtrainingrequiresasignicantfocusbythe
facilityanditsstafftomaintainthequalityofthe
tnessenvironment.Ifpossible,thefacilityshould
providedirectsupervisionofthetnessequipment
atalltimesbypeopleknowledgeableaboutthe
safe operation of the equipment and trained to
recognize potential problems.
• Ifanystaffmemberwitnessunsafeuseofthe
equipment,heorsheshouldaddresstheuser
directly,demonstratethepropertechnique,
andreviewtheImportant Safety Information for
Users. Precor recommends posting a copy of the
ImportantSafetyInformationforUsersnear the
equipment in a prominent location.
• Makesuretheequipmentisstableandplacedon
asolid,levelsurface.Theequipmentisdesignedto
befreestanding;however,equipmentcanbebolted
totheoorforextrastability.Consultaqualied
general contractor for proper fastening methods.
• Makesurethattheequipmentisinstalledwith
enough free space for safe operation. With most
equipment,thegeneralruleistoallowabouta
4-foot (1.2-meter) circle of space from the user’s
center.ForFunctionalTrainingequipment,make
sure that the operating space is large enough to
allowthecablestobefullyextendedinallpossible
directions.
• Checktheequipmentthoroughlybasedonthe
recommended inspection schedules outlined in
thismanual,includingdaily,weekly,monthlyand
annual checks.
• Placean“out-of-order”signontheequipment
during maintenance of the equipment or the
surroundingarea.Usersshouldneverbe
allowed to operate the equipment until it has
beeninspectedandworksproperly.Ifapieceof
equipmentneedsservice,keepitoutofuseuntil
repaired.
• Wheneveraweightcandropandhita
user,suchaswithanOlympicbench,
Precorhighlyrecommendsthata
helper or spotter be used.
• Donotplacetheequipmentoutdoorsor
on wet surfaces.
Obtaining Service
For information about product operation
orservice,refertothePrecorwebsite
atwww.precor.comwhereyoucanalso
ndcustomersupportnumbersoralistof
Precorauthorizedservicecenters.
Ifyoucallore-mailCustomerSupport,have
theserialnumberavailable.
Youcanndtheserialnumberprintedon
alabelafxedtotheequipment.Forfuture
reference,writetheserialnumberinthe
spaceprovidedbelow.
Serialnumber:
_______________________
CW-608 Assembly Guide
page 4
IMPORTANT SAFETY INSTRUCTIONS
Important Safety Instructions
Important Safety Information
for Users
Beforebeginninganytnessprogram,youshould
obtainacompletephysicalexaminationfromyour
physician.
French equivalent of the preceding paragraph, for the
Canadian market: Il est conseillé de subir un examen
médical complet avant d’entreprendre tout programme
d’exercise. Si vous avez des étourdissements ou des
faiblesses, arrêtez les exercices immédiatement.
Whenusingexerciseequipment,youshouldalways
takebasicprecautions,includingthefollowing:
• Ifyoudonotunderstandhowtooperateapieceof
equipment,asksomeonefromthefacilitysuchas
a trainer to demonstrate how to use it and explain
anysafetyinstructions.
• Donotallowchildrenonorneartheequipment.
Donotleavechildrenunsupervisedaroundthe
equipment.
• Usetheequipmentonlyforitsintendedpurpose.
Donotuseaccessoryattachmentsthatarenot
recommendedbythemanufacturer,assuch
attachmentsmaycauseinjuries.
• Wearproperexerciseclothingandshoesforyour
workout—no loose clothing.
• Do not overexert yourself or work to
exhaustion.Usereasonablejudgmentwhen
workingwithweights.Avoidusingexcessive
weight,whichmaycauseinjury.
• Ifyoufeelpain,faintness,dizziness,orabnormal
symptoms,stopexercisingimmediatelyand
consultyourphysician.
• Keephead,limbs,ngers,andhairclearofall
movingpartswhiletheequipmentisinuse.Keep
hands clear of racking pegs.
• Neverdroporinsertobjectsintoanyopeninginthe
equipment.
• Alwayschecktheequipmentbeforeusingit.If
youspotapotentialproblem,contactsomeonein
thefacilityimmediately.Donotusetheequipment
untilthefacilityhasveriedthattheequipmentis
workingproperly.Donotattempttoxabrokenor
jammedmachine.
• Donotusetheequipmentoutdoorsor
on wet surfaces.
• Donotdroporslamtheweightstack
while exercising.
• Donotusetheequipmentifan
“outoforder”signhasbeenplaced
on it.
• Readallpostedinstructions,including
allsafetyinstructionsandwarnings.
CW-608 Assembly Guide
page 5
Important Safety Guidelines for Owners ................................................................ 3
ObtainingService ...................................................................................................................................... 3
Important Safety Information for Users ................................................................... 4
Preparations ............................................................................................................... 6
UnpackingtheEquipment ......................................................................................................................... 6
RequiredTools ......................................................................................................................................... 6
InstallationRequirements .......................................................................................................................... 6
Hardware Kit ............................................................................................................................................. 7
Assembly Instructions .............................................................................................. 9
OpentheBox ............................................................................................................................................ 9
AssembletheUnit ..................................................................................................................................... 10
CleantheUnit ........................................................................................................................................... 13
Specifications ............................................................................................................ 16
Table of Contents
1
2
Table of Contents
CW-608 Assembly Guide
page 6
1
Preparations
Preparations
TheCW-608partsareinspectedbeforeshipment.
Eachunitcontainsseveralpiecesthatrequire
assembly.Youwillneedtoobtainadultassistance
duringtheassemblyprocess.
Unpacking the Equipment
Whenyouopenthebox,carefullyunpackthepieces
andlaythemontheoornearthelocationwhereyou
plan to use them.
CAUTION: Be careful when you remove the
packaging material with a utility knife. Do not
scratch the paint.
Ifanyitemsaremissing,contactthedealerfromwhom
youpurchasedtheunit.Formoreinformation,referto
Obtaining Service.
Required Tools
Toolsthatyouneedtoobtainbeforeassemblingthe
unit include:
❏ Wirecutterorutilityknife
❏ ¾-inch open-end wrench
Installation Requirements
Follow these installation requirements when
assembling the unit:
• Review the Important Safety Guidelines for
Owners.
• Assemble the unit where it will be used.
Provideamplespacearoundtheunit.
• Install components in the sequence shown.
• Insert all fasteners in the same direction.
Foraestheticpurposes,insertallthefasteners
inthesamedirectionunlessspecied(intextor
illustrations) to do otherwise.
• Leave room for adjustments.Tightenthe
fastenerstokeeptheunitstable,butleaveroom
foradjustments.Donotfullytightenfastenersuntil
instructed to do so.
CW-608 Assembly Guide
page 7
½x5-inchCarriagebolt(G) 14
½x¾-inchButtonheadscrew(E) 8
½x4¾-inchButtonheadscrew(D) 8
Fastener Qty Fastener Qty
Hardware Kit
Preparations, continued
½x5¼-inchButtonheadscrew(A) 8
½-inchLocknut(C) 30
½-inch Washer (B) 50
½-inchSplitwasher(F) 12
Hat washer (H) 30
Plasticcap(J) 30
CW-608 Assembly Guide
page8
Fastener Qty
Hardware Kit (continued)
Bumper(M) 8
Preparations, continued
½ x 1¼-inch Buttonhead screw (K) 4
Spacer(L) 4
CW-608 Assembly Guide
page 9
2
Assembly
Instructions
Assembly Instructions
AssemblyoftheCW-608takesabout40minutesto
complete.Ifthisisthersttimeyouhaveassembled
thistypeofequipment,planonallowingmoretime.
Be careful to open boxes and assemble components in
the sequence presented in this manual.
Note:Withsomanyassembledparts,properalignment
andadjustmentiscritical.Whiletighteningthe
fasteners,besuretoleaveroomforadjustments. Do
not fully tighten fasteners until instructed to do so.
Open the Box
Usewirecutterstoopentheboxandremovethe
packing materials.
TheillustrationshowshowtheCW-608willlookwhen
youhavecompleteditsassembly.Thecalloutsidentify
specicpieces.
Cross Brace
Rear Upright
Rear Base
Front Upright
Weight Bar Plate
Safety Catch
Plate
Weight Plate
Holder
CW-608 Assembly Guide
page 10
Assemble the Unit
1. AttachtheRearBasetotheRearUprightswithtwo
longBackingPlatesusing
four 5¼-inch buttonhead screws (A)
eight ½-inch washers (B)
four ½-inch hat washers (H)
four½-inchlocknuts(C)
LooselytightenthefastenerssotheRearUprights
are stable.
2. AttachtheCrossBracetotheRearUprightswith
twoshortBackingPlatesusing
four 5¼-inch buttonhead screws (A)
eight ½-inch washers (B)
four ½-inch hat washers (H)
four½-inchlocknuts(C)
Wrench tighten both sets of fasteners using a
¾-inchopen-endwrenchandsnapaplasticcap(J)
overeachlocknut.
Note: You will need a ¾-inch open-end wrench to
tightenmostofthefastenersinthisassembly.
Assemble the Unit
4-5¼”buttonheadscrews
8-washers
4 - hat washers
4 - locknuts
4 - plastic caps
4-5¼”buttonheadscrews
8-washers
4 - hat washers
4 - locknuts
4 - plastic caps
Rear Upright
Rear Base
Cross Brace
CW-608 Assembly Guide
page 11
3. AttachtwoconnectorstotheRearUprightsusing
four4¾-inchbuttonheadscrews(D)
eight ½-inch washers (B)
four½-inchlocknuts(C)
Looselytightenthefasteners.
4. AttachthelowerFrontUprightstotheConnectors
using
four4¾-inchbuttonheadscrews(D)
eight ½-inch washers (B)
four½-inchlocknuts(C)
LooselytightenthefastenerssotheFrontUprights
are stable.
5. AttachtheupperFrontUprightstotheRear
Uprightsusing
eight¾-inchbuttonheadscrews(E)
eight ½-inch split washers (F)
Wrench tighten all three sets of fasteners.
Assemble the Unit, continued
8-¾”buttonheadscrews
8-splitwashers
4-4¾”buttonheadscrews
8-washers
4 - locknuts
Front Upright
Connector
4-4¾”buttonheadscrews
8-washers
4 - locknuts
CW-608 Assembly Guide
page 12
Important: Inthefollowingtwosteps,insertthe
bolts so that their heads face outward on both
sides.Iftheheadsoftheboltsfaceinward,their
threaded ends can protrude far enough to damage
thenishonbarbellweightplates.
6. Attachtheleft-handWeightBarPlatetotheoutside
oftheleft-handFrontUprightusing
ve5-inchcarriagebolts(G)
ve½-inchwashers(B)
ve½-inchhatwashers(H)
ve½-inchlocknuts(C)
WrenchtightenandsnapaPlasticCap(J)over
each locknut.
7. Repeat step 6 to attach the right-hand Weight Bar
Platetotheoutsideoftheright-handFrontUpright.
8. AttachaSafetyCatchPlatetotheoutsideofeach
FrontUprightusing
four5-inchcarriagebolts(G)
four ½-inch washers (B)
four ½-inch hat washers (H)
four½-inchlocknuts(C)
WrenchtightenandsnapaPlasticCap(J)over
each locknut.
4-5”carriagebolts
4 - washers
4 - hat washers
4 - locknuts
4 - plastic caps
Assemble the Unit, continued
10-5”carriagebolts
10 - washers
10 - hat washers
10 - locknuts
10 - plastic caps
Weight Bar
Plate
Safety Catch
Plate
CW-608 Assembly Guide
page 13
Assemble the Unit, continued
9. InsertthefourWeightPlateHoldersintotheRear
Uprights.TurntheWeightPlateHolderssothe
mounting holes align with the holes in the Rear
Uprights.
10. SecuretheWeightPlateHoldersusing
four 1¼-inch buttonhead screws (K)
four ½-inch split washers (F)
four ½-inch washers (B)
four spacers (L)
Wrench tighten.
Note: Foreaseofassembly,placeasplitwasher,
aatwasher,andaspacerontoeachscrewbefore
inserting the screw.
11. SlideaBumper(M)ontoeachendoftheWeight
PlateHolders,andpressrmlyagainsttheRear
Uprights.
Note: MakesurethesmallsideoftheBumper
facestheRearUprights.
ThiscompletestheassemblyoftheCW-608.
Clean the Unit
Tocleantheunit,moistenaclean,softclothinamild
solution of soap and water and wipe all the parts
thoroughly.
FrequentlyvacuumtheoorunderneaththeCW-608to
preventtheaccumulationofdustanddirt.
4-1¼”buttonheadscrews
4 - split washers
4 - washers
4 - spacers
Weight Plate
Holder
CW-608 Assembly Guide
page 14
Notes:
CW-608 Assembly Guide
page 15
Notes:
Precor,Icarian,andMoveBeyondareregisteredtrademarksofPrecorIncorporated.
Copyright2014PrecorIncorporated.
Specicationssubjecttochangewithoutnotice.
www.precor.com
NOTICE:
Precoriswidelyrecognizedforitsinnovative,awardwinningdesignsofexerciseequipment.PrecoraggressivelyseeksU.S.and
foreignpatentsforboththemechanicalconstructionandthevisualaspectsofitsproductdesign.Anypartycontemplatingtheuseof
Precor’sproductdesignsisherebyforewarnedthatPrecorconsiderstheunauthorizedappropriationofitsproprietaryrightstobea
veryseriousmatter.Precorwillvigorouslypursueallunauthorizedappropriationofitsproprietaryrights.
PrecorIncorporated
20031142ndAvenueNE
P.O.Box7202
Woodinville,WAUSA98072-4002
1-800-347-4404
CW-608 Specifications
Length:73inches(184cm)
Height: 71 inches (179 cm)
Width:68inches(173cm)
Shippingweight:315lb(143kg)
CW-608 Assembly Guide CW33683-107 rev G
17 December 2014
General Safety &
Maintenance Manual
Precor Icarian Line
Commercial Strength Equipment
General Safety and Maintenance Manual: Important Safety Guidelines for Owners 1
IMPORTANT SAFETY GUIDELINES
Important Safety Guidelines for Owners
Follow these guidelines to maintain proper working condition of the
equipment:
Important: Do not modify the equipment or any of its parts, or
permanently remove any part from the equipment. Do not use
accessory attachments that are not recommended by Precor, as
such attachments might cause injuries.
• Qualified technicians must perform all regular maintenance.
• Check that all fasteners are securely tightened. Cables should be
secured at both end connections and properly threaded. Weight
stacks should be secure and functioning properly. Handle
attachments should be properly connected.
• Make sure that trainers, facility personnel, and maintenance
technicians understand how to use the equipment, know
important safety guidelines, and can recognize potential
problems such as a worn cable, loose hardware, or cracked
weld.
• Strength training requires a significant focus by the facility and its
staff to maintain the quality of the fitness environment. If possible,
the facility should provide direct supervision of the fitness
equipment at all times by people knowledgeable about the safe
operation of the equipment and trained to recognize potential
problems.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners 2
IMPORTANT SAFETY GUIDELINES
• If any staff member witnesses unsafe use of the equipment, he or
she should address the user directly, demonstrate the proper
technique, and review the Important Safety Information for
Users. Precor recommends posting a copy of the Important
Safety Information for Users near the equipment in a prominent
location.
• Make sure the equipment is stable and placed on a solid, level
surface. The equipment is designed to be freestanding; however,
it can be bolted to the floor for extra stability. Precor highly
recommends that the equipment be bolted to the floor to reduce
the risk of toppling the equipment due to improper use. Since
floor construction varies, please consult a professional building
engineer for proper fastening.
• Locate the equipment at least 40 inches (1 meter) away from
walls or furniture on either side of the equipment, and 40 inches
(1 meter) away from objects behind the equipment. For
Functional Training equipment, make sure that the operating
space is large enough to allow the cables to be fully extended in
all possible directions.
• Check the equipment thoroughly based on the recommended
inspection schedules outlined in this manual, including daily,
weekly, monthly and annual checks. Ensure all bolt connections
are tight and that the threaded cables are properly and tightly
secured at both ends.
• Place an “out-of-order” sign on the equipment during
maintenance of the equipment or the surrounding area. Users
should never be allowed to operate the equipment until it has
been inspected and works properly. If a piece of equipment
needs service, keep it out of use until it is repaired.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners 3
IMPORTANT SAFETY GUIDELINES
• When working with the weight stacks, do not attempt to free any
jammed assemblies without assistance as this may cause injury.
With the help of another person, carefully return the weight stack
to the proper position with the top plate resting on the first
weight.
• Do not allow the equipment to be used if the top plate or weight
stack is pinned in a raised position. With the help of another
person, carefully return the machine to the proper position with
the top plate resting on the first weight. Inspect the cable to
ensure that it is seated in all of the pulleys.
• Whenever a weight can drop and hit a user, such as with an
Olympic bench, Precor highly recommends that a helper or
spotter be used to ensure a safe workout with the equipment.
• Do not place the equipment outdoors or on wet surfaces.
Safety Approval
Certain Precor commercial strength equipment is Class S/C
certified according to EN957 –1/2 standards. See an authorized
Precor dealer for a complete and current listing of certified
machines.
General Safety and Maintenance Manual: Important Safety Guidelines for Owners 4
Important Safety Information for Users
Before beginning any fitness program, you should obtain a complete
physical examination from your physician.
French equivalent of the preceding paragraph, for the Canadian
market: Il est conseillé de subir un examen médical complet avant
d’entreprendre tout programme d’exercise. Si vous avez des
étourdissements ou des faiblesses, arrêtez les exercices
immédiatement.
When using exercise equipment, you should always take basic
precautions, including the following:
• If you do not understand how to operate a piece of equipment, ask
someone from the facility such as a trainer to demonstrate how to
use it and explain any safety instructions.
• Do not allow children on or near the equipment. Do not leave
children unsupervised around the equipment.
• Use the equipment only for its intended purpose. Do not use
accessory attachments that are not recommended by the
manufacturer, as such attachments may cause injuries.
• Wear proper exercise clothing and shoes for your workout—no loose
clothing.
• Do not overexert yourself or work to exhaustion. Use reasonable
judgment when working with weights. Avoid using excessive
weight, which may cause injury.
• If you feel pain, faintness, dizziness, or abnormal symptoms, stop
exercising immediately and consult your physician.
• Keep head, limbs, fingers, and hair clear of all moving parts while the
equipment is in use. Keep hands clear of racking pegs.
• Never drop or insert objects into any opening in the equipment.
• Check that all fasteners are securely tightened. Cables should be
secured at both end connections and properly threaded. Weight
stacks should be secure and functioning properly. Handle
attachments should be properly connected. Pay particular attention
to the condition of cables and cable ends. If you notice a loose
cable end or any fraying of the cable or cable jacket, do not use the
product and contact someone in the facility immediately.
• Always check the equipment before using it. If you spot a potential
problem, contact someone in the facility immediately. Do not use the
equipment until the facility has verified that the equipment is working
properly. Do not attempt to fix broken or jammed equipment.
• Do not use the equipment outdoors.
• Do not drop or slam the weight stack while exercising.
• Be sure the selector pin is completely inserted. Use only the pin
provided by the manufacturer. If unsure, contact someone in the
facility.
• Never pin the weights in an elevated position. Do not use the
equipment if the top plate or weight stack is pinned in a raised
position. Notify facility’s personnel to repair the equipment and
ensure that it is working properly.
• Do not use the equipment if an “out of order” sign has been placed
on it.
• Read all posted instructions, including all safety instructions and
warnings.
General Safety and Maintenance Manual: Table of Contents 5
Table of Contents
Important Safety Guidelines for Owners ...........................1
Safety Approval ............................................................................... 3
Important Safety Information for Users ...................................... 4
Before You Begin .....................................................................7
Recommended Tools ..................................................................... 7
Obtaining Service ........................................................................... 8
Daily Inspection ........................................................................9
Clean Upholstery ............................................................................ 9
Inspect Pads for Wear ................................................................10
Clean and Inspect Frames .........................................................10
Inspect All Fasteners ...................................................................11
Inspect Cables and End Connections .....................................11
Check Warning Labels and Instruction Placards .................13
Weekly Inspection ................................................................. 15
Condition and Deep Clean Upholstery ...................................15
Clean and Lubricate Cable Rod Ends .....................................16
Clean and Lubricate Guide Rods .............................................16
Inspect Cables, Connections, and Tension ...........................17
Inspect Cable Handle Attachments .........................................18
Inspect Pulleys ..............................................................................18
Inspect Weight Stack and Selector Pin ..................................18
Inspect and Lubricate Bearings and Bushings .....................19
Check Seat Adjustment and Test Pop Pins ...........................20
General Safety and Maintenance Manual:: Table of Contents 6
Monthly Inspection ................................................................21
Inspect Frames and Movement Arms ......................................21
Lubricate Pop Pins .......................................................................22
Check and Lubricate Ratcheting Seat Lever .........................23
Inspect All Fasteners ...................................................................24
Annual Maintenance ..............................................................25
Weight Stack Annual Maintenance ..........................................25
Inspect and Lubricate Pop Pins ................................................26
Recommended Maintenance Checklist ............................27
General Safety and Maintenance Manual: Before You Begin 7
Before You Begin
Precor recommends implementing a thorough maintenance program
that incorporates regular safety inspections by qualified maintenance
technicians as outlined in this manual.
This manual explains how to maintain the Precor Icarian line of
commercial strength equipment. It provides information about items
that need to be inspected and maintained on a daily, weekly, monthly,
and annual basis. You should perform those tasks that are appropriate
for the equipment you are maintaining, and skip those tasks that do
not apply. To help you, a checklist is located at the back of this manual
that you can follow during your maintenance checks to ensure that
nothing appropriate is missed and that your inspection process is
documented.
This manual covers the general maintenance procedures that you can
perform in the fitness facility. However, if the equipment requires
service beyond the maintenance procedures covered in this manual,
refer to Obtaining Service.
Important: Always purchase replacement parts and hardware from
Precor. These parts are tested and manufactured specifically for the
Precor Icarian line of commercial strength equipment. If you use parts
not approved by the manufacturer, you could void the Precor Limited
Warranty. Use of parts not approved by Precor may cause injury.
Precor recommends that maintenance technicians thoroughly read
and understand the safety guidelines and maintenance procedures
covered in this manual.
Note: If the equipment requires assembly, a separate assembly guide
is provided. For information on how to use a piece of equipment, refer
to the instructional label found on the equipment.
Recommended Tools
We recommend that you put together a toolbox with the following
tools. This list covers the tools you may need when you inspect and
maintain the equipment.
• Complete combination box wrench set from ¹⁵⁄₁₆ to ¹₂-inch
• Complete socket set from ¹⁵⁄₁₆ to ¹₂-inch
• Hex nut driver: ¹₄-inch
• 12-inch adjustable wrench
• Complete hex key set from ³⁄₈ to ⁵⁄₆₄-inch
• Rubber mallet
• Straight shank punch: ¹₄-inch
General Safety and Maintenance Manual: Before You Begin 8
Obtaining Service
You should not attempt to service the strength equipment, except for
the maintenance tasks described in this manual. If any items are
missing, contact your dealer. If you need more information regrading
customer support numbers or a list of Precor authorized service
centers, visit the Precor website at www.precor.com.
If you have any questions regarding a piece of equipment, locate its
serial number and contact Precor Customer support. Precor uses the
serial number to establish the model and year of the product. You can
generally find the serial number underneath the seat support.
For future reference, write the serial numbers, model numbers, and
dates of purchase for your Precor strength training equipment in the
space provided. You may want to list all equipment information below
for easy reference.
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
Model #: _______ Serial #: _______________________
Date purchased: _________________________
General Safety and Maintenance Manual: Daily Inspection 9
Daily Inspection
You will need to perform the following tasks each day to maintain the
equipment and keep it operating smoothly:
• Clean any upholstery on the equipment.
• Inspect pads for wear.
• Clean and inspect equipment frames.
• Inspect cables and end connections for wear.
• Check warning and instructional labels for readability.
• Check that all fasteners are properly secured.
Clean Upholstery
To remove surface dirt and perspiration, clean upholstery daily with a
mild soap and water solution in a spray bottle. Spray upholstered
surfaces lightly and wipe dry with a clean cloth.
Important: To clean the upholstery, do not use cleaning products that
have any of these ingredients: solvents, alcohol, ammonia, or
petroleum. Use a mild detergent-based cleaner instead.
General Safety and Maintenance Manual: Daily Inspection 10
Inspect Pads for Wear
Inspect pads for cracks in the upholstery, broken and loose stitching,
loose staples, and loose mounting bolts. Replace pads as needed
(refer to Obtaining Service to purchase new pads.)
Important: Do not reupholster pads or use pads not approved by
Precor.
Clean and Inspect Frames
To remove grease and dirt, clean frames daily with a mild soap and
water solution in a spray bottle. Wipe the equipment down with a
damp cloth and dry completely. Be sure to wipe down both painted
parts and chrome or plated parts.
To restore and maintain luster of chrome parts, use a commercial
chrome cleaner.
As you clean, inspect the frames for cracks, rust, or other damage.
Make sure welds are solid and fasteners are properly secured.
General Safety and Maintenance Manual: Daily Inspection 11
Inspect All Fasteners
Fasteners can loosen with normal use. Inspect all nuts, bolts, screws
and other fasteners to make sure they are tight and installed correctly.
Be sure to check fasteners at bolted joints to make sure the
connections are secure. If a fastener is loose but in good condition,
retighten it. If you are concerned about the integrity of the fastener,
remove it, clean the threads and inspect it for any damage such as
cracks, bad threads, corrosion, or rust. Reinstall the fastener if it
appears to be in good condition. Otherwise, remove the equipment
from service until a new fastener can be installed properly. You can
order new fasteners from Customer Support. For additional
information refer to Obtaining Service.
Important: Fastener quality and specifications vary considerably.
Replace only with the Precor approved fastener specifically
engineered for the precise application. Failure to do so will void the
Precor Limited Warranty.
Inspect Cables and End Connections
CAUTION: Carefully inspect the cables, pulleys, fasteners, and
related hardware regularly. Replace any cable at the first sign of
wear using only Precor-supplied replacement parts. With regular
use, a cable can become worn and might fail. Sudden failure of
a worn cable can cause severe injury to a user. Refer to
Obtaining Service to purchase replacement parts.
Inspect the cables and end connections each day, and replace if
damaged. Check for kinks, frayed wires, or deterioration of the cable
coating. Look for signs of wear particularly at crimped ends of the
cable and near pulleys. (Refer to Figure 1.)
Important: Cables must be replaced immediately if they are
damaged to avoid possible injury to users.
General Safety and Maintenance Manual: Daily Inspection 12
Some obvious signs of cable damage are as follows:
1. Exposed inner wire, stretching or cuts in the coating, or broken
coating in the area that passes over a pulley
2. A zigzag or wavy pattern
3. Kinks, which may indicate internal damage
4. A necked-down cover
5. A ‘ballooned” cover
Figure 1: Signs of cable damage
In addition to inspecting the cables and end connections for damage,
check the following:
• Ensure that each cable is properly adjusted and tightened at the top
of the weight stack.
• Check cable pulleys, end connections, and end fittings. Make sure
all connections are tight, adjusting cable tension as necessary.
• Make sure that the cable bolt is threaded at lease seven turns into
the selector stem or a minimum of ¹₂-inch (13 mm). The distance
shown should be ³₄-inch (19 mm) or less. Tighten the locking jam
nut to 600 in-lb (68 N-m). Refer to Figure 2.
Figure 2: Proper cable bolt insertion
Exposed inner wire
Zig-zag/wavy
Kinked
Necked-down
Ballooned
Cable bolt must be inserted a
minimum of 7 threads into the
selector stem.
Locking jam nut
General Safety and Maintenance Manual: Daily Inspection 13
Check Warning Labels and Instruction
Placards
Inspect warning and instructional labels daily tom make sure that all
the information can be clearly read. If any portion is not visible or part
of the label is not adhered properly, replace that label immediately
(refer to Obtaining Service for purchase information).
Clean labels and placards as needed with a mild soap and water
solution in a spray bottle, and dry thoroughly with a soft cloth.
The following figure shows an example of a user instructional label.
Figure 3 shows a typical user instruction placard.
Figure 3: Sample user instruction placard
Improper use of this machine will result in injury.
Before using, consult a qualified instructor.
Inspect cables and connections and do not use
if any component is worn or damaged.
CAUTION
PULLDOWN 304
Select appropriate lifting weight.
Adjust thigh pad to rest securely
on top of legs.
Grip bar with hands evenly spaced.
Pull bar down to upper chest
with a slow, controlled movement,
pulling handles behind neck is
not recommended, as injuries
could result.
Slowly return to the start position.
General Safety and Maintenance Manual: Daily Inspection 14
Precor products come equipped with a number of standard warning
labels. The following figures show sample warning labels you may see
on the equipment depending on the model and product line:
Figure 4: This warning label may appear on weight stacks with a pulley
mounted at the top
Figure 5: This warning label may appear on or near weight stacks where
a cable bolt is threaded into the selector stem
Figure 6: A version of this warning label appears on the equipment frame
KEEP HANDS AND FEET CLEAR WHILE MACHINE IS IN USE
The weight stack cable bolt must be
inserted a minimum of seven full turns
into the selector stem, and the jam nut
tightened down firmly against the
selector stem top.
General Safety and Maintenance Manual: Weekly Inspection 15
Weekly Inspection
This section covers the tasks you should do each week to maintain the
equipment. Perform the following tasks as appropriate for the unit you
are maintaining:
• Condition and deep clean upholstery.
• Clean and lubricate cable rod ends.
• Clean and lubricate guide rods.
• Inspect cables, connections, and tension.
• Inspect cable handle attachments.
• Inspect pulleys.
• Inspect each weight stack and selector pin.
• Inspect and lubricate bearings and bushings.
• Check seat adjustment and test pop pins.
Condition and Deep Clean Upholstery
Condition and deep clean the upholstery weekly with a lanolin-based
hand cleaner or upholstery cleaner.
Important: To clean the upholstery, do not use cleaning products that
have any of these ingredients: solvents, alcohol, ammonia, or
petroleum. Use a mild detergent-based cleaner instead.
General Safety and Maintenance Manual: Weekly Inspection 16
Clean and Lubricate Cable Rod Ends
Inspect the exposed areas of the guide rods for cleanliness. Using a
dry cloth, wipe any buildup of dirt of grease from the rods. Check
cable rod ends to ensure the shoulder bolt is secure. If cable rod ends
are noisy, you can lubricate them with a silicone spray lubricant, such
as Super Lube
®
. Spray the lubricant onto the joint where the spherical
portion is enclosed in the outer housing (refer to Figure 7). Wipe off
any excess lubricant with a cloth.
Figure 7: Lubricate cable rod ends with silicone spray lubricant
Important: Do not use petroleum-based lubricants such as WD-40
®
,
Vaseline
®
, or motor oil.
Clean and Lubricate Guide Rods
Inspect the exposed areas of the guide rods for cleanliness. Using a
dry cloth, wipe any buildup of dirt or grease from the rods.
Lubricate the exposed areas of the guide rods by applying a light coat
of a silicone spray lubricant. Spray the silicone lubricant on a cloth and
then wipe the guide rods with the cloth. Be careful with any lubricant
spray; it can stain carpet and clothing.
CAUTION: Do not attempt to lubricate the guide rods when the
equipment is in use. Attempting to lubricate between the weight
plates without completely disassembling the stack will result in
serious injury.
Important: Do not use petroleum-based lubricants or motor oil.
These lubricants tend to cause a rapid buildup of dirt and hair on the
weight plates, which can cause the plates to stick together.
Note: The CW802 Smith Machine has counter-balance guide rods
behind the maintenance shields, which should be cleaned and
lubricated weekly.
Lubricate here
General Safety and Maintenance Manual: Weekly Inspection 17
Inspect Cables, Connections, and
Tension
Each week, give the cables and connections a thorough inspection
and check cable tensions. The following lists the specific things you
need to inspect:
• Check the cable termination at the weight stack. Make sure that the
cable bolt is threaded at least a minimum of seven turns into the
selector stem or a minimum of ¹₂-inch (13 mm), so that there is no
more than ³₄-inches (19 mm) between the top of the jam nut and
base of the bolt head. Check and adjust accordingly. Also make
sure that the locking jam nut is tight against the selector stem.
• Check the cable, especially near all pulleys, wheels, and cams.
• Check the cable as it terminates at the cam, which is stationary on
most equipment. Inspect the bolt passing through the cam end
fitting to be sure the two jam nuts are tightened against each other.
Also, check the entire cable routing to verify that there is no
interference with any structure.
• Inspect the ball end of the cable where the cable connection rests
in the clevis housing.
• Ensure that each cable is properly adjusted and tightened at the top
of the weight stack.
• Check cable pulleys, end connections, and end fittings. Make sure
all connections are tight, adjusting cable tension as necessary.
General Safety and Maintenance Manual: Weekly Inspection 18
Inspect Cable Handle Attachments
Check the cable-to-handle attachment area very closely. Refer to
Figure 8. Look for frayed cable ends, broken thimbles, bent cables,
worn spring clips, worn handles, and any other unusual wear.
Figure 8: Check connections to handles carefully
Also, check the spring clip gate and make sure it closes properly and
engages securely. Refer to Figure 9. Check the spring clip, links, and
cable to ensure integrity; replace any spring clip link that does not
function properly or shows wear.
Figure 9: Check spring clip gate to ensure proper closure
Inspect Pulleys
Precor uses precision ball bearing idler pulleys to smoothly guide
the cable.
Inspect each pulley for damage, including hairline cracks, chips, or
missing sections. Worn surfaces in the pulleys can cause severe
damage to the cables and must be replaced at the first sign of wear or
damage.
Be certain that the wheels turn freely as the equipment is used.
Inspect each pulley for excessive side-to-side play, which indicates
worn bearings or loose mounting bolts. If excessive play is discovered,
remove the pulley to inspect the bearings, and replace the entire
pulley if necessary.
Inspect Weight Stack and Selector Pin
Weight stacks are made of precision machine plates that are
designed as a single mechanism to stack precisely. Use only Precor-
supplied add-on weights and weight selector pins.
On a weekly basis, inspect weight stacks and selector pins. Wipe
each plate with a damp cloth as needed. Inspect all plates for sharp
burs or damage. Wipe dirt and dust off the guide rods.
Make sure the equipment uses only the original Precor selector pin. In
addition, make sure the selector pin can be fully inserted and retained
in each weight plate.
Check these
areas closely.
Spring clip gate
properly closed
Spring clip gate not
properly closed
General Safety and Maintenance Manual: Weekly Inspection 19
Inspect and Lubricate Bearings and
Bushings
Precor uses high quality bearings designed for strength applications
and long service life. Each week, do the following to maintain the
bearings and bushings on the equipment:
• Bronze bushings: Precor recommends using a small amount of
silicone spray lubricant to lubricate the bushings. Spray directly
onto the guide rod and then rotate the guide rod through its
complete range of motion several times. Inspect bushings for
excessive wear and damage. Be careful when using the spray
lubricant; it can stain carpet and clothing. Wipe off any excess
lubricant with a cloth.
• Nylon bushings: Lubricate the nylon bushings on the guide rods by
applying a light coat of silicone spray lubricant. Spray the silicone
lubricant on a clot, then wipe the cloth along the full length of the
guide rod.
• Sealed Bearing Pivot Points: These locations are protected from
the outside environment and require no lubrication. While cleaning
the equipment, wipe down the guide rods and external bearing
surfaces with a cloth to prevent the build up of dust and
perspiration.
• Linear Bearings: Case hardened guide rods are used in areas that
use linear bearings (refer to Figure 10). Inspect each end of the rod
to ensure they are fastened correctly and all bolts are tight.
Wipe down rods using a light application of a silicon spray lubricant
to remove dust, hair, and dirt. Polish the guide rod using fine grade
steel wool if surface rust or oxidation is present.
Important: Do not use petroleum-based lubricants or motor oil.
These lubricants tend to cause a rapid buildup of dirt and hair on
the weight plates, which can cause the plates to stick together.
If you lubricate the rods regularly, then the bearings will function as
designed. Otherwise, the rods may corrode, which can cause the
bearing to become clogged and jammed, leading to the bearing
actually gouging the rod. Be sure to remove surface rust and
oxidation from the hardened rails immediately.
Figure 10: Shows a typical location of a linear bearing in its housing
General Safety and Maintenance Manual: Weekly Inspection 20
Check Seat Adjustment and
Test Pop Pins
Precor strength equipment has two types of adjustments:
• 2x4-inch or 2x2-inch telescoping sleeve adjustment for most seat
assemblies
• ¹₂-inch slotted plate adjustments used on most free-weight bench
adjustments
Inspect all adjustments for proper fit and function. Inspect plastic
sliders for excessive wear or damage.
Adjustments use either a high-tensile pop pin plunger assembly or a
ratcheting lever assembly. Inspect and tighten all pop pin caps.
General Safety and Maintenance Manual: Monthly Inspection 21
Monthly Inspection
This section covers the tasks you should perform each month to
maintain the equipment. Perform the following tasks as appropriate for
the unit you are maintaining:
• Inspect frames and movement arms.
• Lubricate pop pins.
• Check and lubricate ratcheting seat lever
• Inspect all fasteners.
Inspect Frames and Movement Arms
Inspect frames and movement arms monthly for proper function and
integrity. Check for cracks, chipped paint, or rust. Touch up dings and
chips in the paint as needed. Replace any component at first signs of
wear.
Note: You can order touch-up paint from Precor by calling Customer
Support. Refer to Obtaining Service.
Inspect frames for cracks particularly at the joints. If any cracks are
found, immediately take the equipment out of service, and repair it
using a qualified maintenance technician. Refer to Important Safety
Guidelines for Owners and Obtaining Service).
General Safety and Maintenance Manual: Monthly Inspection 22
To remove surface rust from the frame, rub lightly with a fine wet/dry
sand paper or fine steel wool. Finish with Precor’s touch-up paint if
needed. Maintain paint luster with an application of a mild automotive
wax product.
To maintain the powder coated and chrome parts, use a mild
detergent-based cleaner for light dirt and grime removal. For removing
heavier dirt and grease and for polishing, use a good automotive
polish. For scuffs and marks that are not removed by the above
methods, use a fine-grit cleanser. Do not use solvents, lacquer thinner,
acetone, or finger nail polish remover. For high wear areas, ABS
shields have been provided. Replacement shields are available from
Precor Customer Support. For additional information refer to
Obtaining Service.
Lubricate Pop Pins
Pull out the pop pin as far as it goes and apply a small amount of
silicone spray lubricant. Wipe off any excess lubricant with a cloth.
(Refer to Figure 11.)
CAUTION: Pulling out the pop pin may cause the unit to adjust
position suddenly. To avoid injury, keep your hands and head
away from moving parts.
Test the pop pin for proper function and engagement in each
adjustment hole.
Figure 11: Lubricate the pop pin by pulling it out
General Safety and Maintenance Manual: Monthly Inspection 23
Check and Lubricate Ratcheting
Seat Lever
Precor designed the ratcheting seat so users can easily move the seat
to a comfortable position. After lowering the seat by pressing on the
lever to disengage, a user can sit on the seat and pull it up to the
desired position. As the seat moves, the ratcheting lever snaps in and
out of each hole, making an audible noise.
The ratcheting seat requires little maintenance. However, because
seat safety is important to the safety of a workout, you should check
the ratcheting seat lever each month to see if it sticks when used. You
also want to ensure that the pin fully engages in each adjustment hole.
To test if the seat lever needs lubrication, slightly elevate the seat while
pressing and releasing the lever. The lever should snap back out
easily. If the lever sticks, lubricate the pivot pin in the lever with silicone
spray lubricant. Wipe off any excess lubricant with a cloth. (Refer to
Figure 12.)
Figure 12: If needed, lubricate the pivot pin on the ratcheting seat lever
If desired, you can detach the seat by removing the retaining pin,
allowing you to remove the chrome for cleaning. Removing the seat
also allows clear access to the ratcheting lever to test its pivoting
action.
Lubricate on each side with a
silicone spray lubricant.
General Safety and Maintenance Manual: Monthly Inspection 24
Inspect All Fasteners
Precor products are assembled with Grade 5 fasteners or better. With
normal use, these fasteners can loosen. Inspect all nuts, bolts, hex key
bolts, screws, and other fasteners to ensure they are tight and
installed correctly.
Be sure to check fasteners at bolted joints to ensure connection is
secure. If the fastener is loose, but in good condition, retighten it. If
you are concerned about the integrity of the fastener, remove it, clean
the threads, and inspect it for any damage such as cracks, bad
threads, corrosion, or rust. Reinstall the fastener if it appears to be in
good condition. Otherwise, remove the equipment from service until a
new fastener can be installed properly. You can order new fasteners
from Customer Support. Refer to Obtaining Service.
General Safety and Maintenance Manual: Annual Maintenance 25
Annual Maintenance
Perform these tasks on an annual basis, as appropriate for your
equipment:
Weight Stack Annual Maintenance
Once a year, Precor recommends disassembling the weight stack to
clean and inspect it thoroughly.
• Carefully remove the cable and guide rods from the weight stack.
Completely disassemble the weight stack in a well-ventilated area,
away from the exercise floor.
• Inspect weight plates and clean them thoroughly. Cracked or
broken plates should be replaced immediately (refer to Obtaining
Service to purchase replacements). Clean each plate individually
and inspect guide bushings.
• Inspect the bushings of the top weight plate and each individual
weight plate and replace a plate if it is excessively worn or broken.
• Clean the selector stem and inspect it for wear and damage.
• Reassemble the weight stack.
• Wipe down the weight stack enclosures (shrouds) with a damp
cloth as needed. Inspect all fasteners to ensure the shroud is
securely mounted.
Important: Precor recommends that you replace worn and damaged
cables during routine maintenance. It is recommended that all cables
be replaced annually.
General Safety and Maintenance Manual: Annual Maintenance 26
Inspect and Lubricate Pop Pins
Remove the pop pin assembly by loosening the hex head cap.
CAUTION: Pulling out the pop pin may cause the unit to adjust
position suddenly. To avoid injury, keep your hands and head
away from moving parts.
Inspect the plunger and spring for excessive wear and damage, and
replace as required.
Apply a small amount of silicone spray lubricant to the spring and
plunger, and then reinstall the entire assembly. Tighten hex head cap.
Wipe off any excess lubricant with a cloth.
Figure 13: Inspect pop pins (pop pin shown in exploded view for clarity)
Pop pin plunger
assembly shown with
telescoping sleeve type
adjustment
Hex head cap
General Safety and Maintenance Manual: Recommended Maintenance Checklist 27
Recommended Maintenance Checklist
Initial box when completed: write N/A if not applicable to the equipment.
Daily Check 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031
Clean upholstery
Clean & inspect frames
Inspect pads for wear
Inspect cables & end connections
Check labels and placards
Weekly Check
7 14 21 28
Condition & clean upholstery
Clean & lubricate cable rod ends
Clean & lubricate guide rods
Inspect cables/connections/tension
Inspect cable handle attachments
Inspect pulleys
Inspect each weight stack & Pin
Inspect & lube bearings & bushings
Check seat adjust. and pop pins or
ratcheting lever
Monthly Check 28
Inspect frames & movement arms
Inspect & lubricate pop pins or
ratcheting lever
Check & lubricate ratcheting seat
Inspect all fasteners
Annual Check
Weight stack maintenance Date: Initials:
Inspect & lubricate pop pins or
ratcheting lever
Date Initials:
Maintenance Tips
Upholstery Wipe clean using a mild soap and water solution or other appropriate cleaner for vinyl.
Cable Replace any cable that shows signs of wear or damage.
Frames Wipe clean using a mild soap and water solution.
Guide rods Lubricate guide rods with silicone spray lubricant.
Important: It is recommended that cables be changed annually. Only factory provided selector key, lanyard, handle attachment, and handle should be used on selectorized weight
stacks. Use of any parts other than those provided by the manufacturer will invalidate the product warranty and may cause injury to users.
Please retain for your records.
Maintenance Record the Month of ______________________
Brand Name ______________________
Model Name & Number ______________________
Serial Number ______________________
In Service Date ______________________
General Safety and Maintenance Manual: Recommended Maintenance Checklist 28
Notes:
General Safety & Maintenance Manual CW39162-111 rev A, en
31 October 2014
Precor, Icarian, Jade, and Move Beyond are registered trademarks of Precor Incorporated.
Super Lube is a registered trademark of Synco Chemical Corporation.
WD-40 is a registered trademark of CD-40 Company.
Vaseline is a registered trademark of Unilever.
Copyright 2014 Precor Incorporated.
Specifications subject to change without notice.
www.precor.com
NOTICE:
Precor is widely recognized for its innovative, award winning designs of exercise equipment. Precor
aggressively seeks U.S. and foreign patents for both the mechanical construction and the visual aspects of its
product design. Any party contemplating the use of Precor product designs is hereby forewarned that Precor
considers the unauthorized appropriation of its proprietary rights to be a very serious matter. Precor will
vigorously pursue all unauthorized appropriation of its proprietary rights.
Precor Incorporated
20031 142nd Ave NE
P.O . B ox 7202
Woodinville, WA USA 98072-4002
