CYBEX PP-ACO Assembly Manual
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CYBEX PP-ACO Assembly Manual

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Assembly Manual
PP-ACO, PP-ACOFS, PP-ADC, PP-AP, PP-AP41, PP-AXO, PP-BLNKSHRD, PP-BM, PP-BX,
PP-CORE, PP-DIP, PP-DPH, PP-DPL, PP-FCO, PP-FXO, PP-HAR, PP-HL, PP-LP, PP-LPD, PP-PP,
PP-RP, PP-RPL, PP-RW, PP-RWD, PP-SB, PP-SC, PP-STP, PP-SX, PP-TP
Part Number
1006701-0001 AA

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Summary of Contents for CYBEX PP-ACO

  • Page 1 PWR Play Assembly Manual PP-ACO, PP-ACOFS, PP-ADC, PP-AP, PP-AP41, PP-AXO, PP-BLNKSHRD, PP-BM, PP-BX, PP-CORE, PP-DIP, PP-DPH, PP-DPL, PP-FCO, PP-FXO, PP-HAR, PP-HL, PP-LP, PP-LPD, PP-PP, PP-RP, PP-RPL, PP-RW, PP-RWD, PP-SB, PP-SC, PP-STP, PP-SX, PP-TP Part Number 1006701-0001 AA...

  • Page 3: Table Of Contents

    Cybex logo are registered trademarks of Cybex International, Inc. DISCLAIMER: Cybex International, Inc. makes no representations or warranties regarding the contents of this manual. We reserve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes.

  • Page 4: Safety Information

    Inspection • DO NOT use or permit use of any equipment that is damaged and/or has worn or broken parts. For all CYBEX INTERNATIONAL INC. equipment use only replacement parts supplied by CYBEX INTERNATIONAL INC..

  • Page 5: Operating Warnings

    CYBEX INTERNATIONAL INC. will provide service and maintenance training at our corporate facility upon request or in the field if proper arrangements are made. • Before any use, examine all accessories approved for use with the CYBEX INTERNATIONAL INC. equipment for damage or wear.

  • Page 6: Product Labels

    Product Labels General Warning Label Body Weight Strap Training Label Serial Number Label Weight At Handle Label Carriage Label Pinch Hazard Label Power Pivot Label Description Location General Warning Label Tower Frame Body Weight Strap Training Label Tower Frame Carriage Label Carriage Serial Number Label Tower Frame and Top or Lower Mount of Stations...

  • Page 7: Customer Service

    Provide the model and serial number of your Cybex equipment. At Cybex’s discretion, the technician may request that you return the problem part(s) to Cybex for evaluation and repair or replacement. The technician will assign you a RMA number and will send you an ARS label. The ARS label and the RMA numbers must be clearly displayed on the outside of the package that contains the item(s) to be returned.

  • Page 8: Damaged Parts

    Damaged Parts Materials damaged in shipment should not be returned for credit. Shipping damages are the responsibility of the carrier (UPS, Federal Express, trucking companies, etc.) Apparent Damage Upon receipt of your shipment, check all items carefully. Any damage seen with a visual check must be noted on the freight bill and signed by the carrier’s agent.

  • Page 9: Assembly

    Assembly Install Weight Stacks Tools Required: • 5 mm Allen wrench • Retaining ring pliers • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5 HXS, 50 mm Guide rod retainer Retaining ring Guide rod Description Guide rod retainer...
  • Page 10 Weight Stack Table Product Weight Stack Weight Plates 10 lb./4.5 kg. plate (x12) Attached Cable Crossover (PP-ACO) 2 x 190 lb./95 kg. stack 15 lb./6.8 kg. plate (x16) 10 lb./4.5 kg. plate (x12) Free Standing Cable Crossover (PP-ACOFS) 2 x 190 lb./95 kg. stack 15 lb./6.8 kg.
  • Page 11 Product Weight Stack Weight Plates Assist Dip Chin (PP-ADC) 295 lb./147.5 kg. stack 20 lb./9 kg. plate (x19) 10 lb./4.5 kg. plate (x6) Adjustable Cable Column (PP-AP) 190 lb./91 kg. stack 15 lb./6.8 kg. plate (x8) Adjustable Pulley 4:1 (PP-AP41) 390 lb./195 kg.

  • Page 12: Install Top Mount

    Install Top Mount The following procedure shows how to install the top mounts to the CORE for the following products: PP-AP, PP-AP41, PP-AXO, PP-ACOFS, PP-ACO, PP-ADC, PP-FCO, PP-FXO, PP-HL, PP-LP, PP-LPD, PP-RP, PP-RPL, PP-RWD, PP-RW, and PP-TP. Tools Required: • 7 mm Allen wrench •...

  • Page 13: Install Top Mount

    Description Bottom cap cover Install Top Mount The following procedure shows how to install the top mounts to the CORE for the following products: PP-DPH and PP-DPL. Tools Required: • 5 mm Allen wrench • 7 mm Allen wrench • 17 mm Open end wrench •...
  • Page 14 Description Screw, M10 x 1.5 HXS, 50 mm Guide rod retainer Retaining ring Guide rod Description Guide rod retainer Guide rod Description Pulley weldment Guide rod Page 14 of 54...
  • Page 15 Description Guide rod retainer Guide rod Description Screw, M10 x 1.5 HXS, 50 mm Guide rod retainer Retaining ring Guide rod Description Screw, M10 x 1.5, 65 mm Washer Nut, hex nylock Pulley weldment Top mount Page 15 of 54...

  • Page 16: Install Lower Mount

    Bottom cap cover Install Lower Mount The following procedure shows how to install the lower mounts to the CORE for the following products: PP-AP, PP-AP41, PP-AXO, PP-ACOFS, and PP-ACO. Tools Required: • 7 mm Allen wrench (x2) • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS.
  • Page 17 Description Adjustment tube Nut, M10 x 1.5 socket head Washer Screw, M10 x 1.5, 90 mm Screw, M10 x 1.5, 45 mm Description Adjustment tube Carriage Description Nut, M10 x 1.5 socket head Washer Screw, M10 x 1.5, 90 mm Screw, M10 x 1.5, 45 mm Page 17 of 54...

  • Page 18: Install Lower Mount

    Description Screw, M10 x 1.5, 130 mm Screw, M10 x 1.5, 60 mm Washer Nut, M10 x 1.5 socket head Adjustment tube bracket Install Lower Mount The following procedure shows how to install the lower mounts to the CORE for the following products: PP-HL, PP-FCO, PP-FXO.

  • Page 19: Install Lower Mount

    Install Lower Mount The following procedure shows how to install the lower mounts to the CORE for the following products: PP-DPH, PP-DPL, PP-RWD, PP-RPL, PP-RW, and PP-SB. Tools Required: • 7 mm Allen wrench (x2) • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5, 130 mm Washer...

  • Page 20: Install Lower Mount

    Install Lower Mount The following procedure shows how to install the lower mounts to the CORE for the following products: PP-ADC. Tools Required: • Retaining ring pliers • 5 mm Allen wrench • 7 mm Allen wrench (x2) • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS.
  • Page 21 Description Guide rod Weight stack cushion Description Screw, M10 x 1.5, 130 mm Washer Nut, M10 x 1.5 socket head Description Short guide rod Weight stack cushion Page 21 of 54...
  • Page 22 Description Short guide rod Weight Stack Weight stack Table Description Guide rod retainer Short guide rod Description Set screw, M10 x 1.5 HXS, 50mm Guide rod retainer Retaining ring Short guide rod Page 22 of 54...

  • Page 23: Install Crossover

    Install Crossover The following procedure shows how to install the crossover to the top mount for the following products: PP-ACO, PP-ACOFS, PP-AXO, PP-BM, PP-FCO, PP-FXO. Tools Required: • Flat head screwdriver • 7 mm Allen wrench (x2) • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS.

  • Page 24: Install Handle Accessory Rack

    Install Handle Accessory Rack The following procedure shows how to install the Handle Accessory Rack (HAR) to the CORE. Tools Required: • 7 mm Allen wrench (x2) • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5, 130 mm Washer...

  • Page 25: Install Storage Connector

    Install Storage Connector The following procedure shows how to install the Storage Connector (SX) to the CORE. Tools Required: • 7 mm Allen wrench (x2) • 17 mm Open end wrench • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5, 65 mm Washer...

  • Page 26: Install Storage Station

    Install Storage Station The following procedure shows how to install the Storage Station (SC) to the CORE. Tools Required: • 7 mm Allen wrench (x2) • 17 mm Open end wrench • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5, 25 mm Washer...
  • Page 27 Description Screw, M10 x 1.5, 130 mm Washer Spacer Nut, M10 x 1.5 socket head Storage station Page 27 of 54...

  • Page 28: Install Blank Shroud

    Install Blank Shroud The following procedure shows how to install the BLNKSHRD to the CORE. Tools Required: • 7 mm Allen wrench • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5, 55 mm Washer Threaded insert Bracket...

  • Page 29: Install Front Shroud

    Install Front Shroud The following procedure shows how to install the optional front shrouds to the CORE. Tools Required: • 5 mm Allen wrench • 7 mm Allen wrench • Retaining ring pliers • Torque wrench Note: All screws must be torqued to 25-30 FT-LBS. (27.1-33.9Nm). Description Screw, M10 x 1.5 HXS, 50 mm Guide rod retainer...

  • Page 30: Weight Stack Cushion

    Description Bracket, bottom Guide rod Weight stack cushion Description Guide rod retainer Guide rod Description Set screw, M10 x 1.5 HXS, 50 mm Guide rod retainer Retaining ring Guide rod Page 30 of 54...

  • Page 31: Screw, M10 X 1.5, 130 Mm

    Description Bracket, top left Bracket, top right Description Screw, M10 x 1.5, 20 mm Washer Shroud, left Threaded insert Bracket, top left Description Screw, M10 x 1.5, 20 mm Washer Shroud, left Threaded insert Bracket, bottom 9. Repeat steps 7 and 8 for right shroud. Page 31 of 54...

  • Page 32: Install Placard

    Install Placard The following procedure shows how to install placards to the CORE. Description Placard 2. Install placard on right upright of CORE. Description Placard Core, right upright Page 32 of 54...

  • Page 33: Carriage Adjustment Guide

    Carriage Adjustment Guide Tools Required: • 7 mm Allen wrench • 17 mm Open end wrench 1. While tightening the nut and bolt, apply downward pressure to each side of the rear roller so it travels down the slotted bolt holes, moving the roller closer to the adjustment tube. Description Rear roller Adjustment tube...

  • Page 34: Cable Routing

    Cable Routing Adjustable Cable Column (PP-AP), Adjustable Pulley 4:1 (PP-AP41), Attached Cable Crossover (PP-ACO), Embedded Cable Crossover (PP-AXO) Page 34 of 54...
  • Page 35 Free Standing Cable Crossover (PP-ACOFS) Page 35 of 54...
  • Page 36 Dip/Chin Assist (PP-ADC) Page 36 of 54...
  • Page 37 Dual Lat Pull (PP-LPD) Page 37 of 54...
  • Page 38 Dual Pulley High (PP-DPH) Page 38 of 54...
  • Page 39 Dual Pulley Low (PP-DPL) Page 39 of 54...
  • Page 40 Dual Row (PP-RWD) Page 40 of 54...
  • Page 41 High Low (PP-HL), Attached High Low Crossover (PP-FCO), Embedded High Low Crossover (PP-FXO) Page 41 of 54...
  • Page 42 Lat Pull (PP-LP) Page 42 of 54...
  • Page 43 Row (PP-RW) Page 43 of 54...
  • Page 44 Triceps Pushdown (PP-TP) Page 44 of 54...

  • Page 45: Cable Handling Guide

    Use of non certified “techs” note: Service warranties may be void if a non-Cybex International, Inc.-certified technician performs service work. Replacement of any strength cables should be performed by a Cybex International, Inc.

  • Page 46: Cabling Procedure

    Cabling Procedure Direct Link 1. Thread the cable into the head plate assembly at least to the jam nut. 2. Cycle the machine to ensure that it is in proper working order. 3. Check the cable to ensure there is proper tension. 4.

  • Page 47: Tensioning Cable

    9. Torque the jam nuts to 20-25 FT-LBS. (27.2 - 34.0 Nm). Tensioning Cable Cable should have enough tension so it stays seated into the pulley but not so tight that it pulls the head plate off the weight plate below it. 1.
  • Page 48 FRAYED/EXPOSED WIRE ROPE: Any exposed wire rope protruding through the casing or at either end. FLATTENED: Section of cable is compressed and will not retain its shape (outside diameter). PERMANENTLY BENT: Cable has ‘kink’ and prohibits cable from laying straight. Wire rope may be unraveling beneath casing and is compromised warranting replacement.

  • Page 49: Bolt To Floor Guidelines

    Bolt to Floor Guidelines Introduction Cybex designs its products to be stable when used as designed. Because strength training is dynamic, we cannot predict how users will ultimately use the products in all circumstances. Therefore, Cybex recommends that strength training equipment be secured to a solid, level surface to stabilize and eliminate rocking or tipping over. For some equipment, securing the equipment to the floor is REQUIRED.

  • Page 50: Delivery And Installation Tips

    This will help avoid the carpet threads from being wrapped around and pulled by the drill bit. Competitor Product • The bolt down guidelines and procedures for Cybex products were determined by the company’s Engineering and Installation Development groups. These guidelines include which anchors to use and positioning of the anchors are required for Cybex product.

  • Page 51: Pullout Force

    • HUS-H 8mm: 75mm (2-3/32”) Pullout Force Cybex specifies Hilti™ static and dynamic anchors. According to the anchor manufacturer, the recommended design pullout force (in tension) for the specified anchors, when properly installed in cracked concrete, is provided in the side table. This table should be used for reference only; for additional and up-to-date information on the anchor capabilities or the design pullout force in other substrates, please consult Hilti directly at https://www.us.hilti.com.

  • Page 52: Static Anchor Procedure

    Static Anchor Procedure If it is possible that the length of your bolt will not provide the minimum requirement of 2.5” (63.5mm) of engagement, a longer anchor should be used. 1. Place unit into position to be mounted and cycle unit to set stance. 2.

  • Page 53: Foot Dimensions

    4. Insert fastener and tighten to 18 Foot-Pounds (24Nm) for 1/4” (6mm) anchor or 40 Foot-Pounds (54Nm) for 3/8” (8mm) anchor. Note: If the legs/frame do not contact the mounting surface DO NOT pull down with the fastener or anchor. Loosen frame hardware and re-tighten to allow machine to align. Foot Dimensions Use below images to determine foot height thickness per strength family.
  • Page 54 Columbia Center III - 9525 West Bryn Mawr Ave, Rosemont, IL 60018 • 800-351-3737 • 847-288-3700 • FAX 800-216-8893 www.cybexintl.com...

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