Batca Fusion 3 User manual

www.batcafitness.com Fusion 3 Owner’s Manual

FEB 2016

Revision 5

Serial Number Here

Date of Purchase

Owner’s Manual

1207 New Hope Road, Raleigh, NC - 919.255.1233 - www.batcafitness.com

P E R S O N A L G Y M

Batca Fitness Systems 2 Fusion 3 Owner's Manual

__________ Page

Instructions 2

Parts Listing 3-5

Hardware Comparison 6-9

Cable Comparison 10

Main Frame Assembly 11-19

Cable Routing 20-25

Upholstery 26-27

Leg Press Option 28-33

Congratulations on the purchase of your new Fusion 3. This gym will provide you with a

lifetime of enjoyment to meet your strength training needs. Batca Fitness Systems strives to

build the best quality multi-station gyms and to package these gyms in such a way to avoid any

damage during shipping.

In order to get started with your assembly you should first familiarize yourself with

this manual. It is recommended that you read through each step thoroughly before you begin.

Begin by opening your boxes and separating all of your parts. Verify that all parts are

accounted for and have no damage. When all parts are accounted for, you may begin your

assembly. Some items may have been pre-assembled for your convenience. Please note that

hardware quantities shown reflect total quantities for your gym and may not reflect actual

quantities in each bag. Assemble your gym on a solid level surface. This will ensure the best

possible performance, function, and safety for the gym and your workout.

Assemble your gym according to the step by step instructions found in this manual.

Failure to do so will void your warranty and may result in personal injury. After assembly, you

should check each station to ensure correct operation. If a problem arises, recheck your

assembly with these instructions to verify correct assembly. If you are unable to correct a

problem or have questions with your assembly please contact your authorized Batca dealer.

Batca Fitness Systems has built this gym to give you a safe, effective and

enjoyable workout. However, there is a risk assumed by individuals who use this

type of equipment. It is very important that all warnings and instructions are

read and followed before beginning any exercise program.

It is also very important to read and follow the preventative maintenance

schedule described in this manual. If any of the warning labels or stickers are

worn, faded, torn, scratched or missing they should be replaced immediately.

WARNING: There is a risk assumed by individuals who use this type of equipment. To

minimize risk always follow these rules.

1) It is essential that you consult with your physician before beginning any

exercise program.

2) Inspect equipment before each use for loose, worn, or frayed parts (including

cables, nuts and bolts). Replace parts at first signs of wear (use only genuine

BATCA replacement parts). Use of equipment that is damaged, worn, frayed or

not completely assembled on a solid, level surface may result in injury.

3) Make sure all adjustment pins are fully engaged before using equipment.

4) Keep all parts of the body and clothing outside the path of any moving parts of

the gym. Be alert to the possibility of injury. Do not be careless.

5) Minors and children should not be allowed to play on or around this gym.

6) If you have any questions on proper use or maintenance of this gym, do not

hesitate to call your local BATCA FITNESS SYSTEMS distributor or BATCA

FITNESS SYSTEMS at (919) 255-1233. www.batcafitness.com

__________ Page

Leg Press Cable Routing 32

Leg Press Attachment 34

Weight Stack Decals and Serial Number 35

Cable Tension and Adjustments 36-37

Final Assembly and Troubleshooting 38

Maintenance 39

Warranty 40

Floor plan Layout 41-42

Table of Contents

Instructions

Warning

www.batcafitness.com 3 Fusion 3 Owner’s Manual

Frame Components

Accessories

Upholstery

ITEM NO. PART NO. DESCRIPTION QTY

156 BFC-10103 Strap Handle 4

200 BFM-10771 Press Arm Lock (Optional) 1

ITEM NO. PART NO. DESCRIPTION QTY

31 BFU-10117 Large Bottom Pad 1

11 BFU-10119 Head Pad 1

32 BFU-10120 Back Pad With Lum-

bar

43 BFU-50187 Large Roller 1

28 BFU-50189 7" Roller 6

ITEM NO. PART NO. DESCRIPTION QTY

1 BFM-10593 Rear Base 1

2 BFM-10566 Right Vertical Support 1

3 BFM-10567 Left Vertical Support 1

4 BFM-10568 Middle Base 1

5 BFM-10569 Middle Pole Assembly 1

6 BFM-51044 Guide Rod Holder 1

7 BFM-51022 1 1/4" Spacer 6

9 BFM-50529 Rubber Donut 2

10 BFM-50256 Weight Plate 19

12 BFM-51051 Guide Rod 2

13 BFM-10570 Right Arm Assembly 1

14 BFM-10574 Left Arm Assembly 1

15 BFM-10573 Functional Arm Mount 1

16 BFM-10571 User Right Functional Arm 1

17 BFM-10572 User Left Functional Arm 1

18 BFL-50197 Middle Pole Connector Plate 2

19 BFL-50203 Pulley Holder Connector Plate 1

20 BFM-10577 8" Telespar 1

21 BFM-10578 Seat Frame Assembly 1

24 BFM-10579 10" Chrome Adjustment 1

25 BFM-10141 Knee Alignment Roller 1

30 BFM-10580 Back Chrome Adjustment 1

33 BFM-10581 Leg Extension/ Curl Frame 1

35 BFM-51080 .45” Spacer 1

36 BFM-10582rev1 Functional Arm Swivel Pulley 2

37 BFM-10583 Top Swivel Pulley Holder 2

38 BFM-51082 Weight Stack Shroud 2

39 BFM-10584 Leg Extension Shaft 1

40 BFM-10585 Leg Extension Cam Assembly 1

41 BFM-51084 1 1/4" OD x .120 Wall x .225" Spacer 1

42 BFM-10586 Leg Extension Arm Assembly 1

44 BFL-50207 Hold Down Adjustment Plate 1

45 BFL-50211 Plate 1

46 BFM-10587 Knee Hold Down Assembly 1

47 BFM-51094 2” Axle 1

48 BFM-10588 Knee Hold Down Handle 1

50 BFL-50221 Pulley Plate 1

53 BFM-51143 8” Anti-Deflection Plate 1

54 BFM-51148 1" x 13 3/16" Arm Shaft 1

77 BFM-50505 3 1/2" Pulley Cover 11

79 BFM-10603 Left Arm Adjustment Handle 1

80 BFM-10602 Right Arm Adjustment Handle 1

87 BFM-51158 1" OD x 25/64" ID Spacer 1

91 BFM-10607 Press Arm 2

93 BFM-10609rev1 Pulley Holder 2

94 BFM-10611 Criss-Cross Free Floater 1

96 BFM-10610rev1 Lower Pulley Holder 2

105 BFM-10612 Cable Tie Out Plate 1

107 BFM-10299 Top Plate 1

108 BFM-50258 Selector Shaft 1

121 BFM-50222 2 9/16” Axle 1

122 BFM-50931 3” Axle 1

123 BFM-51173 Weight Stack Pull Pin 1

180 BFM-51130 Front Pivot 1

185 BFM-51158 Spacer 1

ITEM

NO. PART NO. DESCRIPTION QTY

BFM-10736 Right Press Arm Assembly 1191

BFM-10737rev1 Right Swing Arm Assembly 1192

BFM-10733rev1 Left Swing Arm Assembly 1193

BFM-10735 Left Press Arm Assembly 1194

195 BFM-52410 Weight Stack Shroud w/Logo 1

201 BFM-11038 Short Bar Holder 1

Batca Fitness Systems 4 Fusion 3 Owner's Manual

Hardware

Cables

ITEM NO. PART NUMBER DESCRIPTION QTY

8 BFH-50173 3 1/2" Pulley 31

22 BFH-50103 1/2" Flanged Bushing 4

23 BFH-50102 5/8" Flanged Bushing 2

26 BFH-50222 Rubber Bumper 2

27 BFH-50221 3" Plastic Washer 4

29 BFH-50252 Plastic Collar 6

34 BFH-50101 1" Flanged Bushing 28

49 BFH-50280 1" Round Plastic Cap 5

51 BFH-10002 Threaded Bearing 2

55 BFH-50165 1" Snap Ring 7

56 BFH-50146 3/8" Flat Washer (Black) 113

57 BFP-51752 SHCS 3/8"-16 X 2 1/4" 21

58 BFH-50157 3/8"-16 Nylock (Black) 69

59 BFH-50270 SHCS 3/8"-16 X 5 1/4" 8

60 BFH-50147 3/8" Lock Washer (Black) 16

61 BFP-51653 SHCS 3/8"-16 X 1 1/4" 4

62 BFP-51750 SHCS 3/8"-16 X 2 3/4" 8

63 BFP-51747 SHCS 3/8"-16 X 3" 5

64 BFH-50251 1/2" Flat Washer (Black) 4

65 BFP-51760 SHCS 1/2”-13 X 3 1/2” 1

66 BFP-51884 SHCS 1/2”-13 X 4 1/4” 1

67 BFP-51747 SHCS 1/2”-13 X 3” 1

68 BFH-50155 1/2"-13 Nylock (Black) 3

70 BFP-51759 SHCS 3/8"-16 X 2" 13

72 BFP-51753 SHCS 3/8"-16 X 4 3/4" 6

73 BFP-52397 SHCS 3/8"-16 1 3/4" 2

74 BFP-52396 SHCS 3/8"-16 X 5 1/2" 2

75 BFH-50605 3/8" Pulley Spacer 2

76 BFP-52394 SHCS 3/8"-16 X 2 1/2" 3

92 BFH-50256 1/2” Jam Nut 6

95 BFH-50174 4 1/2" Pulley 4

98 BFH-50253 Beveled Leveler 2

99 BFH-50149 3/8"-16 Jam Nut (Zinc) 6

110 BFH-51174 Large Logo/Chrome & Red 2

111 BFH-50192 Weight Stack Decals 2

ITEM NO. PART NUMBER DESCRIPTION QTY

113 BFH-50351 1 3/8" Shoulder Bolt 2

114 BFH-50267 5/16"-18 Nylock (Black) 2

115 BFH-50144 FHSCS 3/8"-16 X 1" 2

116 BFP-52340 SHCS 3/8”-16 X 3/4” 2

118 BFP-51799 SHCS 3/8”-16 X 5" 4

119 BFH-50245 FHSCS 5/16"-18 X 1" 2

128 BFH-50188 Snap Hook 4

129 BFH-50211 2" Square Plastic Cap 1

130 BFH-50212 2" x 3" Plastic Cap 2

131 BFH-50215 1 1/2" Square Plastic Cap 6

133 BFH-50227 Cable Strap 5

136 BFH-50238 Pin 2

137 BFH-50239 Snap Ring 2

138 BFH-50244 1/2" Bronze Bushing 8

140 BFH-50248 13/32" Bushing 8

143 BFH-50297 1" Flanged Bushing x 1/2"L 2

144 BFH-50590 Plastic Sleeve 3

145 BFH-50602 1" ID Bearing 14

146 BFH-50604 2" Interior Snap Ring 26

147 BFH-50607 Pull Pin Threaded Cap 2

148 BFH-50608 5" Plastic Sleeve 1

149 BFH-50609 Molded Grip 1" ID 1

150 BFH-50611 2" Round Plastic Cap 3

151 BFH-50612 1 3/4" x 4" Rectangular Cap 4

152 BFH-50614 6" Rubber Grips 2

153 BFH-50618 Mounting Bracket 2

154 BFH-50203 1/2" Curved Pulley Spacer 8

155 BFH-50204 3/8” Curved Washer (Black) 8

181 BFH-50339 Large Flat Leveler 2

182 BFH-50337 Wavy Washer 5

183 BFH-50630 FHSCS 3/8”-16 X 3/4” 2

184 BFP-52420 BHSCS 3/8”-16 X 1/2” 4

186 BFH-50620 BHSCS 3/8”-16 X 3/4” 6

187 BFH-50622 Upholstery Cap 6

188 BFH-50620 BHSCS 3/8” x 1” 2

189 BFM-52421 1 1/2” Aluminum Cap 2

190 BFH-50220 1” Shaft Collar 2

197 BFM-52422 Red Pivot Point Cap 1

ITEM

NO. PART NUMBER DESCRIPTION QTY

101 CAB-13021 Fusion Lat Pull to Functional Arm 2

109 CAB-13022 Fusion Weight Stack to Cable Tie Out 1

103 CAB-13024 Fusion Floating Pulley Cable 1

104 CAB-13025 Fusion Leg Extension Cable 1

106 CAB-13026 Fusion Tie Out Cable 1

www.batcafitness.com 5 Fusion 3 Owner’s Manual

Leg Press Components

Tools Required

 1/2” Wrench

 9/16” Wrench

 9/16” Ratchet

 3/4” Wrench

 3/4” Ratchet

 Allen Wrench

Set

 Tape Measure

 Snap Ring

Pliers

Leg Press Hardware

Upholstery

Cables

ITEM NO. PART NUMBER DESCRIPTION Qty

102 CAB-13023 Fusion Leg Press Cable 1

ITEM NO. PART NUMBER DESCRIPTION Qty

61 BFP-51653 SHCS 3/8"-16 X 1 1/4" P5 2

70 BFP-51759 SHCS 3/8"-16 X 2" P5 1

76 BFP-52394 SHCS 3/8"-16 X 2 1/2" P5 2

63 BFP-51747 SHCS 3/8"-16 X 3" P5 2

69 BFP-51748 SHCS 3/8"-16 X 3 1/4" P5 2

82 BFP-51760 SHCS 3/8"-16 X 3 1/2" P5 3

83 BFP-51884 SHCS 3/8"-16 X 4 1/4" P5 1

84 BFP-51751 SHCS 3/8"-16 X 4 1/2" P5 1

56 BFH-50146 3/8" Flat Washer (Black) 34

60 BFH-50147 3/8" Lock Washer (Black) 4

99 BFH-50149 3/8"-16 Jam Nut (Zinc) 3

58 BFH-50157 3/8"-16 Nylock (Black) 22

8 BFH-50173 3 1/2" Pulley 5

ITEM NO. PART NUMBER DESCRIPTION Qty

113 BFH-50351 1 3/8" Shoulder Bolt 1

64 BFH-50251 1/2" Flat Washer (Black) 2

98 BFH-50253 Beveled Leveler 1

114 BFH-50267 5/16"-18 Nylock (Black) 1

59 BFP-51756 SHCS 3/8"-16 X 5 1/4" P5 4

73 BFP-52397 SHCS 3/8"-16 1 3/4" P5 1

75 BFH-50605 3/8" Pulley Spacer 5

92 BFH-50256 1/2” Jam Nut 1

181 BFH-50339 Large Flat Leveler 1

198 BFP-51696 2” Aluminum Cap 2

199 BFH-50620 BHSCS 3/8” x 1” 4

ITEM NO. PART NUMBER DESCRIPTION Qty

166 BFM-10597 Back Seat Frame 1

164 BFM-10598 Bottom Seat Frame 1

157 BFM-10605rev1 Leg Press Frame 1

170 BFP-10918 Four Bar 2

159 BFM-51155 2 1/32" Axle 3

160 BFM-51157 3 1/32" Axle 1

180 BFM-51130 Front Pivot 1

ITEM NO. PART NUMBER DESCRIPTION Qty

172 BFP-10916 Foot Plate 1

162 BFL-50219 Bench Frame Plate 2

165 BFM-10106 Chrome Pad Adjustment 1

158 BFM-10575 Leg Press Connector

Assembly 1

167 BFP-10919 Leg Press Pivot Arm 1

163 BFM-10595 Chrome Adjustment 1

161 BFM-10596 6" Telespar 1

198 BFP-52029 Four Bar Spacer 2

ITEM NO. PART NUMBER DESCRIPTION Qty

173 BFU-10117 Large Bottom Pad 1

174 BFU-10120 Back Pad With Lumbar 1

Batca Fitness Systems 6 Fusion 3 Owner's Manual

Bolt Length Note: Bolt length is measured from

the underside of the head of the bolt.

www.batcafitness.com 7 Fusion 3 Owner’s Manual

Beveled Leveler

BFH-50253

Upholstery

Cap

3” Plastic

Washer

Large Flat Leveler

BFH-50339

3 1/2” Pulley

BFH-50173

Threaded

Bearing

BFH-10002

BFH-50238

4 1/2” Pulley

BFH-50174

Cable Strap

BFH-50227

Strap Handle

BFC-10103

Snap Hook

BFH-50188

Batca Fitness Systems 8 Fusion 3 Owner's Manual

www.batcafitness.com 9 Fusion 3 Owner’s Manual

Long Pop Pin

BFM-51172 Magnetic Weight Stack Pin

BFM-51173

Short Pop Pin

BFM-51175

Pop Pin Cap

BFM-51181 Rubber Donut

BFM-50529

3/8” Curved Washer

BFM-50204 3/8” Flat Washer

BFM-50146

1/2” Flat Washer

BFM-50251

3/8” Lock Washer

BFM-50147

Mounting Brackets

BFH-50618

6” Rubber Grips (Yellow)

BFH-50614

1 3/4” x 4” Rectangular Cap

BFH-50612

Plastic Cap

Part # Size

BFH-50211 2” X 2”

BFH-50212 2” X 3”

BFH-50213 1 1/2” X 2”

BFH-50214 1 3/4” X 1 3/4”

BFH-50215 1 1/2” X 1 1/2”

Batca Fitness Systems 10 Fusion 3 Owner's Manual

ITEM NO. PART NUMBER DESCRIPTION QTY

101 CAB-13021 Fusion Lat Pull to Functional Arm 2

109 CAB-13022 Fusion Weight Stack to Cable Tie Out 1

102 CAB-13023 Fusion Leg Press Cable 1

103 CAB-13024 Fusion Floating Pulley Cable 1

104 CAB-13025 Fusion Leg Extension Cable 1

106 CAB-13026 Fusion Tie Out Cable 1

Cables

Cable Comparison Chart

71 5/8”

22 5/8”

187 1/2”

90 1/2”

85 1/4”

90 3/8”

CAB-13021 CAB-13024

CAB-13022 CAB-13025

CAB-13023 CAB-13026

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