Keiser Keiser 300 User manual
Keiser 300 / Air 300
Parts and
Maintenance
Manual
2
Table of Contents
Introduction – How it Works 4
Preventive Maintenance 5
Troubleshooting 6
Air Hoses and Fittings 7
Filter 9
Valves 10
Cylinders 14
Mufflers 17
Fasteners 18
Arm Locks 19
Bearings 21
Hand Grips 23
Upholstery – Decals 25
Parts Identification 26
SAFETY CAUTIONS:
We’ve put a number of safety cautions in this book. We use the word CAUTION to tell
you about things that could cause bodily injury to persons on or around the equipment if
you were to ignore the warning.
MACHINE DAMAGE NOTICE:
Also, in this book you will find the word NOTICE. This tells you about things that
could hurt the machine if you were to ignore these warnings.
3
4
K300 – HOW IT WORKS
Two basic systems are used to operate the KEISER 300 series exercise machines.
On machines that exercise the muscle groups of the upper body, the resistance is
controlled by means of foot pedals mounted on the base of the machine. Thumb buttons
in the handles operates machines for lower body muscle groups.
When the quick-disconnect is plugged into the air system, compressed air flows
into the machine. In all but the Seated Chest Press, Lateral Shoulder Raise, Military
Press, Tricep, and Seated Butterfly, the air flows through the filter to the increase valve
(in the machine above, the filter is in a different location, but its function is identical).
The filter removes moisture and particles, which may be harmful to the cylinders.
When the increase valve is depressed, the air flows into the cylinders, tanks, and
gauge through one or more manifolds. Moving the exercise arm through its range drives
the piston in the cylinder against the air pressure. The air, in effect, pushes back against
the piston, creating mechanical resistance. When the increase valve is held down, the
resistance becomes greater until the maximum cylinder pressure is reached.
Depressing the decrease valve opens the system to the atmosphere, allowing the
cylinder air to escape. The resistance decreases as the pressure is reduced.
The gauge is calibrated to show the maximum amount of resistance developed by
the machine. The gauge reading is correct when the exercise arms are against their stops.
The gauge needle will move during the exercise motion. This is characteristic of the
system and does not indicate a malfunction.
5
6
7
PROBLEM: Pressure changes without valves being actuated.
Service the Valves (see pg. 9)
AIR HOSES AND FITTINGS
All K300 machines use polyethylene tubing and “Compress-align” fittings to connect the
various pneumatic components within the machine.
If an air leak is suspected, first listen closely to the air hose connections. Leaks will
make a hissing noise. Very slight leaks may not be loud enough to hear. These may be
detected by dabbing soapy water on the suspected leak. Escaping air will make bubbles.
If the leak is at a fitting, first tighten the nut about one-quarter (1/4) of a turn. Test the
connection again. If the fitting still leaks, the nut must be replaced. In most cases the air
hose should be long enough to allow this; if not, order a new air hose from KEISER.
To install a new nut:
TOOLS REQUIRED: adjustable wrench and a sharp knife
1. Cut the tubing as close as possible to the nut. The cut must be clean and square.
2. Slip a new nut over the tubing.
3. Insert the tubing into the fitting all the way to the shoulder inside the fitting (see the
cutaway illustration).
4. Hold the tubing in the fitting and slide the nut down onto the fitting. Tighten the nut
as tight as possible with the fingers, then another one full turn with a wrench.
If reinstalling an air hose, tighten the nut finger-tight, plus one-quarter (1/4) turn. This
will allow the nut to be used three more times before it must be replaced.
8
QUICK – DISCONNECT
The feed hose is connected to the quick-disconnect and the machine with compress-align
fittings. If the feed hose must be repaired or replaced, follow this procedure:
1. To replace hose, unscrew the compress-align nuts on both ends and remove the hose
(new hoses and compress-align nuts are available from KEISER).
2. To shorten the hose, unscrew chrome compress-align nut from the quick-disconnect
and cut the hose to the desired length. Slide a new chrome nut (an extra one is
supplied with each machine) onto hose.
3. To tighten the compress-align nuts, slide the hose all the way into the fitting and
thread the nut on hand-tight. Tighten the brass nut one full turn more with a ½ in.
open-end wrench. The chrome nut may require more turns, due to the chrome on the
threads. Make sure the hose is held securely in place at both fittings.
9
FILTER
The air filter keeps moisture and dirt out of the cylinders and other components. The
filter bowl must be kept free of moisture. Filter bowls that fill quickly with water
indicate a problem with the air dryer. If your air system does not include a dryer, the
filters on all machines must be checked and/or drained daily.
This is best done by pressing on the drain valve until all moisture blows free. The
moisture can be caught in a towel. CAUTION: IF THE FILTER BOWL IS CRACKED,
IT MUST BE REPLACED IMMEDIATELY. NOTICE: IF FILTER BOWL IS
CRACKED, AN AIR LEAK COULD RUN THE COMPRESSOR CONTINUOUSLY,
PUTTING EXCESSIVE WEAR ON THE COMPRESSOR.
The internal parts of the filter and the bowl can be cleaned. Always decrease resistance
to zero before starting service or repair on any K300 machine.
To service:
Unplug the quick-disconnect and unscrew the bowl and element holder from the housing.
Clean all parts with dish soap and water. Do not use solvent or other strong chemicals on
any part of the filter. Allow the element to dry thoroughly. Lightly coat the bowl seal
with SAE 30 wt. Oil and reassemble. Leaky drain valves can be replaced with a bicycle
tire tube valve available at most hardware stores.
10
VALVES
The valves in the pedals or handles can be removed for service or repair. Always unplug
the quick-disconnect from the air system and decrease the resistance to zero before
working on the valves. The following groups of machines state the type of valve and its
maintenance procedures.
LEG EXTENSION, LEG CURL, SQUAT, HIP ABDUCTOR, LEG PRESS,
STANDING HIP, ABDOMINAL, LOWER BACK, AND SEATED CALF
1. Trace the hoses on the valves to their connections on the filter or manifold. An
increase valve is connected to two hoses, one from the filter and one to the manifold.
Decrease valves are connected to one hose from the manifold and one from the
exhaust muffler. Mark the hoses with tape so they can be reassembled properly, then
disconnect.
2. Decrease the resistance to zero. Remove the grip end cap from the handle and pull
the valve out to a point where the hose can be cut about ½ inch from the bottom of the
valve housing. Cut the hoses clean and square, and cut the small remaining piece off
the barbed fittings. NOTICE: DO NOT DAMAGE BARBS. DAMAGED BARBS
ARE AREAS FOR POSSIBLE LEAKS.
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