Keys Fitness Power System 1850 Users Manual Kps

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Page Count: 34

Owner’s Manual

Read all precautions and instruc-

tions in this manual before using

this equipment.

215-00009

09/04

Table of Contents

2

Important Safety Information 3

Before You Start 4

Assembly 5-26

Weight Ratios 27

Weight Stack Sticker Placement 28

Cable View 29

Top View 30

Exploded View 31

Parts List 32

Warranty Information 33

Important Safety Information

3

THANK YOU for making this Power System unit a part of your exercise pro-

gram. Keys Fitness and our Power System Series assures the very best in value,

appearance, durability and biomechanics.

This manual will guide you through the assembly process. If at any time you are

having trouble with the assembly or use of this product, then please contact us at

our Keys Fitness Help-line. We have trained service technicians on site to take

care of you, our valued customer.

REGISTRATION CARD

To avoid unnecessary delays in warranty parts and to insure that a permanent

record of your purchase is on file with our company, be sure to send in the war-

ranty registration card or register on-line at www.keysfitness.com within 10 days

of purchase.

POWER SYSTEM SERIES

QUESTIONS?

CALL

1-888-340-0482

Monday-Friday

8:30-5:30 Central Time

When calling please have the following product information available:

• Product Series

• Model #

• PO # (located on the front of the manual)

• Part Number

• Part Description

Before You Start

4

Prior to assembly, remove components from the box and verify that all the listed parts were supplied.

SAFETY INFORMATION WARNING!

Before using this unit or starting any exercise program, consult your physician.

This is especially important for persons over the age of 35 and/or persons with

pre-existing health problems. Keys Fitness Products LP assumes no responsibili-

ty for personal injury or property damage sustained by or through the use of this

product.

It is the owner’s responsibility to ensure that all users of this unit have read the

Owner’s Manual and are familiar with safety information and precautions.

SAFETY PRECAUTIONS

• This Power System unit should only be used on a level surface and is intended

for indoor use only. Keys Fitness recommends an equipment mat be placed

under the unit to protect the floor or carpet and for easier cleaning.

• Wear comfortable, good-quality walking or running shoes and appropriate

clothing. Do not use this unit with bare feet, sandals, socks or stockings!

• Always examine your unit before using to ensure all parts are in working order.

• Do not leave children unsupervised near or on the unit.

• Service to your Power System unit should only be performed by an authorized

service representative, unless authorized and/or instructed by a Keys Fitness

technician. Failure to follow these instructions will void the warranty.

NOTE: Hand tighten bolts and nylon nuts until machine is fully assembled.

Assembly

5

Box 1

Assembly

6

Box 2

Assembly

7

Box 3

Box 5 Box 6

Box 4

Assembly

8

Assembly

9

STEP 1

Insert the two Guide Rods (24) into Rear Base (1) and secure them in place using two Washers (102), two

Spring Washers (103), and two Allen Bolts (97).

Assembly

10

Figure 1

Assembly

11

STEP 2

Attach the Seat Pad Support Receptacle (2) to Rear Base (1) and secure in place using three Nylon Locknuts

(104), six Washers (102), and three Bolts (94).

Connect the Front Upright (86) to Seat Pad Support Receptacle (2) and secure together using two Nylon

Locknuts (104), four Washers (102), and two Bolts (95).

Insert the Pec Dec Mount (7) onto Seat Pad Support Receptacle (2) using two Nylon Locknuts (104), four

Washers (102), and two Bolts (94) on the side. Next, insert one Washer (107), one Spring Washer (103), and

one Bolt (93) at the top.

Figure 2

Assembly

12

Step 3

Install the Main Upright (3) onto Seat Pad Support Receptacle (2). Secure it in place using three Nylon

Locknuts (104), six Washers (102), and three Bolts (94) on the side. Two Bolts (98), one Spring Washer

(117), three Washers (101), one Nylon Locknut (95) will secure it at the bottom.

Figure 3

Assembly

13





Step 4

Slide one Weight Stack Bumper (30) down each Guide Rod (24). Next, slide the weight plates down the

Guide Rods (24) in this order - five 15lb Plates (36), nine 10lb Plates (37), five 5lb Plates (38), and the Top

Plate (27).

Insert the Main Top Beam (4) onto the two Guide Rods (24) and the Main Upright (3). Secure Main Top

Beam (4) to Main Upright (3) using two Nylon Locknuts (104), four Washers (101), two Bolts (98). Last, use

two Washers (102), two Spring Washers (103), and two Allen Bolts (97) to secure the Main Top Beam (4) to

the two Guide Rods (24).

Figure 4

Step 5

Attach Press Arm Support (5) to Main Upright (3) by aligning the holes and sliding the Shaft (74) through.

Secure the Shaft (74) in place using two Set Screws (84).

Install Press Arm (6) to Press Arm Support (5) by aligning the holes and sliding the Shaft (73) through.

Secure the Shaft (73) in place using two Set Screws (84).

Assembly

14

Figure 5

Assembly

15

Step 6

Slide the Right Pec Dec Arm (8) on to the shaft of the Pec Dec Mount (7). Secure the arm in place using

one Big Washer (76), one Washer (102), one Spring Washer (103), and one Allen Bolt (97).

Slide Pec Dec Handle Bar (19) onto the top of the Right Pec Dec Arm (8) and secure using one Chrome

Washer (106), one Washer (102), one Spring Washer (103), and one Allen Bolt (97).

Repeat this step to complete the Left Pec Dec assembly.

Figure 6

Assembly

16

Step 7

Install the Right and Left Hold Leg Frames (17 & 18) to Main Upright (3) and secure using two Nylon

Locknuts (104), four Washers (102), and two Bolts (95).

Make sure the both Hold Leg Frames are angled upwards.

Figure 7

Assembly

17

Step 8

Slide the Shaft (72) into the Leg Extension Lever (10). Attach Leg Extension Lever (10) to Seat Pad

Support Receptacle (2) and secure using one Washer (119), one Spring Washer (115), and one Allen Bolt

(118).

Slide Foam Frame w/ Shaft (11) through the Leg Extension Lever (10) and attach the Foam Frame w/o

Shaft (12) to the other side. Insert the Slip Tension Pin (80) through the hole where the two foam frames

meet. Note: You may need to use a rubber mallet to install Slip Tension Pin (80).

Figure 8

Assembly

18

Step 9

Attach the Seat Pad (26) to the Seat Pad Support (13) using two Washers (102) and two Allen Bolts (96).

Slide the Seat Support assembly into the Seat Pad Support Receptacle (2) and secure by tightening the

Locking Pop Pin (52).

Install the Telescope (14) to the Back Pad Support (16) and secure in place using one Nylon Locknut (104),

two Washers (101), and one Bolt (99).

Install the Tilting (15) to the Back Pad Support (16) and secure in place using one Nylon Locknut (104), two

Washers (102), and one Bolt (88).

Attach the Back Pad (25) to Back Pad Support (16) using two Washers (102) and two Bolts (89).

Last, slide the Back Pad Support assembly into the receptacle on the Main Upright (3) and secure by tighten-

ing the Locking Pop Pin (52).

Figure 9

Assembly

19

Step 10

Slide two Upholstered Roller Pads (42) onto Foam Frames (11 & 12) and secure using two Big Plugs (65).

Slide the Long Foam Tube (77) through the hole in Seat Pad Support (13). Slide two Plastic Washers (87)

onto each end of Long Foam Tube (77). Next, slide two Upholstered Roller Pads (42) onto each side of Long

Foam Tube (77) and secure using two Big Plugs (65).

Slide two Upholstered Roller Pads (42) onto the Leg Hold Frames (17 & 18) and secure using two Big

Plugs (65).

Figure 10

Assembly

20

Step 11

Note: Stretch all cables out completely and make sure all twisting is removed before installing.

Install Chest Press Cable (45) as detailed in Figure 11. Follow dotted lines to identify exact

location of pulleys. See Page 29 “Cable View” for more detail.

Start by threading cable end into Top Plate (27).

You will need the following for installation:

Pulley (44) - Qty. 9

Cable (45) - Qty. 1

Nylon Locknut (104) - Qty. 9

Long Pulley Spacer (53) - Qty. 6

Longer Pulley Spacer (55) - Qty. 4

Adjustable Stopper (75) - Qty. 1

Bolt (90) - Qty. 2

Bolt (91) - Qty.2

Bolt (93) - Qty 3

Bolt (95) - Qty. 2

Washer (102) - Qty. 18

Hex Nut (100) - Qty. 1

Figure 11

Assembly

21

Step 12

Note: Stretch all cables out completely and make sure all twisting is removed before installing.

Install Mid Pulley Cable (46) as detailed in Figure 12. Follow dotted lines to identify exact location

of pulleys. See Page 29 “Cable View” for more detail.

Start by installing cable under the pulley at Leg Extension location.

You will need the following for installation:

Pulley (44) - Qty. 8

Cable (46) - Qty. 1

Nylon Locknut (104) - Qty. 8

Long Pulley Spacer (53) - Qty. 6

Longer Pulley Spacer (55) - Qty. 4

Short Pulley Spacer (54) - Qty. 2

Bolt (91) - Qty. 3

Bolt (92) - Qty. 1

Bolt (93) - Qty 1

Bolt (94) - Qty. 1

Bolt (95) - Qty. 1

Washer (102) - Qty. 18

Pulley Bracket w/ Shaft (21) - Qty. 1

Pulley Bracket Block (22) - Qty. 1

Pulley Bracket (23) - Qty. 1

Figure 12

Assembly

22

Step 13

Note: This step is only used if you do not have the Leg Press 2 attachment. Use the Cable Adapter (113) in

place of the pulley.

Note: Stretch all cables out completely and make sure all twisting is removed before installing.

Install Leg Press Cable Substitute (47) as detailed in Figure 13. Follow dotted lines to identify exact location

of pulleys.

You will need the following for installation:

Cable Adapter (113) - Qty. 1

Longer Pulley Spacer (55) - Qty. 2

Cable (47) - Qty. 1

Bolt (95) - Qty. 1

Washers (102) - Qty. 2

Nylon Locknut (104) - Qty. 1

Figure 13

Assembly

23

Step 14

Note: Stretch all cables out completely and make sure all twisting is removed before installing.

Install Pec Dec Cable (49) as detailed in Figure 14. Follow dotted lines to identify exact location of pulleys.

See Page 29 “Cable View” for more detail.

You will need the following for installation:

Cable (49) - Qty. 1

Pulley (44) - Qty. 3

Pulley Bracket Block (22) - Qty. 1

Bolt (91) - Qty. 3

Washers (102) - Qty. 6

Nylon Locknut (104) - Qty. 3

Philips Screw (85) - Qty. 2

Figure 14

Assembly

24

Step 15

Connect Long Lat Bar (70) to the Chest Press Cable (45) using two Gear Hooks (33) and Short Chain (35).

Connect Ab Strap (40) or Lat Strap (34) to Mid Pulley Cable (46) using one Gear Hook (33).

Connect Short Lat Bar (71) to Mid Pulley Cable (46) using two Gear Hooks (33) and Long Chain (32).

Figure 15

Assembly

25

Step 16

Install Weight Shrouds (20) to each side of the Main Top Beam (4) using two Washers (102), two Spring

Washers (103), and Allen Bolts (97 & 118).

Secure the bottom portion of the Weight Shrouds (20) to the Rear Frame (1) using two Washers (119) and

two Allen Bolts (118).

Note: Tighten all hardware securely.

Figure 16

Assembly

26

Congratulations!

You have completed the assembly of your new KPS-1850.

Weight Ratios

27

KPS-1850

Weight(lbs) 100% 95% 90% 65% 45%

10 10 9.5 9 6.5 4.5

15 15 14.25 13.5 9.75 6.75

20 20 19 18 13 9

25 25 23.75 22.5 16.25 11.25

30 30 28.5 27 19.5 13.5

35 35 33.25 31.5 22.75 15.75

45 45 42.75 40.5 29.25 20.25

55 55 52.25 49.5 35.75 24.75

65 65 61.75 58.5 42.25 29.25

75 75 71.25 67.5 48.75 33.75

85 85 80.75 76.5 55.25 38.25

95 95 90.25 85.5 61.75 42.75

105 105 99.75 94.5 68.25 47.25

115 115 109.25 103.5 74.75 51.75

125 125 118.75 112.5 81.25 56.25

140 140 133 126 91 63

155 155 147.25 139.5 100.75 69.75

170 170 161.5 153 110.5 76.5

185 185 175.75 166.5 120.25 83.25

200 200 190 180 130 90

WEIGHT RATIOS

Weight Stack Sticker Placement

28

10 10

15

20

20

25

30

40

50

60

70

80

90

100

30

35

45

55

65

75

85

95

105

115

115

125

140

155

170

130

145

160

175

190

205

220

235

250

185

200

200 LB Stack 250 LB Stack

Your new POWER SYSTEM unit can be purchased with either a 200 LB or 250 LB weight

stack. Depending on which weight stack you have purchased will determine which weight

stack sticker numbers will be used.

The weight stack images below show which weight stack sticker numbers are to be used on

your weight stack. Please note that these stickers should not be put on until the entire unit has

been assembled and all bolts and nuts have been tightened.

Cable View

29

Top View

30

Exploded View

31

REF# KEYS PART# DESCRIPTION QTY. REF# KEYS PART# DESCRIPTION QTY.

1 223-00235 Rear Base 1 61 206-00020 Square Plug 44.5 2

2 223-00236 Seat Pad Support Receptacle 1 62 206-00140 Square Plug 50.8 2

3 223-00237 Main Upright 1 63 206-00001 Square Plug 76.2*50.8 4

4 223-00238 Main Top Beam 1 64 206-00102 Round Plug 32 4

5 223-00239 Press Arm Support 1 65 206-00141 Big Plug 25.4 6

6 223-00240 Press Arm 1 66 206-00142 Nylon Stopper 1

7 223-00241 Pec Dec Mount 1 67 206-00143 Pec Dec Stop Bumper 1

8 223-00242 Right Pec Dec Arm 1 68 206-00061 Base Pad 3

9 223-00243 Left Pec Dec Arm 1 69 206-00099 End Cap Bumper 1

10 223-00244 Leg Extension Lever 1 70 223-00092 Long Lat Bar 1

11 219-00265 Foam Frame w/Shaft 1 71 219-00136 Short Lat Bar 1

12 219-00266 Foam Frame w/o Shaft 1 72 230-00017 Shaft for Leg Extension 1

13 223-00245 Seat Pad Support 1 73 230-00018 Shaft for Chest Press Adjustment 1

14 219-00267 Telescope for Back Pad 1 74 230-00019 Shaft for Chest Press 1

15 219-00268 Tilting for Back Pad 1 75 210-00097 Adjustable Stopper 1

16 219-00269 Back Pad Support 1 76 202-00145 Washer 6.6*18*1.6 2

17 219-00270 Right Leg Hold Leg Frame 1 77 219-00031 Long Foam Tube 1

18 219-00271 Left Leg Hold Leg Frame 1 78 219-00281 Cable Retainer Bracket 1

19 219-00272 Pec Dec Handle Bar 2 79 206-00138 Round Plug 25 2

20 223-00246 Weight Shroud 2 80 202-00146 Slip Tension Pin 1

21 219-00273 Pulley Bracket w/Shaft 1 81 202-00147 “U” Shape pin 1

22 219-00274 Pulley Bracket Block 1 82 202-00144 Small Spring 1

23 219-00275 Pulley Bracket 1 83 202-00142 Nut M6 1

24 223-00247 Guide Rod 2 84 202-00143 Screw M8*6 5

25 228-00085 Back Pad 1 85 202-00122 Philip Screw M4*20 2

26 228-00084 Seat Pad 1 86 223-00248 Front Upright 1

27 228-00031 Top Plate 1 87 206-00134 Plastic Washer 2

28 202-00121 Screw Bolt M12*35 1 88 202-00123 Bolt M12*75 1

29 219-00276 Selector Rod 1 89 202-00124 Bolt M10*30 2

30 206-00026 Weight Stack Bumper 2 90 202-00085 Bolt tM10*50 2

31 210-00002 Weight Pin 1 91 202-00086 Bolt M10*45 9

32 229-00038 Long Chain 1 92 202-00087 Bolt M10*65 1

33 210-00008 Gear Hook 7 93 202-00083 Bolt M10*70 5

34 210-00061 Lat Strap 2 94 202-00081 Bolt M10*75 9

35 229-00037 Short Chain 1 95 202-00082 Bolt M10*80 8

36 219-00277 15LB Plate 5 96 202-00125 Allen Bolt M10*50 2

37 219-00278 10LB Plate 9 97 202-00087 Allen Bolt M10*25 8

38 219-00279 5LB Plate 5 98 202-00126 Bolt M12*80 4

39 214-00001 Decal Weight Number 1 99 202-00077 Bolt M12*85 1

40 210-00060 Ab Strap 1 100 202-00129 Regular Hex Nut10 1

41 210-00059 Ankle Strap 1 101 202-00127 Washer 13*24*1.5 11

42 228-00077 Upholstered Roller Pad 100*22*180 6 102 202-00128 Washer 11*20*2 78

43 206-00146 Handle Grip 4 103 202-00100 Spring Washer 10 9

44 223-00228 Pulley 20 104 202-00091 Nylon Locknut M10 33

45 229-00047 Chest Press Cable 1 105 202-00092 Nylon Locknut M12 5

46 229-00048 Mid Pulley Cable 1 106 202-00129 Chrome Washer 38*11*2 2

47 229-00049 Leg Press Cable Substitute 1 107 202-00130 Washer 38*11*2 1

48 202-00138 Washer 6.6*18*1.6 1 108 202-00131 Philip Screw M6*15 2

49 229-00050 Pec Dec Cable 1 109 202-00132 Hex Key 6 1

50 210-00095 Pop Pin 1 110 202-00133 Hex Key 4 1

51 202-00139 Spring Washer 6 1 111 206-00135 Grip 4

52 210-00096 Pop Pin (Locking) 2 112 206-00136 Rubber stopper 3

53 202-00071 Long Pulley Spacer 10 113 210-00093 Cable Adaptor 1

54 202-00025 Short Pulley Spacer 2 114 206-00137 Nylon Cover 1

55 202-00140 Longer Pulley Spacer 8 115 202-00134 Spring Washer 8 1

56 202-00016 Bronze Bushing ID25.4 8 116 210-00091 Lube 1

57 202-00023 Bronze Bushing ID12.2 4 117 202-00135 Spring Washer 12 1

58 202-00024 Bearing ID25 6 118 202-00136 Allen Bolt M8*15 5

59 202-00141 Bronze Bushing ID16 2 119 202-00137 Washer 9*22*2 3

60 206-00139 Square Plug 50*25 5

KPS-1850 Parts List

Parts List

32

Warranty Information

KEYS FITNESS PRODUCTS, L.P.

POWER SYSTEM SERIES

LIFETIME WARRANTY

This Warranty applies in the United States and Canada to products manufactured or distributed by

Keys Fitness Products, LP (“Keys”) under the KEYS brand name. The warranty period to the original

purchaser is lifetime of the original purchaser.

Keys warrants that the Product you have purchased for non-commercial, personal, family, or house-

hold use from Keys or from an authorized Keys reseller is free from defects in materials or workmanship under normal use dur-

ing the warranty period. Your sales receipt, showing the date of purchase of the Product, is your proof of purchase. This war-

ranty only extends to you, the original purchaser. It is not transferable to anyone who subsequently purchases the Product from

you. It excludes expendable parts (wear items). Wear items pertain to components that might need to be replaced due to nor-

mal wear and tear. These items vary per product but will include grips, chains, cables, pads, upholstery, pulleys, bearings, etc.

Please contact a Keys customer service representative for specifics on wear items. This Warranty becomes VALID ONLY if the

product is purchased through a Keys Fitness authorized dealer unless otherwise authorized by Keys Fitness in writing and

must be assembled / installed according to the instructions included with the Product.

In a light institutional setting, Keys will extend a one year warranty to the the original purchaser.

During the warranty period Keys will repair or replace (at Keys' option) the product if it becomes defective, malfunctions, or oth-

erwise fails to conform with this Warranty under normal use. In repairing the Product, Keys may replace defective parts, or at

the option of Keys, serviceable used parts that are equivalent to new parts in performance. All exchanged parts and Products

replaced under this warranty will become the property of Keys. Keys reserves the right to change manufacturers of any part to

cover any existing warranty.

This warranty DOES NOT COVER shipping charges, export taxes, custom duties and taxes, or any other charges associated

with transportation of the parts or Product. To obtain warranty service, you must contact a Keys authorized retailer, service

technician or Keys Fitness at our phone number located in this manual. Any parts determined to be defective must be returned

to Keys to obtain warranty service. You must prepay any shipping charges, export taxes, custom duties and taxes, or any other

charges associated with transportation of the parts or Product. In addition, you are responsible for insuring any parts or

Product shipped or returned. You assume the risk of loss during shipment. You must present Keys with proof-of-purchase doc-

uments (including the date of purchase). Any evidence of alteration, erasing or forgery of proof-of-purchase documents will be

cause to void this Warranty.

This Warranty does not extend to any product not purchased from Keys or from an authorized Keys reseller. This Limited

Warranty does not extend to any Product that has been damaged or rendered defective; (a) as a result of accident, misuse, or

abuse; (b) by the use of parts not manufactured or sold by Keys; (c) by modification of the Product or normal wear and tear;

(d) operation on incorrect power supplies; or (e) as a result of service by anyone other than Keys, or an authorized Keys war-

ranty service provider. Product on which the serial number has been defaced or removed is not eligible for warranty service.

Should any Product submitted for warranty service be found ineligible, an estimate of repair cost will be furnished and the

repair will be made if requested by you upon Keys' receipt of payment or acceptable arrangements for payment.

EXCEPT AS EXPRESSLY SET FORTH IN THIS WARRANTY, KEYS MAKES NO OTHER WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR-

POSE. KEYS EXPRESSLY DISCLAIMS ALL WARRANTIES NOT STATED IN THIS LIMITED WARRANTY. ANY IMPLIED

WARRANTIES THAT MAY BE IMPOSED BY LAW ARE LIMITED TO THE TERMS OF THIS LIMITED WARRANTY. NEITHER

KEYS NOR ANY OF ITS AFFILIATES SHALL BE RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR

LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR EXCLUSION MAY NOT

APPLY TO YOU. This Limited Warranty gives you specific legal rights and you may also have other rights that may vary from

state to state. This is the only express warranty applicable to Keys-branded products. Keys neither assumes nor authorizes

anyone to assume for it any other express warranty.

PLEASE SEND IN THE INCLUDED WARRANTY CARD OR REGISTER ON-LINE AT www.keysfitness.com WITHIN

TEN (10) DAYS OF PURCHASE TO REGISTER YOUR UNIT WITH KEYS FITNESS PRODUCTS, LP.

MAIL WARRANTY CARD TO: KEYS FITNESS PRODUCTS, PO BOX 551239, DALLAS, TX 75355

33

Customer Service

1.888.340.0482

Keys Fitness

4009 Distribution Drive

Suite 250

Garland, TX 75041

www.keysfitness.com