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Owner’s Manual
Discovery Plate Loaded™ Line
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Discovery Series Plate Loaded Line Owner's Manual: Important Safety Guidelines for Owners 1
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.
Regular maintenance must be performed by qualified technicians.
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 cracked weld.
Strength training requires 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.
If any facility personnel witness unsafe use of the equipment, the staff
member should address the user directly, to demonstrate the proper
technique, and review with the users 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 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 the equipment toppling 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.
Check the equipment thoroughly based on the recommended inspection
schedules outlined in this manual, including daily, weekly, monthly, and
annual checks.
Place an “out-of-order” sign on the equipment during maintenance of the
equipment or the surrounding area, and make sure the facility’s personnel
know not to allow anyone to use the equipment until it has been inspected
and works properly. If a piece of equipment needs service, keep it out of
use until repaired.
Do not attempt to free any jammed assemblies alone as this may cause
injury. With the help of another person, carefully return the mechanism to
its proper resting position.
Do not place the equipment outdoors or on wet surfaces.
Safety Approval
Precor commercial strength equipment is designed and tested according
to EN 957-1/2 standards.
Important Safety Guidelines for Owners
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Discovery Series Plate Loaded Line Owner's Manual: Important Safety Information for Users 2
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 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.
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 or on wet surfaces.
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.
Important Safety Information for Users
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Discovery Series Plate Loaded Line Owner's Manual: Table of Contents 3
Important Safety Guidelines for Owners................................... 1
Safety Approval .......................................................................................1
Important Safety Information for Users .................................... 2
Before You Begin ....................................................................... 4
Recommended Tools ........................................................................... 4
Obtaining Service ................................................................................. 4
Maintaining Your Plate Loaded Equipment ............................... 5
Daily Maintenance ................................................................................ 5
Weekly Maintenance ........................................................................... 7
Monthly Maintenance .......................................................................... 7
Table of Contents
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Discovery Series Plate Loaded Line Owner's Manual: Before You Begin 4
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 Discovery Plate Loaded line
of commercial strength equipment. It provides information about items that
need to be inspected and maintained on a daily, weekly, and monthly basis.
You should perform those tasks that are appropriate for the equipment you
are maintaining and skip those tasks that do not apply.
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. Many
parts are tested and manufactured specifically for Precor commercial strength
equipment. If you use parts not approved by Precor, you could void the Precor
Limited Warranty. Use of parts not approved by Precor may cause injury.
Recommended Tools
We recommend that you keep the following tools available to maintain the
equipment:
Complete combination box wrench set (common metric sizes)
Complete socket set (common metric and SAE sizes)
Complete hex key set (common metric sizes)
12-inch adjustable wrench
Rubber mallet
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 regarding 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, you may want to write the serial numbers, model
numbers, and dates of purchase of your Precor strength training equipment in
the space provided below for easy reference.
Model #: Serial #:
Date purchased:
Model #: Serial #:
Date purchased:
Model #: Serial #:
Date purchased:
Model #: Serial #:
Date purchased:
Before You Begin
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Discovery Series Plate Loaded Line Owner's Manual: Maintaining Your Plate Loaded Equipment 5
Precor recommends implementing a thorough maintenance program that
incorporates regular safety inspections by qualified maintenance technicians
as outlined in this manual.
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, contact Precor Customer
Support.
Precor recommends that maintenance technicians thoroughly read and
understand the safety guidelines and maintenance procedures covered in this
manual.
Important: Always purchase replacement parts and hardware from Precor. Many
parts are tested and manufactured specifically for Precor commercial strength
equipment. If you use parts not approved by Precor, you could void the Precor
Limited Warranty. Use of parts not approved by Precor may cause injury.
Daily Maintenance
Perform the following tasks daily to maintain the equipment and keep it
operating smoothly:
Clean upholstery
Inspect upholstery pads for wear
Clean and inspect frames
Check warning and instructional labels
Clean Upholstery
To remove surface dirt and perspiration, spray upholstery daily with a mild
soap and water solution. 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.
Inspect Upholstery 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, spray the frames daily with a mild soap and water
solution. Wipe the equipment down with a damp cloth and dry completely. Be
sure to wipe down both painted parts and chrome or plated parts. As you
clean, inspect the frames for cracks, rust, or other damage. Make sure welds
are solid and fasteners are properly secured.
To restore and maintain the luster of chrome parts, use a commercial chrome
cleaner.
Maintaining Your Plate Loaded Equipment
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Discovery Series Plate Loaded Line Owner's Manual: Maintaining Your Plate Loaded Equipment 6
Check Warning and Instructional Labels
Inspect warning and instructional labels daily to 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).
Spray labels as needed with a mild soap and water solution, and dry
thoroughly with a soft cloth.
The following figure shows an example of an instructional placard assembly,
which contains labels for the name of the equipment and the workout
instructions.
Figure 1: Example instructional placard
Precor products come equipped with a number of standard warning labels. The
following two figures show sample warning labels you may see on the
equipment depending on the model and product line:
Figure 2: Warning label indicating
pinching hazard
Figure 3: General warning label
mounted on the equipment frame
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Discovery Series Plate Loaded Line Owner's Manual: Maintaining Your Plate Loaded Equipment 7
Weekly Maintenance
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.
Monthly Maintenance
Perform the following tasks monthly to maintain the equipment and keep it
operating smoothly:
Inspect frames and movement arms
Inspect the bearings and bushings
Check and lubricate the seat adjustment
Inspect all fasteners
Inspect Frames and Movement Arms
Inspect frames and movement arms monthly for proper function and integrity.
Inspect frames (particularly at the joints) for cracks, chipped paint, or rust. If
any cracks are found, take the equipment out of service immediately and have
a qualified maintenance technician repair it.
Touch up dings and chips with paint and replace any component at the first
sign of wear. You can order touch-up paint from Precor by calling Customer
Support.
To remove surface rust from the frame, rub lightly with a fine wet/dry
sandpaper or fine steel wool. Finish with Precor touch-up paint if needed.
Maintain paint luster with an application of a mild automotive wax product.
To maintain the powder coated, plated, 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 fingernail polish remover.
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Discovery Series Plate Loaded Line Owner's Manual: Maintaining Your Plate Loaded Equipment 8
Inspect the Bearings and Bushings
Each month, inspect the bearings and bushings for smooth operation. If
bearings or bushings require replacement, please contact Customer Support.
Important: Bushing and bearing quality and specifications vary considerably so
please replace them with Precor approved hardware specifically engineered for the
precise application. Failure to do so will void the Precor Limited Warranty.
Check and Lubricate the Seat Adjustment
The seat adjustment mechanism requires little maintenance. However,
because seat safety is important to the safety of a workout, you should check
the seat lever regularly to see if it sticks when used.
To test if the seat lever needs lubrication, elevate the seat slightly while
pressing and releasing the lever. The lever should snap back out easily. If the
lever sticks, lubricate its pivot pin with a Teflon
®
spray lubricant. Wipe off any
excess lubricant with a cloth.
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.
Important: Fastener quality and specifications vary considerably so please replace
them with Precor approved fasteners specifically engineered for the precise
application. Failure to do so will void the Precor Limited Warranty.
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Precor Incorporated
20031 142nd Ave NE
P.O. Box 7202
Woodinville, WA USA 98072-4002
1-800-347-4404
Precor is a registered trademark of Precor Incorporated.
Copyright 2015 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.
Discovery Plate Loaded™ Line Owner’s Manual
CWP997777-111 rev C, en
16 April 2015
Page 13
Attaching the Weight Bar
The weight bar is packaged with the Smith Machine and must be attached
before use.
To attach the weight bar:
1. Latch safety stops in position 7 (see figure below).
2. Align the two brackets on the weight bar assembly with the linear
bearing housings on the base frames.
3. Make sure the stop screw is on the right hand side of the equipment
and below the bar.
WARNING The stop screw and tab must be in the position shown
below to ensure the machine functions properly.
4. Secure each bracket in place using two M12 × 30 mm socket head cap
screws and two M12 split washers. Alternate turning cap screws two
turns each until brackets are flush.
Component Quantity
Storage horn bumper 6
Weight bar assembly
includes stop screw and
retainer pin
1
Weight storage horn 6
The Smith Machine arrives partially assembled. Follow the instructions below to
complete the assembly. If you need to disassemble the equipment to move it, please
refer to the disassembly section of this guide before completing the assembly steps.
WARNING At least two people are required to assemble the equipment.
DO NOT attempt assembly by yourself.
Assembly Requirements
When assembling the equipment, we recommend you:
• Assemble the equipment close to where you plan to use it.
• 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.
• Assemble the equipment on a solid, flat surface, so that it remains level and
stable.
Important Before you wrench tighten a fastener, check that its head is flush with the
surface of the product. If not, cross-threading may have occurred. Do not attempt to
rework the assembly as more damage to the equipment will occur. Instead, contact
Customer Support at www.precor.com.
• Do not move the equipment without assistance.
Component Quantity
Socket head cap screw
(M12 × 30 mm)
6
Socket head cap screw
(M6 × 60 mm)
2
Split washer (M12) 6
End cap 1
Discovery™ Series Plate Loaded Line Smith Machine
Assembly Guide
Hardware Kit
• 19 mm open-end wrench
• 18 mm open-end wrench
• Torque wrench
• Rubber mallet
• 10 mm hex bit
• 6 mm hex bit
• 5 mm hex bit
Weight Bar
Weight
Storage
Horns
Base Frames
Adjustable
Foot
Right Side
Left Side
Adjustable
Safety
Stop
Adjustable
Safety
Stop
Linear Bearing
Housing
Upper Frame
5. Tighten the fasteners to 806 inch-pounds (91 newton-meters)
of torque.
6. Insert a retainer pin in the end of each weight bar.
Attaching the Weight Storage Horns
Repeat this procedure to attach all of the weight storage horns to the
equipment.
To attach a weight storage horn:
1. Insert the weight horn into the hole in the equipment frame until it stops.
If needed, use a rubber mallet to tap it gently into place.
2. Secure the weight horn using a M12 x 30 mm socket head cap screw
and M12 split washer. Torque to 806 in-lb (91 N-m).
3. Push the storage horn bumper into the weight horn with its wide side
facing outward. If needed, use a weight plate to push the bumper against
the equipment frame.
Weight storage horn attachment
Retainer pin installation
Required Tools
Position 7 and correct stop screw and tab locations
Tab location
and detail
Stop screw
location
Position 7
Bracket installation
Page 14
Stabilizing the Equipment
Once you have assembled the Smith Machine, test its stability by pushing
down on its corners. If the base frame rocks or wobbles, you need to adjust
the foot to stabilize it.
To stabilize the equipment:
1. Locate the round, adjustable foot at the lower back corner of the unit.
2. Using a 19 mm open-end wrench, turn the positioning bolt to the left or
the right to level the unit.
If you want to move
the adjustable foot ... Then turn the bolt ...
Upward To the right
Downward To the left
3. Continue to test the corners of the unit and
readjust the foot as needed.
4. Re-tighten the jam nut with an 18 mm
open-end wrench to 600 inch-pounds
(67.79 newton-meters).
5. Insert the frame end cap and secure it
using two M6 × 60 mm socket head
cap screws. Tighten the screws to
10 inch-pounds (1.12 newton-meters)
of torque.
Adjustable foot
End cap Installation
DPL Smith Machine Assembly Guide | P/N CW39173-113
, rev E
©2016 Precor Incorporated | June 2016
Bolting the Equipment to the Floor
Precor recommends that the strength equipment be bolted down at all
anchoring points. Bolting is made possible by removing the end caps at the
frame base and exposing the mounting holes that accommodate the bolts
(see the accompanying figure). Replace end caps when bolting is complete.
CAUTION Place the weight bar in the bottom (lowest) position before
bolting the machine to the floor.
Note The metal frame housing the adjustable
foot does not have an anchoring point.
Important As floor materials vary, it is important
that you consult a licensed contractor to
advise you on proper bolting techniques and
appropriate fastener types.
Standards occasionally change or are updated. Precor recommends that you keep
apprised of your local industry standards. Precor shall not be held liable for failure
to properly bolt the strength equipment to the floor.
Bolt down location
Disassembling the Smith Machine
If you need to move the Smith Machine, use the following procedure to disassemble and reassemble the equipment before attaching the weight bar and
weight horns.
WARNING At least two people are required to assemble the equipment. DO NOT attempt this procedure by yourself.
Step Procedure
Using a 10 mm hex bit, remove the bolts that attach the bar to the
equipment.
Using a rubber mallet, tap the bar to loosen it from the frame.
With assistance, set the machine on the floor.
Using a 6 mm hex bit, remove the access cover and then remove the
bolts and washers that connect the upper frame to the base frames.
Using a 6 mm hex bit, remove the bolts and washers that connect
the base frames to the upper frame.
Remove the upper frame from the base frames.
Move the equipment frame pieces to where you want to reassemble
the equipment.
Step Procedure
Position the upper frame so that the connections are properly
aligned with the base frames.
Using a 6 mm hex bit, connect the front base frame to the upper
frame using the bolts and washers previously removed.
Important DO NOT tighten the fasteners until instructed to do so.
Using a 6 mm hex bit, connect the upper frame to the back base
frame using the bolts and washers previously removed.
With assistance, set the equipment upright.
Torque all frame bolts to 265 inch-pounds (29.94 newton-meters).
Using a 6 mm hex bit, attach the two access covers to the frame.
Torque each bolt to 30 inch-pounds (3.38 newton-meters).
Note Take care not to drop the access cover into the tube.
Follow the procedures to attach the weight bar and horns, stabilize
the equipment, and bolt it to the floor.
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