Objective: Create a stable base that won’t rock.
Why this matters: A twisted base will cause the guide rods to bind. Use a carpenter’s level.
After routing and attaching handles, you must set correct cable tension.
Final tension test: With 20 lbs on the weight stack (or 20 lbs of plates), the carriage should return to its top position within 1 second when released.
This is where most people get stuck. The DP Dual Trac 20 uses a dual-cable system (left and right independent or linked via a center bracket). We’ll describe the independent dual-pulley routing (standard).
| Part | Quantity | Description | |------|----------|-------------| | Base stabilizer (front) | 1 | Long, with rubber feet | | Base stabilizer (rear) | 1 | Shorter, with weight stack footprint | | Left vertical upright | 1 | Marked “L” near bottom | | Right vertical upright | 1 | Marked “R” near bottom | | Top crossmember | 1 | Contains upper pulleys | | Pull-up bar | 1 | Knurled or rubberized grip | | Weight plate holders (if selectorized) | 2 | Chrome posts |
DP Products Support
Web: www.dpproducts.com/support
Email: dualtrac@dpproducts.com
Phone: 1-800-555-TRAC (8722)
For warranty claims, retain original packaging and proof of purchase.
End of Full Assembly Instructions – DP Dual Trac 20
The DP Fit for Life Dual Trac 20 (often referred to as the DP Trac 20) is a classic 1990s multi-gym system known for its variable resistance and multi-functional attachments. Assembling this vintage unit requires careful attention to the frame "skeleton" before moving to the complex pulley and arm systems. Essential Preparation
Required Tools: You will need a 9/16" wrench or socket for the main carriage bolts. A rubber mallet is helpful for seating end caps.
Space: Ensure a clear area of at least 69 x 96 inches for the full assembly.
Inventory: Verify you have the base tubes, main uprights, weight stack/rods, butterfly arms, and the bench assembly. Step-by-Step Assembly Guide 1. Base and Main Frame Skeleton
Bottom Piece: Lay the bottom frame piece flat. Attach the two upright bars that will eventually hold the weight plates.
Stability: Secure these bars to the bottom piece using two carriage bolts. Use a 9/16" wrench to tighten, but leave them slightly loose until the main post is mounted to allow for adjustment.
Main Post: Mount the main vertical post using carriage bolts and stabilizing plates. Secure these with lock nuts. 2. Support and Weight Rods dp dual trac 20 assembly instructions full
V-Shape Formation: Install the horizontal bar through the main and newly installed posts. It is crucial that these posts form a V-shape for structural integrity.
Weight Stack: Slide the weight plates onto the rods. Ensure the pin holes face forward and the larger holes face outward.
Top Plate: Place the small top plate over the weight stack to secure the post and prevent removal. 3. Top Bar and Structural Soundness
Connection: Attach the top bar to the two main posts using pre-threaded holes and bolts.
Alignment: Use Allen wrench bolts on the top bar to pull the vertical poles into the final correct position. Once these are tightened, the main frame is structurally sound and you can go back to fully tighten the base bolts. 4. Dynamic Arm Attachments
Butterfly/Bench Arms: Attach the swinging arm pieces using the provided rods, bolts, and nuts. It is vital to screw these in evenly on both sides so the gaps remain uniform.
Free Play: Ensure there is a small amount of "free play" in the swinging arms; over-tightening can create unwanted resistance and friction.
Padding: Secure the arm paddings using specific #50 bolts and #61 washers. 5. Bench and Leg Extension
Bench Mounting: The incline bench usually attaches via spring-loaded pins for easy removal or adjustment.
Leg Lever: Attach the leg lift assembly to the front of the bench or main frame as indicated by your specific model (e.g., Model #15-7000). Maintenance & Safety Tips
Bolt Check: Re-check and tighten all frame and pivot bolts after your first few workouts, as they may settle.
Cable Care: Inspect the extension cables regularly for fraying. If you ever need to replace them, parts are often sourced through FitnessRepairParts.com or Sears Parts Direct.
Lubrication: Periodically grease the pivot points to ensure smooth movement.
Are there any specific attachments or cable routing paths you're having trouble with? Fitness Gear Assembly DIY Step By Step Guide
DP Dual Trac 20 Assembly Guide: Step-by-Step Instructions The DP Dual Trac 20 is a versatile piece of fitness equipment designed to provide a full-body workout using a unique cable-and-pulley system. While it's built to last, getting it from the box to your first workout can be a bit intimidating. Objective: Create a stable base that won’t rock
This guide breaks down the assembly process into clear, manageable steps to ensure your machine is safe and ready for use. Before You Start: Preparation
Space: Clear a flat, level area at least 8' x 6' for assembly and operation.
Tools: You will need two adjustable wrenches (or a socket set) and a Phillips head screwdriver.
Inventory: Open all boxes and lay out the parts. Cross-reference them with the parts list in your manual. Ensure all nuts, bolts, and washers are accounted for. Step 1: The Main Frame & Base
Stabilizers: Attach the front and rear stabilizers to the main base frame. Use the long carriage bolts provided, ensuring the curved ends of the stabilizers face outward for maximum stability.
Upright Support: Position the main upright mast onto the base frame. Secure it using the hex bolts and flat washers. Pro Tip: Tighten these bolts only finger-tight until the entire frame is assembled to allow for alignment adjustments. Step 2: The Seat and Rail System
Seat Rail: Slide the seat onto the chrome seat rail. Ensure the rollers are seated properly in the grooves.
Attachment: Connect the seat rail to the main upright mast and the rear stabilizer. Use the hitch pins or bolts as specified by your specific model revision.
Foot Plates: Attach the pivoting footplates to the front of the frame. Ensure the straps are facing upward. Step 3: The Pulley and Arm System
This is the most critical part of the assembly for smooth operation.
Swivel Arms: Attach the two "Dual Trac" swivel arms to the top of the main mast.
Pulley Housing: Install the pulley wheels into the bracket housings. Ensure the plastic spacers are placed on either side of the wheel to prevent grinding.
Tension Knobs: Thread the resistance adjustment knobs into the arm joints. Step 4: Cable Routing (The "Tricky" Part) The Dual Trac uses a continuous loop system.
Start at the Handles: Feed the cable through the end of the swivel arm.
Internal Routing: Guide the cable over the top pulley, down through the center of the mast, and around the lower base pulley. Why this matters: A twisted base will cause
Connection: Bring the cable back up to the weight carriage or resistance stack.
Check for Kinks: Before tightening anything, pull the handles to ensure the cable moves freely without rubbing against the metal frame. Step 5: Final Calibration
Tighten All Hardware: Now that the frame is aligned, go back and tighten every bolt with your wrenches.
Test Resistance: Adjust the tension knobs from the lowest to the highest setting to ensure the friction pads or magnetic resistance (depending on your specific model) engage correctly.
Lubrication: Apply a small amount of silicone lubricant to the seat rail and the chrome swivel arms for a whisper-quiet workout. Safety Checklist Bolt Check: Ensure no bolts are "floating" or loose.
Cable Integrity: Look for any fraying in the nylon coating of the cables.
Leveling: If the machine wobbles, check your floor level or adjust the end caps on the stabilizers. Maintenance Tips
Monthly: Re-tighten bolts, as vibration from use can loosen them over time.
Cleaning: Wipe down the seat and handles after every workout to prevent perspiration from corroding the finish.
Objective: Connect the uprights and add the pull-up station.
Inspection: Pull gently on the crossmember. It should not shift or creak.
To keep your DP Dual Trac 20 operating like new for a decade:
Weekly:
Monthly:
Quarterly:
Annually:
Lay out all parts. Check for shipping damage, especially on the dual track rails. Remove any protective film.