EQUIPMENT ASSEMBLY PROCEEDURE

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1. According to your schedule, locate and identify the product that needs to be assembled.

2. Clock-in on your “Assembly Record” sheet.3. Move the product to the designated assembly area. If the item is difficult to move ask for assistance.

IMPORTANT NOTE: The designated assembly area should be clean and clear from any equipment, parts, garbage and

debris.

4. Inspect the box

a. If there is any damage to the box immediately note it on your “Assembly Record” sheet and notify amember of the management team. Make sure that the manager initials the section of the box condition.

While your manager is present with his/her help remove the item out of the box and inspect the conditionof the equipment. Layout parts on the blanket. If there is any damage to the equipment; indicate it in

your “Assembly Record” sheet and have your manager initial the sheet. At this point your manager will let

you know how to proceed with the installation.b. If there is no damage to the box note it on your “Assembly Record” sheet and proceed to the next step.

5. If the hardware (nut, bolts, etc…) are in a plastic bag and are not organized and numbered in a shrink wrap;organize the hardware by type and size as this will help ensure a faster and more efficient assembly process.

6. Check the hardware and parts provided against the manual to make sure that you have the right quantity and

correct parts and tools. If you are missing parts note it on your “Assembly Record” sheet and, immediately notifyyour manager and have him/her initial your “Assembly Record” sheet. At this point your manger or supervisor will

let you know how to proceed.

If a manager is not available at this stage do the following a. proceed with the installation if:

I. There are scratches on the unit.

II. Any hardware missing try to find replacement hardware from the scrounge box.b. Do not proceed with the installation if:

I. The damaged part must be replaced before the unit is fully assembled.II. The damage is too severe and the unit will not function properly once it is assembled.

If you come across any of above 2 circumstances that will prevent you from proceeding with your

assembly then go to the next task on your schedule.

7. Remove all parts and hardware from the box. Lay them on a blanket so they don’t get scratched.8. Remove the tools needed and required by the manufacturer for the installation out of your tool box and get them

ready. The type and size of tool needed to assemble the equipment is indicated in the manual. Some

manufactures use metric and others use standard. It is imperative that you use the correct size. Even though attimes you may think that you can interchange these tools, YOU SHOULD NOT.

9. Remove the parts out of the plastic wrapping and place the plastic wrappings and small Styrofoam pieces in thelargest bag that is included with the equipment to be discarded in the green trash bin at a later time.

IMPORTANT NOTE: Never USE or lose the tools provided by the manufacturer. Set the provided tools aside since the

customer is entitled to all the tools that came with the unit.

10. Always follow the assembly instructions step by step as provided by the manufacturer. Even if you are familiar

with the product still use the assembly instructions as a guide and follow the steps. For those who are veryfamiliar with the product you may find that after a while you will not be reading the steps but following the

diagram. However for those who do not have experience with the product please read the steps carefully.

11. If you are interrupted to receive a shipment or help a member or the team or a customer before leave yourassigned task of assembling clock-out on your “Assembly Sheet” and write down the reason prior to stepping

away to help.Do not forget to clock back in when you are done with the interruption(s).

12. Always lubricate the shafts, bushings and bearings with heavy grease.

13. Hand tighten all bolts until equipment is fully assembled then go back and tighten all the bolts.

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14. If you are installing bicycle pedals you must hand tighten the pedals all the way in and do not use a wrench to

tighten it until you have hand tightened it all the way. This method will prevent cross threading. If crossthreaded, the crank arm must be replaced and this is something that can easily be prevented.

15. Any bolt that is not secured with a nylock nut should have blue loctite applied to it.16. Before installing the cosmetic shroud covers test the equipment to make sure that you do not have to adjust

anything. The reason for this is because if you put the covers on first then you may have to remove them to

make adjustment during the testing period. This would be a waste of time.17. Testing procedure is as follows:

a. Adjust the tension level to its highest while using the equipment. Increase the tension one at a time andobserve to see if the unit responds. Then lower the tension level to its lowest.

b. If the unit is a treadmill adjust the elevation level following the same pattern as the tension adjustmenttest.

c. If the unit is an elliptical trainer with an incline feature or adjustable stride, adjust the unit following the

same pattern as the tension adjustment test.d. Check the heart rate grip sensors. Hold the sensors for at least one minute and the reading should be

pretty constant. If the reading is erratic (for example jump from 80 to 120 back down to 75 up to 140etc…) or no reading at all then there is a problem.

e. If there is a problem with the unit do not proceed to repair but notify your manager to receive further

instructions on how to proceed.

18. After testing the unit, if the unit is in fully functional condition, then install the cosmetic shroud covers.19. Handle the instruction manual, factory tools, assembly instruction, power supply or cord, chest strap(if supplied

by the manufacturer) in the following manner:a. If it is the customer’s unit place them in a plastic shopping bag and hang them off of the unit.

b. If it is for the showroom them place the manual in a zip loc bag and file it in the green military filing

cabinet alphabetically in the warehouse.20. Stick the sticker “This product was proudly assembled by________________” in a straight and neat fashion next

to the serial number section. The sticker should be placed in a way that it can stay on the machine permanently.

IMPORTANT NOTE: Your assembly is not completed until you have put away your tools and handled the trash

properly

21. Plastic bags and small Styrofoam should be placed in the green metal trash bin (dumpster).22. Large Styrofoam should be placed in the Styrofoam bin.

a. These bins are generally made out of oversized equipment boxes. If there is no Styrofoam bin in the backthen find an empty equipment box and use it as a Styrofoam bin.

b. If you don’t find an empty equipment box open one of the boxes that has a little bit of Styrofoam in it anduse the box as a Styrofoam bin and only seal the box if it is full and write full on the box with a sharpie and

seal it.

23. If the equipment box is empty then break the box down and fold it and place it in the break down box bin.

These bins are generally made out of oversized equipment boxes. If there is no break-down box bin in the back thenfind an empty equipment box and use it as a breakdown bin.

24. Place all the tools back in the tool box in their appropriate storage provided by each tool manufacturer.

25. At this stage you are done with assembly, congratulations, now the only thing is left is to clock out on your“Assembly Record” and move on to your next assignment.

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ALLOTTED ASSEMBLY TIME FRAMES

Bikes: 1 hour

Treadmills: 1 Hour Ellipticals: 1 Hour

Rowers: 45 minutes Free-weight benches and racks: 30 minutes to 45 minutes

1 stack weight equipment: 2 to 2.5 hours with 2 technicians

4 to 5 hours with 1 technician Bowflex Extreme2 1 hour 45 minutes with 2 technicians

2.5 hours with 1 technician Bowflex Ultimate2 & Revolution 2 hours with 2 technicians

3 hours with 1 technician 2 stack weight equipment 3 to 3.5 hours with 2 technicians

4.5 to 5 hours with 1 technician

3 stack weight equipment 4.5 to 5 hours with 2 technicians 5.5 to 6 hours with 1 technician

4 stack weight equipment 6.5 to 7 hours with 2 technicians 8 to 9 hours with 1 technician

These timeframes have been allotted by considering the following: a) The technician is following All Around Fitness installation procedures

b) The technician has and is using a complete and authorized All Around Fitness tool box.c) The technician is not an experienced technician however is mechanically and electronically inclined.

d) We have buffered the timeframes by 10 to 15 minutes per cardio machines and 30 to 45 minutes for weight equipment for a novice technician.

e) We have not accounted for errors made by the technician during the assembly process.

f) We subtract interruptions from the total time spent assembling. g) Repair time is not included. If you are instructed to repair the equipment that you just assembled then

you would need to fill out a standard “Work Order” or a manufacturer’s work order for that work. There are specific timeframes allotted for repair procedures as well.

I ___________________________hereby acknowledge that I have completed my training period, all my questions and concerns have been addressed during the training period, have read and understood what is expected of me in regard to equipment assembly procedure and all my questions and concerns have been addressed by the All Around Fitness management team.

Signature________________________

Please Print______________________

Date________________