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Inside the Box

5 Easy Tips to Ensure Successful Fitness Equipment Assembly!

Posted by Christine Dennigan on Jul 27, 2017 10:00:00 AM




Do you feel like you are drowning in nuts and bolts? Not sure where to begin? Save your energy for the workout - we have collected some installation tips to get you pointed in the right direction!

1. Four Hands Are Better Than Two:

Moving and assembling Fitness Equipment can be a challenge! Having a second person on site to help out can make the process much easier. Many of the models being sold today weigh between 200 and 300lbs. If you have to move your equipment from one room to another, prior to assembling it, it's a good idea to have someone on hand to help carry or wheel the unit into place. Even though the unit is not assembled, there may still be large sections in the box that prove difficult to lift without assistance.

  • Choose the shortest, easiest path to move it with ample space around you.
  • If you are planning to unpack the unit and carry it in pieces, you may want to wrap the larger pieces with a blanket or something soft to protect it while moving it.
  • If your machine has transport wheels on it and you plan to roll it into place, you may want to put a protective layer over your floor, such as cardboard or a thin blanket.

Additionally, have your helper assist you with holding parts of the unit together while you assemble. It is much easier to ensure that parts are flush and evenly connected if one person can hold the pieces together while the other person connects them with hardware.

2. Organize and Take Inventory of All Parts:

When opening up your Fitness Equipment, the first step to organizing the assembly process is to check that you have all of the required parts and tools. Sorting the parts out and knowing what's what can really help to eliminate excess time and confusion later. Unpack your machine carefully, using caution not to cut too deeply into the box when opening it. Make sure you some space around you wherever you choose to assemble your product.

Locate the assembly manual and head on over to the parts list inside. Unpack and lay out all parts of the machine and check them against the parts list to be sure that you recognize what each part is and account for everything that should be included in the box. Try to keep hardware in it's package until you are ready to start assembling, so that nothing gets lost.

3. Avoid Pinching Wires:

One of the most common mistakes that a customer can make when assembling is to accidentally pinch wires while connecting parts of the machine. Damaging wires or cables can prevent your equipment from functioning properly. This applies mainly to Cardio machines, such as Treadmills, Ellipticals, Exercise Bikes, etc.


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Cables that connect parts of your machine to the console are often fed through sections of the machine, such as the uprights, or support that holds the console. There may be cables running from the console through the handles on your machine to a heart rate monitor or other accessories as well. When connecting sections that have cable running through them, be sure to carefully tuck the cable inside and not to leave any part of it exposed, where it can get caught between the sections as you are connecting them. In addition, try to push the cable away from any holes where you will be inserting hardware to connect sections of your machine together. This will ensure that the cables are not pinched or crimped in any way during installation.

4. Calibration is Key:

Once you have assembled your machine and checked to make sure that everything is stable and all hardware is tight, it's hard to resist jumping on and diving into a workout! However, make sure to check your assembly manual and verify whether your machine requires any calibration before you use its features. Many machines need to be calibrated before they will correctly display features such as work out time, resistance, incline / decline, etc.

Some newer consoles that have touch screens also need to be calibrated to ensure that the screen will correctly sense and respond to your touch. Calibration is usually quick and easy to do. If your machine requires calibration, the assembly manual will provide instructions on how to do this immediately following the assembly instructions. Calibrating your machine will verify that the console is accurately sensing and controlling the features of the machine. So, for example, that when you increase your resistance from Level 1 to Level 2, you don't want it to feel like you are actually on Level 6! Calibrating the machine should only take a few minutes and will ensure that the resistance, speed levels and incline / decline features will all function properly, among other things.

5. Test Your Equipment:

Your machine is assembled and you are ready to begin using it! The best thing to do once it is ready to use is to test it out and make sure that all features and parts of the machine are working correctly. You want to identify any potential issues immediately. Review your assembly manual for instructions on how to get started using the machine in Quick Start Mode. This will allow you to jump on and start working out without having to select a specific program or enter personalized information.

Once you are ready, start using the machine and try out all of the features and accessories to make sure everything is up and running correctly. Increase the speed levels to their maximum and then reduce back down to minimum speed. Repeat this test with incline / decline, resistance, etc. Test out any accessories that you may have, such as a heart rate monitor, speaker connections, wifi and more. If you do encounter any issues with the machine, the assembly manual will provide contact information for the manufacturer so that you can call and find out how to resolve the problem. Once you have verified that all features are working properly, you are ready to enjoy your machine to the fullest!

If you enjoyed our tips, download our complete guide for Fitness Equipment Assembly here:

 Download Our Assembly Guide


Topics: Fitness Equipment Installation

Putting It All Together

American Direct Logistics specializes in product assembly for products ranging from fitness equipment and medical devices to furniture and recreational products for the home, business or retail setting. We are experts on the products you love and how they compliment your lifestyle!  

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