The DP Dual Trac 20 is a classic home multi-gym that was a staple of many 90s home gyms. If you've just picked one up secondhand or moved it out of storage, putting it back together can feel like a massive puzzle.
Below is a guide to getting your Dual Trac 20 fully functional, including where to find that elusive manual and tips for a safe assembly. 🛠️ Assembly Prerequisites Before you start turning bolts, gather these essentials:
Space: You need an area of at least 69 x 96 x 38 inches for the full unit.
Tools: A socket set (especially a 9/16 key or wrench), an Allen wrench set, and a rubber mallet.
Surface: Assemble on a flat surface. Using rubber flooring or a gym mat underneath is highly recommended to protect your floor and stabilize the machine. 🏗️ Step-by-Step Assembly Guide
While the original PDF can be hard to track down, the assembly flow for DP (Diversified Products) units generally follows this sequence:
The Base Frame: Lay out the bottom stabilizers and attach the main floor frame. Do not fully tighten these bolts until the uprights are in place.
Weight Stack Uprights: Slide the two main vertical poles through the bottom piece. These will eventually hold your weights.
Weight Plates: Slide the weight plates onto the rods. Crucial: Ensure the pin holes are facing forward so you can actually change the weight once it's built.
The Main Post & Top Bar: Install the vertical main post and the top horizontal bar. This "cages" the weight stack and provides the mounting point for the pulleys.
Pulleys & Cables: Thread the cables through the pulleys. This is the trickiest part—ensure the cables sit deep in the pulley grooves to prevent fraying. Assembly Instructions Dp Dual Trac 20 Manual Pdf
Attachments: Connect your "butterfly" arms, bench press bar, and lat pull-down bar using the provided pins and spring-loaded clips. Where to Find the Manual PDF
Since DP is no longer in production, you’ll need to rely on archives:
Sears PartsDirect: Search for model #15-7000. They host diagrams and parts lists that are often more helpful than a text-only manual.
Fitness Repair Parts: You can find specific cable assembly diagrams and pulley guides here.
Manualslib / Yumpu: These sites often have user-uploaded versions of "DP Trac 20" or "Dual Trac 20" instructions. ⚠️ Safety Checklist
Inspect Cables: Look for fraying or cracking in the plastic coating; if you see wire, replace it immediately.
Bolt Check: After your first few workouts, re-tighten every bolt. Vibration can loosen them during the "settling" phase.
Lubrication: Apply a small amount of silicone lubricant to the weight stack guide rods for smooth movement.
💡 Pro Tip: If you're missing a specific bolt, take an existing one to a local hardware store. These machines typically use standard Grade 5 hardware that is easy to replace.
If you have a picture of a specific part or a loose cable you can't figure out, let me know—I can help you narrow down where it fits! DP Dual Trac 20 | Facebook Marketplace - Facebook The DP Dual Trac 20 is a classic
The DP Dual Trac 20 is a versatile multi-gym system designed to provide over 40 exercises
for major muscle groups without requiring frequent cable changes. This guide details the assembly process based on the standard configuration for this "Fit for Life" model. 1. Pre-Assembly Preparation Clear Space : Ensure you have a flat surface area of at least 69 x 96 inches to accommodate the full size of the assembled unit. Tools Required : You will need a 9/16 wrench or key, an Allen wrench rubber mallet for fitting end caps. Inventory Check
: Verify all major components are present, including the base assembly, main frame, weight tubes, bench assembly, and various bars (rowing, lat, and bench press). Sears PartsDirect 2. Base and Main Frame Setup Assemble the Base
: Connect the bottom base tube assembly to the upright bars that will eventually hold the weight plates. Install End Caps
: Use a rubber mallet to secure the black end caps onto the base and frame poles. Attach Weight Rods : Secure the weight plate rods to the base using carriage bolts . Tighten these with a 9/16 wrench. Mount the Main Post
: Use carriage bolts and stabilizing plates to mount the central vertical post to the base. Secure these with lock nuts.
: Keep bolts hand-tight initially to allow for adjustment as you add more components. 3. Weight Stack Installation Orient Plates
: Slide the weight plates onto the support rods. Ensure the pin holes are facing and the weight labels (if applicable) face outward.
: Place the small top plate over the stack to secure the T-bars and prevent the weight post from being removed during use. Secure the Pin
: Insert the plate pin at an angle into the teeth and turn it downward to lock your desired resistance level. 4. Horizontal Bars and Pulley System Horizontal Bar [ ] All bolts torqued to spec
: Thread the horizontal bar through the designated holes in the main and secondary posts, ensuring they form a stable V-shape.
: Attach the top bar to the main posts using pre-threaded holes and Allen wrench bolts. This structure provides critical lateral stability. Cable Routing
: Thread the coated cables through the pulley system. Standard lengths for this model include 89.75-inch sections depending on the specific gym variant. 5. Attachments and Finishing Butterfly Arms
: Attach the arm pieces for pectoral exercises using the provided rods and lock nuts. Ensure even spacing on both sides to allow for smooth, "free play" movement without resistance. Bench and Padding
: Install the incline bench and leg lift assembly to the front of the main frame. Attach arm and seat padding using specific washers and bolts. Final Tightening
: Once all components are aligned, go back and fully tighten all carriage bolts and lock nuts to ensure a structurally sound, freestanding unit. Sears PartsDirect
For specific replacement parts or detailed diagrams, you can consult retailers like Sears Parts Direct Fitness Repair Parts 40+ exercises
compatible with the DP Dual Trac 20 to help plan your first workout? Official Lifestyler 15666-DUAL TRACK 20 weight system parts
These sites host thousands of discontinued product manuals. While they may charge a small fee for instant access, many PDFs are viewable for free in their browser-based reader.
Before first use, the manual requires you to verify: