Sears 831.159460 User Manual

USER'S MANUAL

Model No. 831.159460 Serial No.

CAUTION

Read all precautions and instructions in this manual before using this equipment. Save this manual for future reference.

PATENT PENDING

The serial number can be found in the location shown below. Write the serial number in the space above.

Serial Number Decal (under seat)

TABLE OF CONTENTS

FULL 90 DAY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

CABLE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

Note: A PART IDENTIFICATION CHART and a PART LIST/EXPLODED DRAWING are attached to the center of this manual. Remove the PART IDENTIFICATION CHART and the PART LIST/EXPLODED DRAWING before beginning assembly.

FULL 90 DAY WARRANTY

For 90 days from the date of purchase, if failure occurs due to defect in material or workmanship in this SEARS WEIGHT SYSTEM EXERCISER, contact the nearest SEARS Service Center throughout the United States and SEARS will repair or replace the WEIGHT SYSTEM EXERCISER, free of charge.

This warranty does not apply when the WEIGHT SYSTEM EXERCISER is used commercially or for rental purposes.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

SEARS, ROEBUCK AND CO., DEPT. 817WA, HOFFMAN ESTATES, IL 60179

1. Read all instructions in this manual and in the accompanying literature before using the home gym system.

2. It is the responsibility of the owner to ensure that all users of the home gym system are adequately informed of all precautions.

3. If you feel pain or dizziness at any time while exercising, stop immediately and begin cooling down.

4. Use the home gym system only on a level surface. Place a mat beneath the home gym system to protect the floor or carpet.

5. Inspect and tighten all parts often. Replace any worn parts immediately.

6. The home gym system is designed to be used by only one person at a time.

7. Keep small children and pets away from the home gym system at all times.

8. Keep hands and feet away from moving parts.

9. Always wear athletic shoes for foot protection.

10. Always stand on the foot plate when performing an exercise that could cause the home gym system to tip.

11. Never release the press arm, butterfly arms, leg lever, lat bar, or nylon strap while weights are raised. The weights will fall with great force.

12. Make sure that the cables remain on the pulleys at all times. If the cables bind while you are exercising, stop immediately and make sure that the cables are on all of the pulleys.

13. Al

ways disconnect the lat bar from the home

gym system when perf

orming an exercise

that does not use the lat bar

IMPORTANT PRECAUTIONS

WARNING:To reduce the risk of serious injury, read the following important precautions before using the home gym system.

WARNING: Before beginning this or any exercise program, consult your physician. This is especially important for persons over the age of 35 or persons with pre-existing health problems. Read all instructions before using. SEARS assumes no responsibility for personal injury or property damage sustained by or through the use of this product.

ASSEMBLED DIMENSIONS: Height: 74 in. Width: 40 in. Length: 58 in.

Foot Plate

Low Pulley Station

High Pulley Station

Lat Bar

Leg Lever

Vertical Knee Raise (VKR) Arm

Butterfly Arms

Curl Pad

Curl Frame

Curl Bar

Press Arm

Weight Stack

Backrest

Weight Pin

Seat

BEFORE YOU BEGIN

Thank you for selecting the versatile SEARS LIFESTYLER®SYSTEM 200 Home Gym System. The SYSTEM 200 offers a selection of weight stations designed to develop every major muscle group of the body. Whether your goal is to tone your body, build dramatic muscle size and strength, or improve your cardiovascular system, the SYSTEM 200 will help you to achieve the specific results you want.

For your benefit, read this manual carefully before using the LIFESTYLER®SYSTEM 200 Home Gym System. If you have additional questions, please call

our toll-free HELPLINE at 1-800-736-6879, Monday through Saturday, 7 a.m. until 7 p.m. Central Time (excluding holidays). To help us assist you, please note the product model number and serial number before calling. The model number is 831.159460. The serial number can be found on a decal attached to the SYSTEM 200 (see the front cover of this manual).

Before reading further, please review the drawing below and familiarize yourself with the parts that are labeled.

High Side of Bracket

Slotted Hole

1. Before beginning assembly, be sure that

you have read and understand the information in the box above.

Press a 2” Square Outer Cap (51) onto each end of the Stabilizer (5). Press a 2” Square Inner Cap (27) into the end of the Base (4).

Insert two 5/16” x 2 3/4” Carriage Bolts (14) up through the Stabilizer (5). Insert a 5/16” x 2 1/2” Carriage Bolt (1) up through the Stabilizer. Insert two 5/16” x 2 1/2” Carriage Bolts (1) up through the Base (4).

Slide the indicated end of the Base (4) onto the 5/16” x 2 3/4” Carriage Bolts (14) in the Stabilizer (5). Slide the Rear Upright (56) onto the Carriage Bolts. The high side of

the bracket on the Rear Upright must be on the side shown. Hand tighten a 5/16”

Nylon Locknut (3) onto each Carriage Bolt.

Do not tighten the Nylon Locknuts yet.

Slide the end of the Brace (88) with the round hole onto the 5/16” x 2 1/2” Carriage Bolt (1) in the Stabilizer (5). Hand tighten a 5/16” Nylon Locknut (3) onto the Carriage Bolt. Attach the end of the Brace with the slotted hole to the Rear Upright (56) with a 5/16” x 2 3/4” Bolt (11), a 5/16” Flat Washer (8), and a 5/16” Nylon Locknut (3). Do not

tighten the Nylon Locknuts yet.

FRAME ASSEMBLY

ASSEMBLY

Before beginning assembly, carefully read the following information and instructions:

• Assembly requires two people. Due to the size

and weight of the SYSTEM 200, it should be assembled in the location were it will be used.

• Place all parts of the SYSTEM 200 in a cleared

area and remove the packing materials; do not dispose of the packing materials until assembly is completed.

• The assembly is divided into five stages: 1) frame assembly, 2) press and butterfly arm assembly,

3) cable and pulley assembly, 4) seat and backrest assembly, and 5) VKR assembly. The hardware for each stage is packaged separately.

• Wait until you begin each assembly stage to open that parts bag.

• As you assemble the SYSTEM 200, be sure that all parts are oriented as shown in the drawings.

• For help identifying the small parts used in

assembly, use the PART IDENTIFICATION CHART located at the center of this manual.

• Tighten all parts as you assemble them, unless

instructed to do otherwise.

THE FOLLOWING TOOLS (NOT INCLUDED) ARE REQUIRED FOR ASSEMBLY:

• Two (2) adjustable wrenches

• One (1) standard screwdriver

• One (1) phillips screwdriver

• One (1) rubber mallet

• Lubricant, such as grease or petroleum jelly, and soapy water will also be needed.

Assembly will be more convenient if you have the following tools: A socket set, a set of open-end or closed-end wrenches, or a set of ratchet wrenches.

2. Slide the Front Upright (42) onto the 5/16” x 2 1/2” Carriage Bolts (1) in the Base (4). Hand tighten a 5/16” Nylon Locknut (3) onto each Carriage Bolt. Do not tighten the Nylon

Locknuts yet.

Press a 1” Square Inner Cap (65) into the Front Upright (42).

Press 1” Round Inner Cap (49) into each end of the Footrest (83). Attach the Footrest to the Rear Upright (56) with a 5/16” x 2 3/4” Bolt (11), two 5/16” Flat Washers (8), a 1/2” x 1/2” Bushing (87), and a 5/16” Nylon Locknut (3).

3. Press a 2” Square Inner Cap (27) into the indicated end of the Top Frame (55). Press a 1 3/4” Square Inner Cap (44) into each end of the crossbar on the Top Frame. Press two 1” Round Inner Caps (49) into the top of the crossbar.

Attach the Top Frame (55) to the Front Upright (42) and the Rear Upright (56) with four 5/16” x 2 3/4” Bolts (11), four 5/16” Flat Washers (8), and four 5/16” Nylon Locknuts (3).

Tighten all Nylon Locknuts used in steps 1 through 3.

4. Set two Weight Bumpers (19) on the indicated bracket on the Base (4) as shown.

Stack eight Weights (25) on the Weight Bumpers (19). Be sure that all of the

Weights are turned so the deepest pin grooves are under the Weights and are on the indicated side.

FRAME ASSEMBLY

Crossbar

Pin Grooves

5. Press the Weight Tube Bumper (64) into the end of the Weight Tube (63). Insert the Weight Tube into the stack of Weights (25). Be sure

that the pins on the Weight Tube are sitting in the pin grooves in the top Weight.

Lubricate the insides of the holes in the Top Weight (76). Set the Top Weight on the stack of Weights (25).

Insert both Weight Guides (62) into the stack of Weights (25). Be sure that the indicated

holes in the Weight Guides are at the top.

6. Attach the upper ends of the Weight Guides (62) to the Top Frame (55) with the 5/16” x 6” Bolt (60), two 1/2” x 3/4” Spacers (61), and a 5/16” Nylon Locknut (3).

Be sure that the Pulley Bracket (20) is in front of the right Weight Guide (62) as shown.

7. Press a 1” x 7/8” Plastic Bushing (75) onto each welded spacer on the Press Frame (17). Slide the Press Frame into place on the Base (4). Note: This will be a tight fit. The Plastic

Bushings should fit on each end of the indicated tube in the Base. Be sure that the 3 1/2” Pulleys (15) are on the indicated side.

Lubricate the 3/8” x 8” Bolt (59). Attach the Press Frame (17) to the Base (4) with the 3/8” x 8” Bolt and a 3/8” Nylon Locknut (21).

Holes

Lubricate

Tube

FRAME ASSEMBLY

ARM ASSEMBLY

Lubricate

Welded Spacers

ARM ASSEMBLY

8. Wet the handle of one Press Arm (46) with soapy water. Slide a Hand Grip (31) onto the handle. Press a 1” Round Inner Cap (49) into the other end of the handle. Press a 1 3/4” Square Inner Cap (44) into the Press Arm.

Attach the Press Arm (46) to one side of the Press Frame (17) with two 5/16” x 2 1/2” Bolts (22) and two 5/16” Nylon Locknuts (3).

Assemble the other Press Arm (46) in the same manner.

9. Identify the Right Arm (48) and the Left Arm (47). Note the position of the welded brack-

et on each Arm. Arm identification is very important for step 10.

Attach a “V”-Pulley (6) and a Long Cable Trap (50) to the Right Arm (48) with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21).

Attach a “V”-Pulley (6) and a Long Cable Trap (50) to the Left Arm (47) in the same manner.

10. Lubricate both axles on the Top Frame (55).

Slide the Right Arm (48) onto the right axle.

Note: Be careful not to confuse the Right Arm with the Left Arm (47); refer to step 9 to identify the Right Arm. Be sure that the upper end of the Right Arm is behind the indicated bracket on the Top Frame (55).

Tap two 1” Retainers (69) and a 1” Round Cover Cap (70) onto the right axle. Be sure

that the teeth on the Retainers bend toward the Cover Cap, as shown in the inset drawing.

Attach the Left Arm (47) in the same manner.

Press 1 3/4” Square Inner Caps (44) into the lower ends of the Right and Left Arms (47,

48). Wet the lower end of each Arm with soapy water. Slide a 10” Pad (45) onto the lower end of each Arm.

Welded Brackets

Lubricate Axle

Bracket

CABLE ASSEMBLY

11. During steps 11 through 27, refer to the CABLE DIAGRAM on page 22 of this manual to verify proper cable routing. Before beginning this section, identify the Long Cable (23), the Medium Cable (58), and the Short Cable (35) by comparing the lengths and ends of the cables.

IMPORTANT: While assembling the cables, do not overtighten the bolts and nuts attaching the pulleys. The pulleys must be able to turn freely.

12. Locate the Long Cable (23). Route the Long Cable around the indicated 3 1/2” Pulley (15) attached to the Top Frame (55). Be sure that

the end of the Cable with the ball is on the indicated side of the Pulley and that the Cable is between the Pulley and the hook.

Tighten the 3/8” x 3 3/4” Bolt (71) and the 3/8” Nylon Locknut (not shown).

13. Wrap the Long Cable (23) around a “V”-Pulley (6). Attach the “V”-Pulley and a Long Cable Trap (50) to the indicated bracket on the Front Upright (42) with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21). Be sure that the

Long Cable Trap is positioned to hold the Cable in place.

14. Route the Long Cable (23) around the “V”Pulley (6) on the Left Arm (47). Be sure that

the Cable is in the groove of the Pulley and that the Long Cable Trap (50) is positioned to hold the Cable in place. Tighten

the 3/8” x 2 1/2” Bolt (7) and the 3/8” Nylon Locknut (not shown).

Hook

Ball

+ 19 hidden pages