Weider 831.154021 User Manual

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Page 1

Model No. 831.154021 Serial No.

Write the serial number in the space above for reference.

Serial Number Decal (under seat)

WEIGHT SYSTEM EXERCISER

User's Manual

, Assembly

, Adjustments , Troubleshooting , Part List and Drawing

Patent Pending

,_CAUTION

Read all precautions and instruc- tions in this manual before using this equipment. Save this manu-

al for future reference.

Sears, Roebuck and Co., Hoffman Estates, IL 60179

Page 2

TABLE OF CONTENTS

WARNING DECAL PLACEMENT ............................................................. 2

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

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

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

ADJUSTMENTS .......................................................................... 23

WEIGHT RESISTANCE CHART .............................................................. 25

CABLE DIAGRAM ......................................................................... 26

MAINTENANCE .......................................................................... 28

EXERCISE GUIDELINES .................................................................. 29

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

FULL 90-DAY WARRANTY .......................................................... Back Cover

Note: A PART IDENTIFICATION CHART and a PART LIST/EXPLODED DRAWING are attached in the center of this manual. Remove the PART IDENTIFICATION CHART and PART LIST/EXPLODED DRAWING before begin- ning assembly.

WARNING DECAL PLACEMENT

The decal shown here

has been placed on the weight system, if the decal is missing or illegi=

hie, please call toll=free

1=877=992=5999, Monday through Friday, 6 a.m.

until 6 p.m. Mountain Time, and order a free

replacement decal. Apply the decal in the location

shown.

•Misuseofthis product may resultin serious

injury.

• Readuser's manual and follow all warnings

and operating instruc- tions prior to use.

• Donot allow children on or around machine.

• Replacelabel if damaged, illegible,or

removed.

Page 3

iMPORTANT PRECAUTIONS

kWARNING: To reduce the risk of serious injury, read the following important precautions

before using the weight system.

1. Read all instructions in this manual before

using the weight system. Use the weight sys- tem only as described in this manual.

2. it is the responsibUity of the owner to ensure that all users of the weight system are ade-

quately informed of all precautions.

3. The weight system is intended for home use only. Do not use the weight system in any commercial, rental, or institutional setting.

4. Use the weight system only on a level sup face. Cover the floor beneath the weight sys- tem to protect the floor.

Keep the weight system indoors, away from 13. Always stand on the foot plate when per- moisture and dust. Do not put the weight forming an exercise that could cause the system in a garage or covered patio, or near weight system to tip.

water.

6. Make sure all parts are properly tightened

each time the weight system is used.

Replace any worn parts immediately.

7. Keep children under 12 and pets away from

the weight system at all times.

9. Always wear athletic shoes for foot protec- tion while exercising.

10. Keep hands and feet away from moving parts.

11. Make sure that the cables remain on the pul-

leys at all times, if the cables bind as you are exercising, stop immediately and make sure

that the cables are on the pulleys. Replace all cables at least every two years.

12. Always secure the weight stack with the lock pin and lock after exercising to prevent unauthorized use of the weight system (see LOCKING THE WEIGHT STACK on page 24).

14. Never release the arms, leg lever, lat bar, leg press, ab strap, or handle while weights are raised. The weights wUl fall with great force.

15. Always disconnect the lat bar from the

weight system when performing an exercise

that does not use the lat bar.

8. The weight system is designed to support a 16. if you feel pain or dizziness at any time while maximum user weight of 300 pounds, exercising, stop immediately and begin cool-

ing down.

WAR NING: 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.

Page 4

BEFORE YOU BEGIN

Thank you for selecting the versatile WELDER®PRO 4250 weight system. The weight system offers an impressive array of weight stations designed to devel- op 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 sys- tem, the weight system will help you to achieve the specific results you want.

For your benefit, read this manual carefully before using the weight system. If you have questions after

Right Side

High Pulley Station Butterfly Arm

Ab Pulley Station

reading this manual, call 1-800-4-MY-HOME ® (1-800-469-4663). To help us assist you, please note the product model number and serial number before calling. The model number is 831.154021. The serial

number can be found on a decal attached to the weight system (see the front cover of this manual for

the location of the decal).

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

labeled.

ASSEMBLED

DiMENSiONS: Height: 77 in.

Left Side

Width: 81 in.

Depth: 59 in.

Backrest

Press Arm

Seat

Leg Lever Low Pulley

Station

Foot

Note: The terms "right side" and "left side" are determined relative to a person sitting on a seat; they do not correspond to right and left on the drawings in the manual.

Weight

Stack

Press

Page 5

ASSEMBLY

Make Assembly Easier for Yourself

Everything in this manual is designed to ensure that the weight system can be assem- bled successfully by anyone. Before begi n= ning assembly, make sure to read the

information on this page. This brief intro- duction will save you much more time than

it takes to read it.

Assembly Requires Two Persons

For your convenience and safety, assemble the weight system with the help of another person.

Make sure you have the following tools:

* Two adjustable wrenches * One standard screwdriver _ 1_h

= One phillips screwdriver , One rubber mallet

, You will also need grease or petroleum jelly, a

small amount of soapy water, and clear tape or masking tape.

Note: Assembly will be more convenient if you have

a socket set, a set of open-end or closed-end wrenches, or a set of ratchet wrenches.

Set Aside Enough Time

Due to the many features of the weight system, the assembly process will require several hours. By setting aside plenty of time and by deciding to make the task enjoyable, assembly will go smoothly. You may want to assemble the weight system over

a couple of evenings.

Select a Location for the Weight System

Because of its weight and size, the weight system should be assembled in the location where it will be

used. Make sure that there is enough room to walk around the weight system as you assemble it.

How to Unpack the Box

To make assembly as easy as possible, we have divided the assembly process into four stages. The

parts needed for each stage are found in individual bags. important: Wait until you begin each stage

to open the parts bag for that stage. Place all parts of the weight system in a cleared area and

remove the packing materials. Do not dispose of the packing materials until assembly is completed.

How to Identify Parts

To help you identify the small parts used in assembly, we have included a PART IDENTIFICATION CHART

in the center of this manual. Place the chart on the

floor and use it to easily identify parts during each assembly step. Note: Some small parts may have

been pre-attached. If a part is not in the parts bag, check to see if it has been pre-attached.

How to Orient Parts

As you assemble the weight system, make sure all

parts are oriented exactly as shown in the drawings.

Tightening Parts

Tighten all parts as you assemble them, unless

instructed to do otherwise.

Questions?

If you have questions after reading these assembly instructions, please call 1-800-4-1VlY=HOME®

(1-800-469-4663).

The Four Stages of the Assembly Process

Frame Assembly--You will begin by assembling the base and the uprights that form the skeleton of the weight system.

Arm Assembly--During this stage you will assemble the arms and the leg lever.

Cable Assembly--During this stage you will attach the cables and pulleys that connect the

arms to the weights. Seat Assembly--During the final stage you will

assemble the seats and the backrests.

Page 6

Frame Assembly

Before beginning assembly, make sure you

understand the information in the box on page 5, See the PART iDENTiFiCATION CHART in the center of this manua ! f0r help

identifying small parts.

Insert four M8 x 75mm Carriage Bolts (69) up

through the Right Base (1). Note: It may be helpful to place a piece of tape over each bolt head to hold it in place.

Insert four M8 x 75mm Carriage Bolts (69) up through the Left Base (25). Note: it may be help= ful to place a piece of tape over each bolt head to hold it in place.

Attach the Right Base (1) to the Left Base (25) with two M8 x 78mm Bolts (82), two M8 Washers

(98), and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

Attach the Center Base (52) to the Right Base (1) with two M8 x 78mm Bolts (82), two M8 Washers (98), and an M8 Nylon Locknut (91). Do not tighten the Bolts yet.

Attach the Center Base (52) to the Left Base (25) in the same manner.

98 1

Page 7

See drawing A. Attach the Right Upright (2) to the Right Base (1) with the two indicated M8 x 75mm Carriage Bolts (69) and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

See drawing B. Attach the Left Upright (26) to the Left Base (25) with the two indicated M8 x 75mm Carriage Bolts (69) and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

Attach the Right Seat Frame (3) to the Right Base (1) with the two indicated M8 x 75mm Carriage Bolts (69) and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

Attach the Right Seat Frame (3) to the Right Upright (2) with an M8 x 78mm Bolt (82), an M8 x 96mm Bolt (83), an M8 Washer (98), and an M8 Nylon Locknut (91). Do not tighten the Locknut

yet.

Page 8

Attach the Left Seat Frame (27) to the Left Base (25) with the two indicated M8 x 75mm Carriage

Bolts (69) and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

Attach the Left Seat Frame (27) to the Left Upright (26) with two M8 x 78mm Bolts (82), two

M8 Washers (98), and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

Orient the Weight Guides (44) with the indicated holes closer to the bottom. Attach the Weight

Guides inside of the Center Base (52) with two M8 x 78mm Bolts (82), four M8 Washers (98),

and two M8 Nylon Locknuts (91).

25 91

.44

91 91

Hole

_98

Page 9

Slide two Weight Bumpers (45) onto the Weight Guides (44). Slide the eight Weights (55), with the

pin holes on the indicated side, onto the Weight Guides.

Press the Weight Tube Bumper (46) into the Weight Tube (47). Insert the Weight Tube into the

stack of Weights (55). Make sure the pin on the Weight Tube sits in the groove in the top

Weight.

Grease the indicated holes in the Top Weight (56) with an included grease pack. Slide the Top

Weight onto the Weight Guides (44).

Holes

10. Attach the Right Top Frame (5) to the Right Upright (2) with two M8 x 78mm Bolts (82), two M8 Washers (98), and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet. Make sure the Weight Guides (44) are behind the Right Top Frame.

11. Attach a Weight Guide (44) to the Right Top Frame (5) with an M8 x 78mm Bolt (82), two M8

Washers (98), and an M8 Nylon Locknut (91). Do not tighten the Locknut yet.

Repeat this step with the other Weight Guide (44).

98.

44-

5 i_98

-44

Page 10

12. Attach the Left Top Frame (36) to the Right Top Frame (5) with four M8 x 78mm Bolts (82), two

M8 Washers (98), a Support Plate (31), and four M8 Nylon Locknuts (91). Do not tighten the

Locknuts yet.

13. Attach the Left Top Frame (36) to the Left Upright (26) with two M8 x 78mm Bolts (82), a Support Plate (31), and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

14. Orient the Butterfly Frame (14) as shown. Attach the Butterfly Frame to the Right Upright (2) with two M8 x 72mm Bolts (85), two M8 Washers (98), and two M8 Nylon Locknuts (91). Do not tighten the Locknuts yet.

Attach the Butterfly Frame (14) to the Right Top Frame (5) with two M8 x 78mm Bolts (82), two M8 Washers (98), and two M8 Nylon Locknuts (91).

Tighten the M8 Nylon Locknuts (91) used in steps 3-14.

Arm As sem bly

15. Wet the lower end of the Left Butterfly Arm (6) with soapy water. Slide a Large Foam Pad (15) onto the Left Butterfly Arm.

Note: an entire grease packet should be used for this step. Grease an M10 x 85mm Bolt (74) and the indicated edges of two Arm Bushings (23) with a grease packet. Attach the Left Butterfly Arm (6) to the Butterfly Frame (14) with the Bolt (74), an M10 Large Washer (100), the two Arm Bushings, and an M10 Nylon Locknut (90). Make

sure the bolt head fits inside of the hole in the Butterfly Frame.

Repeat this step with the Right Butterfly Arm (7).

Grease

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16. Attach the Leg Bumper (59) to the Right Seat Frame (3) with an M4 x 16mm Self-tapping Screw

(89) and an M4 Washer (96).

Grease an M10 x 75mm Bolt (60). Attach the Leg Lever (4) to the Right Seat Frame (3) with the

Bolt and an M10 Nylon Locknut (90). Make sure the "U'=rod is on the indicated side of the Leg Lever. Do not overtighten the Locknut; the Leg Lever must be able to pivot easily.

17. Grease an M10 x 108mm Bolt (72). Orient the Press Frame (29) as shown. Attach the Press Frame to the Left Base (25) with the Bolt and an M10 Nylon Locknut (90). Do not overtighten the Locknut; the Press Frame must be able to pivot easily.

18. Attach a Press Handle (32) to a Press Arm (30) with an M10 x 65mm Bolt (77), two M10 Washers

(99), two M10 x 12mm Spacers (101), and an M10 Nylon Locknut (90).

Attach a Press Arm Cap (34) to the Press Arm (30) with an M10 x 45mm Button Bolt (81) and an

M10 Large Washer (100).

100_,f

_29

i Grease

i i

Repeat this step with the other Press Arm (30).

34_

90 99

101

Page 12

19. Attach a Press Arm (30) to the Press Frame (29) with two M8 x 69mm Bolt (86) and two M8 Nylon

Locknuts (91).

Repeat this step with the other Press Arm

(30).

20. Grease an M10 x 108mm Bolt (72). Attach the Leg Press Frame (28) to the Left Base (25) with

the Bolt and an M10 Nylon Locknut (90). Do not overtighten the Locknut; the Leg Press Frame must be able to pivot easily.

21. Grease an M10 x 77mm Bolt (76). Attach the Foot Plate (38) to the Leg Press Frame (28) with the Bolt and an M10 Nylon Locknut (90). Make sure the decal on the Foot Plate is right side up. Do not overtighten the Locknut; the Foot Plate must be able to pivot easily.

25 /

Grease ,_

Cable Assembly

22. See the CABLE DIAGRAMS on pages 26 and 27 as you assemble the cables and to identify

the cables.

Locate the Press Cable (109). Attach the Cable to the Leg Press Frame (28) with an M8 x 86mm Shoulder Bolt (37) and an M8 Nylon Locknut (91).

22 i

109

Page 13

23. Wrap the Press Cable (109) around a 90mm Pulley (63). Attach the Pulley, two Half Finger

Guards (66), a Cable Trap (68), and an MIO Washer (99) to the Left Seat Frame (27) with an

MIO x 103mm Bolt (22) and an MIO Nylon Locknut (90). Make sure the Cable Trap and the

Finger Guards are oriented as shown.

24. Wrap the Press Cable (109) around a "V'-pulley (62). Attach the "V'-pulley, two Half Finger Guards (66), and two MIO Washers (99) to the Leg Press Frame (28) with an MIO x 115mm Bolt (71) and an MIO Nylon Locknut (90). Make sure the Finger Guards are oriented as shown.

25. Wrap the Press Cable (109) around a 90mm Pulley (63). Attach the Pulley, two Half Finger Guards (66), a Cable Trap (68), and an MIO Washer (99) to the Left Upright (26) with an MIO x 108mm Bolt (72) and an MIO Nylon Locknut (90). Make sure the Cable Trap and Finger

Guards are oriented as shown.

J 109

26. Wrap the Press Cable (109) around a 90mm Pulley (63). Attach the Pulley, two Half Finger

Guards (66), a Cable Trap (68), and an MIO Washer (99) to the Press Frame (29) with an MIO

x 135mm Bolt (70). Make sure the Cable Trap and Finger Guards are oriented as shown.

109

Page 14

27. Wrap the Press Cable (109) around a "V"-pulley (62). Attach the "V"-pulley, two Half Finger Guards (66), a Large Cable Trap (111), and an MIO Washer (99) inside the bracket on the Left

Upright (26) with an MIO x 65mm Bolt (77) and an M10 Nylon Locknut (90). Make sure the

Cable Trap and Finger Guards are oriented as shown.

-111 /66

90/

28. Wrap the Press Cable (109) around a 90mm Pulley (63). Attach the Pulley, two Half Finger Guards (66), a Cable Trap (68), and an MIO Washer (99) to the Press Frame (29) with the MIO x 135mm Bolt (70) used in step 26 and an MIO Nylon Locknut (90). Make sure the Cable Trap and Finger Guards are oriented as

shown.

29. Wrap the Press Cable (109) under a 90mm Pulley (63). Attach the Pulley, two MIO Washers (99), and two Half Finger Guards (66) inside the bracket on the Left Base (25) with an MIO x 50mm Bolt (64) and an MIO Nylon Locknut (90). Make sure the Finger Guards are oriented as

shown.

109

66 90

109

30. Wrap the Press Cable (109) over a 90mm Pulley (63). Attach the Pulley and a Cable Trap (68) to the Right Top Frame (5) with an MIO x 45mm Bolt (80) and an MIO Nylon Locknut (90). Make sure the Cable Trap is oriented to hold the Cable in the groove of the Pulley.

80 68

Page 15

31. Attach the end of the Press Cable (109) to a "U'- bracket (50) with an M8 Washer (98) and an M8

Nylon Locknut (91). Note: Do not completely tighten the Locknut; it should be tightened so

that only two threads of the Cable show past the Locknut, as shown in the inset drawing.

)9.

- 98

50 91

32. Locate the Butterfly Cable (106). Grease an M8 x 22mm Shoulder Bolt (39). Attach the Cable to the Left Butterfly Arm (6) with the Bolt and an M8 Nylon Locknut (91). Make sure the flat edge of the Cable is against the Butterfly Arm.

33. Wrap the Butterfly Cable (106) over a "V'-pulley (62). Attach the "V'-pulley, a Large Cable Trap (111), an M10 Washer (99), and two Full Finger Guards (104) to the Right Upright (2) with an M10 x 62mm Bolt (73) and an M10 Nylon Locknut (90).

34. Wrap the Butterfly Cable (106) under a 90mm Pulley (63). Attach the Pulley and two Half Finger Guards (66) to the Double "U'-bracket (61) with an M10 x 48mm Bolt (84) and an M10 Nylon Locknut (90). Make sure the Finger Guards are

oriented as shown.

90 106

111

104

99 104

106

35. Wrap the Butterfly Cable (106) over a "V'-pulley (62). Attach the "V'-pulby, a Large Cable Trap (111), an M10 Washer (99), and two Full Finger Guards (104) to the Right Upright (2) with an M10 x 62mm Bolt (73) and an M10 Nylon Locknut (90).

_73

104062

99 _ ZlO6

___111' _'_ @

Page 16

36. Grease an M8 x 22mm Shoulder Bolt (39). Attach the Butterfly Cable (106) to the Right Butterfly Arm (7) with the Bolt and an M8 Nylon Locknut (91). Make sure the fiat edge of the Cable is against the Butterfly Arm.

Grease_4 _

106_

37. Locate the Short Cable (108). Attach the Cable to the M8 x 96mm Bolt (83) used in step 6 with

an M8 Washer (98), an M8 x 13mm Spacer (103), and an M8 Nylon Locknut (91).

38. Wrap the Short Cable (108) over a 90mm Pulley (63). Attach the Pulley and two Half Finger Guards (66) to the Double "U'-bracket (61) with an MIO x 48mm Bolt (84) and an MIO Nylon Locknut (90). Make sure the Finger Guards are

oriented as shown.

39. Attach the end of the Short Cable (108) to a "U'- bracket (50) with an M8 Washer (98) and an M8 Nylon Locknut (91). Note: Do not completely tighten the Locknut; it should be tightened so that only two threads of the Cable show past the Locknut, as shown in the inset drawing.

103

40. Locate the Weight Cable (110). Route the Cable up through the Right Top Frame (5) and over a

90mm Pulley (63). Attach the Pulley inside the Top Frame with an MIO x 80mm Bolt (75), two MIO Washers (99), two MIO x 19mm Spacers (102), and an MIO Nylon Locknut (90).

110

Page 17

41. Route the Weight Cable (110) over a 90mm Pulley (63) and down through the Right Top Frame (5). Attach the Pulley inside the Top Frame with an MIO x 80mm Bolt (75), two MIO Washers

(99), two MIO x 19mm Spacers (102), and an MIO Nylon Locknut (90).

42. Wrap the Weight Cable (110) under a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68), and two Half Finger Guards (66) at the second hole from the top of the two Pulley Plates (51) with an MIO x 50mm Bolt (64) and an MIO Nylon Locknut (90). Make sure the Cable Trap and Finger Guards are oriented as shown.

110

102

43. Wrap the Weight Cable (110) over a 90mm Pulley (63). Attach the Pulley to the indicated bracket on

the Right Top Frame (5) with an MIO x 45mm Bolt (80) and an MIO Nylon Locknut (90).

44. Wrap the Weight Cable (110) over a 90mm Pulley (63). Attach the Pulley and a Cable Trap (68) to the indicated bracket on the Right Top Frame (5) with an MIO x 45mm Bolt (80) and an MIO Nylon Locknut (90). Make sure the Cable Trap is ori- ented to hold the Cable in the groove of the Pulley.

45. Set the M12 Washer (33) on top of the Weight Tube (47). Thread the M12 Nut (49) all the way onto the Weight Cable (110).

43 Bracket

44 Attach

Thread the Weight Cable (110) into the Weight Tube (47) a couple of turns.

Page 18

46. Locate the Ab Cable (107). Route the small ball on the Cable through the Leg Lever (4) and the

Right Seat Frame (3). Make sure the Cable is over the rod in the Seat Frame.

Attach a 90mm Pulley (63) inside the Leg Lever (4), over the Ab Cable (107), with an MIO x

65mm Bolt (77), two MIO Washers (99), two MIO x 12mm Spacers (101), and an MIO Nylon

Locknut (90).

Large

Ball

107

Rod

47. Attach a 90mm Pulley (63) inside the Right Seat Frame (3), over the Ab Cable (107), with an MIO

x 45mm Bolt (80) and an MIO Nylon Locknut (90).

48. Route the Ab Cable (107) through the Right Upright (2) and under a 90mm Pulley (63). Attach the Pulley and two Half Finger Guards (66) to the Right Base (1) with an MIO x 50mm Bolt (64) and an MIO Nylon Locknut (90). Make sure the Finger Guards are oriented as shown.

49. Wrap the Ab Cable (107) over a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68), and two Half Finger Guards (66) to the lower hole in

the indicated "U'-bracket (50) with an MIO x 50mm Bolt (64) and an MIO Nylon Locknut (90).

Make sure the Cable Trap and Finger Guards are oriented as shown.

Page 19

50. Wrap the Ab Cable (107) under a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68), and two Half Finger Guards (66) to the Right Base (1) with an MIO x 50mm Bolt (64) and an MIO Nylon

Locknut (90). Make sure the Cable Trap and Finger Guards are oriented as shown.

51. Wrap the Ab Cable (107) over a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68), and two Half Finger Guards (66) at the second hole from the bottom of the two Pulley Plates (51) with an MIO x 50mm Bolt (64) and an MIO Nylon Locknut (90). Make sure the Cable Trap and Finger Guards are oriented as shown.

90 66

107

52. Wrap the Ab Cable (107) under a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68), and two Half Finger Covers (66) to the Right Base (1) with an MIO x 50mm Bolt (64) and an MIO Nylon Locknut (90). Make sure the Cable Trap and Finger Guards are oriented as shown.

53. Wrap the Ab Cable (107) over a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68), and

two Half Finger Guards (66) to the lower hole in the indicated "U'-bracket (50) with an MIO x

50mm Bolt (64) and an MIO Nylon Locknut (90). Make sure the Cable Trap and Finger Guards

are oriented as shown.

54. Wrap the Ab Cable (107) under a 90mm Pulley (63). Attach the Pulley, a Cable Trap (68) and two

Half Finger Guards (66) to the Right Base (1) with an MIO x 50mm Bolt (64) and an MIO Nylon

Locknut (90). Make sure the Cable Trap and Finger Guards are oriented as shown.

50,

64,

66-

63 _64

Page 20

55. Wrap the Ab Cable (107) over a 90mm Pulley (63). Attach the Pulley and the two Quarter Finger

Guards (105) to the Right Upright (2) with an MIO x 108mm Bolt (72), an M10 Washer (99), and an

MIO Nylon Locknut (90). Make sure that the rod is inserted through both Finger Guards and is

over the Cable.

,11!

Rod

105

56. ]]ghten the Weight Cable (110) into the Weight Tube (not shown) until all the slack is taken out of

the cables. Tighten the M12 Nut (49) on the Weight Cable against the M12 Washer (33).

Seat Assembly

57. Attach the Press Backrest (113) to the Backrest Frame (53) with two M6 x 16mm Screws (88), an M6 x 35mm Screw (78), and an M6 Washer (97).

Slide the Backrest Frame (53) into the Left Upright (26). Engage the Knob (43) into the Upright and Backrest Frame, and turn it clockwise until it istight.

,113

58. Attach a Seat (8) to the Left Seat Frame (27) with four M6 x 16mm Screws (88).

Repeat this step with the other Seat (8) and the Right Seat Frame (not shown).

Page 21

59. Attach the Butterfly Backrest (9) to the Right Upright (2) with four M6 x 16mm Screws (88).

60. Press the two Shroud Covers (11) onto the Shroud (10). Attach the Shroud to the Right Top Frame (5) and the Center Base (52) with four M6 x 22mm Bolts (87), four M6 Washers (97), and four M6 Nylon Locknuts (92). Be careful not to scratch yourself when reaching through the

hole in the Shroud.

_92

i 5

Page 22

61. Attach the Lock Plate (21) to the Right Seat Frame (3) with an M8 x 68mm Shoulder Bolt (41),

an M8 Washer (98), and an M8 Nylon Locknut (91). Do not overtighten the Locknut; the Lock

Plate must be able to pivot easily.

Attach the Leg Pin (24) to the Right Seat Frame (3) with an M4 x 16mm Self-tapping Screw (89).

Insert the Leg Pin through the Leg Lever (4) and the Lock Plate (21).

91 j 98

62. Insert the Long Pad Tube (16) into the Right Seat Frame (3). Slide two Small Foam Pads (18) onto

the Pad Tube. Press two Foam Caps (17) into the Pad Tube.

Repeat this step with the Leg Lever (4) and the Short Pad Tube (35).

63. Make sure that all parts have been properly tightened. The use of the remaining parts will be explained in ADJUSTMENTS, beginning on the following page.

Before using the weight system, pull each cable a few times to make sure that the cables move smoothly over the pulleys. If one of the cables does not move smoothly, find and correct the problem. IMPORTANT." If the cables are not properly installed, they may be damaged when heavy weight is used. See the CABLE DIAGRAMS on pages 26 and 27 of this manual for proper cable routing. If there is any slack

in the cables, you will need to remove the slack by tightening the cables. See MAINTENANCE on page 28.

Page 23

ADJUSTMENTS

This section explains how to adjust the weight system. See the EXERCISE GUIDELINES on page 29 for important informationabout how to get the most benefit from your exercise program. Also, see the accompanying exercise

guide to see the correct form for each exercise.

Make sure all parts are properly tightened each time the weight system is used. Replace any worn parts immediate- ly. The weight system can be cleaned with a damp cloth and a mild, non-abrasive detergent. Do not use solvents.

CHANGING THE WEIGHT SETTING

To change the setting of the weight stack, insert the Weight Pin (57) under the desired Weight (55). Insert the Weight Pin so that the bent end touches the weight stack. Turn the bent end down. Note: Be careful not to scratch yourself when reaching through the hole in the Shroud (10). Do not use the Top Weight (56, not shown) by itself.

Note: Due to the cables and pulleys, the amount of resistance at each exercise station may vary from the weight setting. Use the WEIGHT RESISTANCE CHART on page 25 to find the approximate amount of resistance at each weight

station.

ATTACHING THE ACCESSORIES TO A PULLEY

STATION

Attach the Handle (93) to the Ab Cable (107) at the low pulley station with a Cable Clip (95). For some exercis- es, the Chain (94) should be attached between the Handle and the Cable with two Cable Clips. Adjust the length of the Chain between the Handle and the Cable so that the Handle is in the correct starting position for the exercise to be performed.

The Lat Bar (not shown), the Ab Strap (79), or the Handle (93) can be attached at any pulley station in the same manner. Always engage the Lock Plate (21) when using the low pulley station (see USING THE LOCK PLATE below).

USING THE LOCK PLATE

When using the low pulley station, engage the Leg Pin (24) into the Leg Lever (4) and the Lock Plate

(21).

To use the Leg Lever (4), engage the Leg Pin (24) into the Right Seat Frame (3) and the Lock Plate (21).

Page 24

ADJUSTING THE BACKREST

To adjust the position of the Press Backrest (113), disengaging the Knob (43) from the Left Upright (26)

and move the Backrest to the desired position. Reengage the Knob into the Left Upright and the

Backrest Frame (53). Make sure the Knob is fully tightened.

LOCKING THE WEIGHT STACK

Lock the weight stack by inserting the Lock Pin (65) through a Weight Guide (44) and securing the Lock (48) onto the Lock Pin.

0 g

JOL JUL

Page 25

WEIGHT RESISTANCE CHART

The chart below shows the approximate weight resistance at each exercise station. "Top" refers to the 6 lb. top weight. The other numbers refer to the 12.5 lb. weight plates. Weight resistance shown for the butterfly arm sta- tion is for each arm. Note: The actual resistance at each station may vary due to differences in individual

weight plates as well as friction between the cables, pulleys, and weight guides.

WEIGHT

Top

1 2

4 5 6 7 8

HiGH BUTTER- PRESS LEG LOW LEG AB

PULLEY FLY ARM ARM LEVER PULLEY PRESS STATION

(Ibs.) (Ibs.) (Ibs.) (Ibs.) (Ibs.) (Ibs.) (Ibs.)

10 16 31 11 27 45 19 25 30 48 22 35 59 27 38 45 81 39 43 84 41 54 51 97 49 61 118 60

67 60 120 66 71 146 73 84 73 138 85 87 162 90

97 88 1550 94 107 193 100

105 93 176 106 120 223 114 122 106 214 126 143 248 130

Page 26

CABLE DIAGRAMS

The cable diagrams below show the proper routing of the Butterfly Cable (106), the Ab Cable (107), the Short Cable (108), the Press Cable (10% and the Weight Cable (110). Use the diagram to make sure that the cables and the cable traps have been assembled correctly. If the cables have not been correctly routed, the weight bench will not function properly and damage may occur. The numbers show the correct route for each cable. Make sure that the cable traps do not touch or bind the cables.

Butterfly Cable (106)

4 Length: 5 feet

Short Cable (108)

Length: 3 feet 11 inches

2 7 Ab Cable (107)

Length: 21 feet 1 inch

Page 27

Weight CabJe (110)

Length: 12 feet 1 inch

--6

Press Cable (109)

Length: 22 feet 6 inches

Page 28

MAINTENANCE

Make sure all parts are properly tightened each time the weight system is used. Replace any worn parts imme- diately. The weight system can be cleaned with a damp cloth and a mild, non-abrasive detergent. Do not use

solvents.

TiGHTENiNG THE CABLES

Woven cable, the type of cable used on the weight system, can stretch slightly when it is first used. If there is slack in the cables before resistance is felt, the cables should be tightened. To tighten the cables, first insert the weight pin into the middle of the weight stack. Slack can be removed from these cables several ways:

See drawing 1. Tighten the M8 Nylon Locknut (91) that connects the end of a cable to a "U'-

bracket (50).

See drawing 1. Remove the MIO Nylon Locknut (90) and the MIO x 50mm Bolt (64) from the Cable Trap (68), the 90mm Pulley (63), the two

Half Finger Guards (66), and a "U'-bracket (50). Reattach the Pulley, Cable Trap, and Finger

Guards to the other hole in the "U'-bracket. Make sure that the Cable Trap and Finger Guards

are oriented as shown and that the cable and Pulley move smoothly.

90 66 50

_91

See drawing 2. Remove the MIO Nylon Locknut (90) and the MIO x 50mm Bolt (64) from the Cable Trap (68), the 90mm Pulley (63), the two Half Finger Guards (66), and the two Pulley Plates (51). Reattach the Pulley, Cable Trap, and Finger Guards to the next closer hole to the cen- ter of the Pulley Plates. Make sure that the Cable Trap is oriented to hold the cable in the groove of the Pulley, that the Finger Guards

are oriented as shown, and that the Cable and Pulley move smoothly.

See drawing 3. Loosen the M12 Nut (49) on the Weight Cable (110). Tighten the Cable into the Weight Tube (not shown) until the slack is removed from the Cable. Retighten the M12 Nut against the M12 Washer (33).

0 O 0 O

Do not overtighten the cables, if the cables are overtightened, the top weight will be lifted off the weight stack, if a cable tends to slip off the pulleys often, it may have become twisted. Remove the cable and re=install it. if the cables need to be replaced, see the part ordering information on the back cover of this manu-

al.

Page 29

EXERCISE GUiDELiNES

THE FOUR BASIC TYPES OF WORKOUTS

Muscle Building

To increase the size and strength of your muscles, push them close to their maximum capacity. Your mus- cles will continually adapt and grow as you progres- sively increase the intensity of your exercise. You can adjust the intensity level of an individual exercise in two ways:

• by changing the amount of weight used

• by changing the number of repetitions or sets per- formed. (A "repetition" is one complete cycle of an

exercise, such as one sit-up. A "set" is a series of repetitions.)

The proper amount of weight for each exercise depends upon the individual user. You must gauge

your limits and select the amount of weight that is right for you. Begin with 3 sets of 8 repetitions for each exercise you perform. Rest for three minutes after each set. When you can complete 3 sets of 12 repeti- tions without difficulty, increase the amount of weight.

Toning You can tone your muscles by pushing them to a mod- erate percentage of their capacity. Select a moderate amount of weight and increase the number of repeti- tions in each set. Complete as many sets of 15 to 20

repetitions as possible without discomfort. Rest for one minute after each set. Work your muscles by complet-

ing more sets rather than by using high amounts of weight.

Weight Loss To lose weight, use a low amount of weight and

increase the number of repetitions in each set. Exercise for 20 to 30 minutes, resting for a maximum

of 30 seconds between sets.

Cross Training Cross training is an efficient way to get a complete and well-balanced fitness program. An example of a bal- anced program is:

• Plan strength training workouts on Monday, Wednesday, and Friday.

• Plan 20 to 30 minutes of aerobic exercise, such as

running on a treadmill or riding on an elliptical or exercise bike, on Tuesday and Thursday.

• Rest from both strength training and aerobic exercise for at least one full day each week to give your body time to regenerate.

The combination of strength training and aerobic exer- cise will reshape and strengthen your body, plus devel- op your heart and lungs.

PERSONALiZiNG YOUR EXERCISE PROGRAM

Determining the exact length of time for each workout, as well as the number of repetitions or sets completed,

is an individual matter. It is important to avoid overdo- ing it during the first few months of your exercise pro-

gram. You should progress at your own pace and be sensitive to your body's signals. If you experience pain or dizziness at any time while exercising, stop immedi- ately and begin cooling down. Find out what is wrong before continuing. Remember that adequate rest and a proper diet are important factors in any exercise pro- gram.

WARMING UP

Begin each workout with 5 to 10 minutes of stretching and light exercise to warm up. Warming up prepares your body for more strenuous exercise by increasing circulation, raising your body temperature and deliver- ing more oxygen to your muscles.

WORKING OUT

Each workout should include 6 to 10 different exercis- es. Select exercises for every major muscle group,

emphasizing areas that you want to develop most. To give balance and variety to your workouts, vary the

exercises from session to session.

Schedule your workouts for the time of day when your energy level is the highest. Each workout should be followed by at least one day of rest. Once you find the schedule that is right for you, stick with it.

EXERCISE FORM

Maintaining proper form is an essential part of an effective exercise program. This requires moving

through the full range of motion for each exercise, and moving only the appropriate parts of the body. Exercising in an uncontrolled manner will leave you feeling exhausted. On the exercise guide accompany- ing this manual you will find photographs showing the

correct form for several exercises, and a list of the muscles affected. See the muscle chart on the next

page to find the names of the muscles.

The repetitions in each set should be performed smoothly and without pausing. The exertion stage of each repetition should last about half as long as the return stage. Proper breathing is important. Exhale during the exertion stage of each repetition and inhale during the return stroke. Never hold your breath.

Page 30

Rest for a short period of time after each set. The ideal resting periods are:

• Rest for three minutes after each set for a muscle

building workout.

• Rest for one minute after each set for a toning work- out.

• Rest for 30 seconds after each set for a weight loss workout.

Plan to spend the first couple of weeks familiarizing yourself with the equipment and learning the proper

form for each exercise.

COOLING DOWN

End each workout with 5 to 10 minutes of stretching. Include stretches for both your arms and legs. Move

slowly as you stretch and do not bounce. Ease into each stretch gradually and go only as far as you can

without strain. Stretching at the end of each workout is an effective way to increase flexibility.

STAYING MOTIVATED

For motivation, keep a record of each workout. The chart on page 31 of this manual can be photocopied

and used to schedule and record your workouts. List the date, the exercises performed, the weight used,

and the numbers of sets and repetitions completed. Record your weight and key body measurements at

the end of every month. Remember, the key to achiev- ing the greatest results is to make exercise a regular and enjoyable part of your everyday life.

MUSCLE CHART

A. Sternomastoid (neck)

B. Pectoralis Major (chest)

C. Biceps (front of arm)

D. Obliques (waist) E. Brachioradials (forearm)

R S

W X

R Hip Flexors (upper thigh)

G. Abductor (outer thigh)

H. Quaddceps (front of thigh) I. Sartodus (front of thigh)

J. Tibialis Anterior (front of calf)

K. Soleus (front of calf) L. Anterior Deltoid (shoulder) M. RectusAbdominus (stomach) N. Adductor (inner thigh)

O. Trapezius (upper back)

P. Rhomboideus (upper back)

Q. Posterior Deltoid (shoulder)

R. Triceps (back of arm) S. Latissimus Dorsi (mid back) T. Spinae Erectors (lower back)

U. Gluteus Medius (hip) V. Gluteus Maximus (buttocks) W. Hamstring (back of leg) X. Gastrocnemius (back of calf)

Page 31

MONDAY EXERCISE WEIGHT SETS REPS

Date:

/ /

TUESDAY

Date:

/ /

AEROBIC EXERCISE

WEDNESDAY EXERCISE WEIGHT SETS REPS

Date:

/ /

THURSDAY

Date:

/ /

AEROBIC EXERCISE

FRIDAY EXERCISE WEIGHT SETS REPS

Date:

/ /

Make photocopies of this page for scheduling and recording your workouts.

Page 32

PART IDENTIFICATION CHART--Model No. 831.154021 RO904A

See the drawings below to identify small parts used in assembly. The number in parentheses by each drawing is the key number of the part, from the PART LIST in the center of this manual. Note: Some small parts may

have been pre=attached. If a part is not in the parts bag, check to see if it has been pre=attached. If a part is missing, call toll=free 1=877=992-5999.

M6 Nylon Locknut (92)

M8 Nylon Locknut (91)

MIO Nylon Locknut (90)

M12 Nut (49)

M4 Washer (96)

MIO x 75mm Bolt (60)

M8 x 72mm Bolt (85)

M8 x 69mm Bolt (86)

M8 x 68mm Shoulder Bolt (41)

MIO x 65mm Bolt (77)

M6 Washer (97)

[

M12 Washer (33)

M8 Washer (98)

MIO Large Washer (100) MIO Washer (99)

MIO x 62mm Bolt (73)

MIO x 50mm Bolt (64)

[

MIO x 48mm Bolt (84)

MIO x 45mm Bolt (80)

MIO x 45mm Button Bolt (81)

Page 33

M6x35mmScrew(78)

M8x22mmShoulderBolt(39)

MIO x 77mm Bolt (76)

(

M8 x 78mm Bolt (82)

M6x22mmBolt(87)

M6x16mmScrew(88)

M4x16mmSelf-tappingScrew(89)

M8 x 75mm Carriage Bolt (69)_

MIO x 80mm Bolt (75)

M8 x 86mm Shoulder Bolt (37)

MIO x 85mm Bolt (74)

M8 x 96mm Bolt (83)

MIO x 103mm Bolt (22)

MIO x 108mm Bolt (72)

MIO x 115mm Bolt (71)

MIO x 135mm Bolt (70)

Page 34

PART LIST--iVlodei No. 831.154021 RO904A

Key No. Qty. Description Key No. Qty. Description

1 1 Right Base 60 1 MIO x 75mm Bolt 2 1 Right Upright 61 1 Double "U"-bracket 3 1 Right Seat Frame 62 4 "V"-pulley 4 1 Leg Lever 63 23 90mm Pulley 5 1 Right Top Frame 64 9 MIO x 50mm Bolt 6 1 Left Butterfly Arm 65 1 Lock Pin 7 1 Right Butterfly Arm 66 34 Half Finger Guard

8 2 Seat 67 2 Base Bushing 9 1 Butterfly Backrest 68 13 Cable Trap

10 1 Shroud 69 8 M8 x 75mm Carriage Bolt

11 2 Shroud Cover 70 1 MIO x 135mm Bolt

12 1 50mm Round Inner Cap 71 1 MIO x 115mm Bolt 13 1 Lat Bar 72 4 MIO x 108mm Bolt

14 1 Butterfly Frame 73 2 MIO x 62mm Bolt 15 2 Large Foam Pad 74 2 MIO x 85mm Bolt 16 1 Long Pad Tube 75 2 MIO x 80mm Bolt

17 4 Foam Cap 76 1 MIO x 77mm Bolt 18 4 Small Foam Pad 77 4 MIO x 65mm Bolt

19 6 63mm Round Inner Cap 78 1 M6 x 35mm Screw 20 7 50mm Round Inner Cap 79 1 Ab Strap 21 1 Lock Plate 80 4 MIO x 45mm Bolt

22 1 MIO x 103mm Bolt 81 2 MIO x 45mm Button Bolt 23 4 Arm Bushing 82 23 M8 x 78mm Bolt

24 1 Leg Pin 83 1 M8 x 96mm Bolt 25 1 Left Base 84 2 MIO x 48mm Bolt

26 1 Left Upright 85 2 M8 x 72mm Bolt 27 1 Left Seat Frame 86 4 M8 x 69mm Bolt

28 1 Leg Press Frame 87 4 M6 x 22mm Bolt 29 1 Press Frame 88 14 M6 x 16mm Screw

30 2 Press Arm 89 2 M4 x 16mm Self-tapping Screw 31 2 Support Plate 90 34 MIO Nylon Locknut

32 2 Press Handle 91 42 M8 Nylon Locknut 33 2 M12 Washer 92 4 M6 Nylon Locknut 34 2 Press Arm Cap 93 1 Handle

35 1 Short Pad Tube 94 1 Chain 36 1 Left Top Frame 95 4 Cable Clip

37 1 M8 x 86mm Shoulder Bolt 96 1 M4 Washer 38 1 Foot Plate 97 5 M6 Washer

39 2 M8 x 22mm Shoulder Bolt 98 29 M8 Washer 40 1 50mm Round Outer Cap 99 22 MIO Washer

41 1 M8 x 68mm Shoulder Bolt 100 4 MIO Large Washer 42 1 56mm Round Inner Cap 101 6 MIO x 12mm Spacer 43 1 Knob 102 4 MIO x 19mm Spacer 44 2 Weight Guide 103 1 M8 x 13mm Spacer 45 2 Weight Bumper 104 4 Full Finger Guard

46 1 Weight Tube Bumper 105 2 Quarter Finger Guard 47 1 Weight Tube 106 1 Butterfly Cable

48 1 Lock 107 1 Ab Cable 49 1 M12 Nut 108 1 Short Cable 50 2 "U"-bracket 109 1 Press Cable

51 2 Pulley Plate 110 1 Weight Cable 52 1 Center Base 111 3 Large Cable Trap

53 1 Backrest Frame 112 2 20mm x 40mm Inner Cap 54 1 25mm x 40mm Inner Cap 113 1 Press Backrest 55 8 Weight # 1 User's Manual 56 1 Top Weight # 1 Exercise Guide

57 1 Weight Pin # 2 Grease Packet 58 2 Handgrip # 1 Allen Wrench 59 1 Leg Bumper

Note: "#" indicates a non-illustrated part. Specifications are subject to change without notice. See the back cover of the user's manual for information about ordering replacement parts. If a part is missing, call toll-free

1-877-992-5999.

Page 35

EXPLODED DRAWING--Model No. 831.154021 RO904A

17 20

107

105

15 /

90-_

9o_.I__-88 .

' "'- _63 "'-.

19 69

68 64

Page 36

19,

82 91

/ 82

31 82 98 82

d_ 48

26 /

88 112 66

90 94

100

66 34_)

-84

_--81 79

101

66 63

101

_77

30_ 66

_\ 90

\ 68

90 6'6

}1 i639(

99 66 8_2

112 \

t-113

88 9!

66 %

66 99

109

_91

.9O

63.

Page 37

Your Home

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FULL 90-DAY WARRANTY

For 90 days from the date of purchase, if failure occurs due to defect in material or workmanship in this 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

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