Weider WESY86301 User Manual

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USER'S MANUAL

QUESTIONS?

As a manufacturer, we are committed to providing complete customer satisfaction. If you have questions, or if there are missing or damaged parts, we will guarantee complete satisfaction through direct assistance from our factory.

TO AVOID UNNECESSARY DELAYS, PLEASE CALL DIRECT TO OUR TOLL-FREE CUSTOMER HOT LINE. The trained technicians on our customer hot line will provide immediate assistance, free of charge to you.

CUSTOMER HOT LINE:

1-800-999-3756

Mon.–Fri., 6 a.m.–6 p.m. MST

Model No. WESY86301 Serial No.

Write the serial number in the space above for future reference.

Patent Pending

CAUTION

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

Serial Number Decal (Under Seat)

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TABLE OF CONTENTS

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

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

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

HOW TO USE THE HOME GYM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 the PART LIST/EXPLODED DRAWING before beginning assembly.

WEIDER is a registered trademark of ICON Health & Fitness, Inc.

LIMITED WARRANTY

ICON Health & Fitness, Inc. (ICON), warrants this product to be free from defects in workmanship and material, under normal use and service conditions, for a period of ninety (90) days from the date of purchase. This warranty extends only to the original purchaser. ICON's obligation under this warranty is limited to replacing or repairing, at ICON's option, the product at one of its authorized service centers. All products for which warranty claim is made must be received by ICON at one of its authorized service centers with all freight and other transportation charges prepaid, accompanied by sufficient proof of purchase. All returns must be pre-authorized by ICON. This warranty does not extend to any product or damage to a product caused by or attributable to freight damage, abuse, misuse, improper or abnormal usage or repairs not provided by an ICON authorized service center, products used for commercial or rental purposes, or products used as store display models. No other warranty beyond that specifically set forth above is authorized by ICON.

ICON is not responsible or liable for indirect, special or consequential damages arising out of or in connection with the use or performance of the product or damages with respect to any economic loss, loss of property, loss of revenues or profits, loss of enjoyment or use, costs of removal, installation or other consequential damages of whatsoever nature. Some states do not allow the exclusion or limitation of incidental or consequential damages. Accordingly, the above limitation may not apply to you.

The warranty extended hereunder is in lieu of any and all other warranties and any implied warranties of merchantability or fitness for a particular purpose is limited in its scope and duration to the terms set forth herein. Some states do not allow limitations on how long an implied warranty lasts. Accordingly, the above limitation may not apply to you.

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

ICON HEALTH & FITNESS, INC., 1500 S. 1000 W., LOGAN, UT 84321-9813

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IMPORTANT PRECAUTIONS

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

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

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

3. Use the home gym system only on a level

surface. Place a mat beneath the home gym system to protect the floor or carpet.

4. Inspect and tighten all parts often. Replace

any worn parts immediately.

5. Keep children under the age of 12 and pets

away from the home gym system at all times.

6. Never release the press arm, butterfly arms,

leg lever, leg press plate, lat bar, ab strap, or nylon strap while weights are raised. The weights will fall with great force.

7. Keep hands and feet away from moving parts.

8. Always wear athletic shoes for foot protec-

tion.

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

10. When using the leg press station, always be sure that the lock pin is fully inserted and that the lock pin is clipped in place on the adjustment tube (see page 23).

11. 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.

12. Always disconnect the lat bar from the home gym system when performing an exercise that does not use the lat bar.

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

14. The home gym system is intended for home use only. do not use the home gym system in any commercial, rental, or institutional setting.

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. ICON assumes no responsibility for personal injury or property damage sustained by or through the use of this product.

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BEFORE YOU BEGIN

ASSEMBLED DIMENSIONS: Height: 78 in. Width: 64 in. Length: 70 in.

Foot Plate

Low Pulley Station

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Press Arm

Weight Stacks

Backrests

Leg Press

Plate

Ab Pulley Station

Thank you for selecting the versatile WEIDER®8630 Training System. The WEIDER®8630 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 WEIDER

8630 will help you to achieve the specific

results you want.

For your benefit, read this manual carefully before using the WEIDER®8630 Training System. If you

have additional questions, please call our Customer

Service Department toll-free at 1-800-999-3756, Monday through Friday, 6 a.m. until 6 p.m. Mountain Time (excluding holidays). To help us assist you, please note the product model number and serial number before calling. The model number is WESY86301. The serial number can be found on a decal attached to the WEIDER®8630 (see the front cover of this manual).

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

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ASSEMBLY

1. Before beginning assembly, be sure that

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

Locate and open the parts bags labeled “FRAME ASSEMBLY BAG ONE” and “FRAME ASSEMBLY BAG TWO.”

Press two 2” Square Outer Caps (58) onto the Weight Base (14) in the indicated locations. Press a 2” Square Inner Cap (56) into the end of the Weight Base.

Insert four 5/16” x 2 1/2” Carriage Bolts (49) up through the Press Base (13). Insert two 5/16” x 2 1/2” Carriage Bolts up through the Weight Base (14).

Attach the Press Base (13) to the Weight Base (14) with two 5/16” x 2 3/4” Bolts (55), two 5/16” Washers (20), and two 5/16” Nylon Locknuts (40). Do not tighten the Nylon

Locknuts yet.

FRAME ASSEMBLY

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

• Place all parts in a cleared area and remove the

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

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

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

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

• For help identifying the small parts used in assembly, use the PART IDENTIFICATION

CHART located in the center of this manual.

Note: Some small parts may have been preattached for shipping. If a part is not in the parts bag, check to see if it has been pre-attached.

• As you assemble this product, be sure that all

parts are oriented as shown in the drawings.

• 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.

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2. Slide the Ab Upright (1) onto the indicated 5/16” x 2 1/2” Carriage Bolts (49) in the Weight Base (14). Hand tighten two 5/16” Nylon Locknuts (40) onto the Carriage Bolts.

Do not tighten the Nylon Locknuts yet.

Slide the Leg Press Upright (4) onto the indicated 5/16” x 2 1/2” Carriage Bolts (49) in the Weight Base (14). Hand tighten two 5/16” Nylon Locknuts (40) onto the Carriage Bolts.

Do not tighten the Nylon Locknuts yet.

3. Press a 2” Square Inner Cap (56) into each end of the Top Frame (2). Press a 2” Square Inner Cap (56) into each side of the Butterfly Frame (3). Press two 1” Round Inner Caps (70) into the top of the Butterfly Frame.

Attach the Butterfly Frame (3) to the Top Frame (2) with a 5/16” x 3” Bolt (92). Be sure

that the Bolt is on the side shown.

Finish attaching the Butterfly Frame (3) to the Top Frame (2) with a 5/16” Nylon Jam Nut (91), a 5/16” x 2 3/4” Bolt (55), a 5/16” Washer (20), and a 5/16” Nylon Locknut (40).

4. Slide the Front Seat Frame (8) onto the indicated 5/16” x 2 1/2” Carriage Bolts (49) in the Press Base (13). Hand tighten two 5/16” Nylon Locknuts (40) onto the Carriage Bolts.

Attach the other end of the Front Seat Frame (8) to the Leg Press Upright (4) with two 5/16” x 2 3/4” Bolts (55), two 5/16” Washers (20), and two 5/16” Nylon Locknuts (40).

Press a 2” Square Inner Cap (56) into the Front Seat Frame (8).

FRAME ASSEMBLY

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5. Insert two Weight Guides (23) into one of the brackets on the Weight Base (14). Attach the lower ends of the Weight Guides with a 5/16” x 6” Bolt (67), two 1/2” x 3/4” Spacers (69), and a 5/16” Nylon Locknut (40). Do not over-

tighten the Nylon Locknut.

Attach the other Weight Guides (23) in the same manner.

6. Slide a Weight Bumper (27) onto each of the Weight Guides (23).

Slide eight Weights (90) onto each set of Weight Guides (23). Be sure that the pin

grooves are on the indicated side of each stack of Weights.

7. Press a Weight Tube Bumper (26) into each Weight Tube (25).

Insert a Weight Tube (25) into each stack of Weights (90). Be sure that the pins on the

Weight Tubes are in the pin grooves in the upper Weights.

FRAME ASSEMBLY

Grooves

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8. Lubricate the insides of the holes in the Top Weights (24) as shown. Slide a Top Weight onto each set of Weight Guides (23).

9. Attach the Top Frame (2) to the Ab Upright (1) with two 5/16” x 2 3/4” Bolts (55), two 5/16” Washers (20), and two 5/16” Nylon Locknuts (40). Do not tighten the Nylon Locknuts

yet.

Attach the Butterfly Frame (3) to the Leg Press Upright (4) with two 5/16” x 2 3/4” Bolts (55), two 5/16” Washers (20), and two 5/16” Nylon Locknuts (40). Do not tighten the

Nylon Locknuts yet.

10. Attach the upper ends of one set of Weight Guides (23) to the Top Frame (2) with a 5/16” x 6” Bolt (67), two 1/2” x 3/4” Spacers (69), and a 5/16” Nylon Locknut (40).

Attach the upper ends of the other set of Weight Guides (23) in the same manner.

Before continuing, firmly tighten all nylon locknuts used in steps 1 through 10.

FRAME ASSEMBLY

Lubricate

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11. Attach the Leg Press Plate (11) to the Adjustment Tube (10) with a 5/16” x 2 1/2” Bolt (39), two 5/16” Washers (20), and a 5/16” Nylon Locknut (40). Be sure that the Leg

Press Plate and Adjustment Tube are oriented as shown.

Press a 1 3/4” Square Inner Cap (48) into the Adjustment Tube (10).

12. Attach the Adjustment Tube (10) to the Leg Press Arm (9) with the Lock Pin (73). Be sure

the Leg Press Plate (11) is oriented as shown.

Press two 2” Square Inner Caps (56) into the Leg Press Arm (9).

13. Locate and open the parts bag labeled

“ARM ASSEMBLY.”

Attach the Leg Press Bumper (53) to the Front Seat Frame (8) with the 1” Tap Screw (72).

Lubricate the 3/8” x 3 1/4” Bolt (71). Attach the Leg Press Arm (9) to the Press Base (13) with the Bolt and a 3/8” Nylon Locknut (42).

14. Press a 1” x 7/8” Plastic Bushing (54) onto each welded spacer on the Press Frame (12). Slide the Press Frame onto the Press Base (13) so that the Plastic Bushings are aligned with the indicated tube. Note: This will be a

tight fit. Make sure that the high pulley is on the side shown.

Lubricate the 3/8” x 8” Bolt (52). Attach the Press Frame (12) to the Press Base (13) with the Bolt and a 3/8” Nylon Locknut (42).

ARM ASSEMBLY

Angle

71—Lubricate

52—Lubricate

Tube

Welded

Spacers

High

Pulley

FRAME ASSEMBLY

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15. Attach a Press Arm (7) to one side of the Press Frame (12) with two 5/16” x 2 1/2” Bolts (39) and two 5/16” Nylon Locknuts (40).

Attach the other Press Arm (7) to the Press Frame (12) in the same manner.

16. Press a 1” Round Inner Cap (70) into one of the Press Arms (7). Press a 1 3/4” Square Inner Cap (48) into the Press Arm.

Repeat this step for the other Press Arm (not shown).

17. Lubricate both axles on the Butterfly Frame (3).

Refer to the drawing and identify the Right Arm (5) and the Left Arm (6).

Press a 1 3/4” Square Inner Cap (48) into the upper end of the Left Arm (6). Slide the Left Arm onto the indicated axle. Note: Be careful

not to confuse the Left Arm with the Right Arm (5). Be sure that the upper end of the Left Arm is behind the indicated bracket on the Butterfly Frame (3).

IMPORTANT NOTE: Before assembling the 1” Retainers (45) used in this step, be sure that you thoroughly understand the step. The Retainers can be assembled only once. If they must be removed, you will need to order new Retainers.

Tap two 1” Retainers (45) and a 1” Round Outer Cap (46) onto the axle. Be sure that

the teeth on the Retainers bend toward the Round Outer Cap, as shown in the inset drawing.

Attach the Right Arm (5) in the same manner.

ARM ASSEMBLY

Lubricate Axle

Axle

Bracket

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18. Press a 1 3/4” Square Inner Cap (48) into the lower end of the Left Arm (6). Wet the lower end of the Left Arm with soapy water. Slide a 10” Pad (45) onto the Left Arm.

Repeat this step with the Right Arm (5).

19. Locate and open the parts bags labeled

“CABLE ASSEMBLY” and “PULLEYS.”

During steps 19 through 50, refer to the CABLE DIAGRAMS on pages 26 and 27 of this manual to verify proper cable routing. Before beginning this section, fully unwind the five Cables and identify the Cables by comparing the lengths and the ends. The approximate length of each Cable, in inches, is listed after the key number in the drawing.

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

20. Insert a 5/16” x 1” Bolt (97) through the bracket on the Right Arm (5). Tighten a 5/16” Nylon Jam Nut (91) onto the Bolt.

Find the Butterfly Cable (89)—this is the second shortest Cable. Slide one end of the

Butterfly Cable onto the 5/16” x 1” Bolt (97). Thread another 5/16” Nylon Jam Nut (91) onto the Bolt, but do not fully tighten it.

Leave enough room between the two Jam Nuts for the Cable to pivot.

CABLE ASSEMBLY ARM ASSEMBLY

88—239”

86—110”

85—101”

89—82”

87—72”

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21. Wrap the Butterfly Cable (89) around a 3 1/2” Pulley (82) as shown. Attach the Pulley and a Cable Trap (80) to the bracket on the Leg Press Upright (4) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). The Cable

Trap must be oriented as shown and be positioned to hold the Cable in the groove of the Pulley.

22. Locate one of the preassembled pairs of Pulley Plates (31) and 3 1/2” Pulleys (82).

Route the Butterfly Cable (89) under the indicated 3 1/2” Pulley (82). The end of the Pulley Plates (31) with two holes should be downward. Refer to the inset drawing. Be sure

that the Cable is between the Cable Trap (80) and the Pulley, and that the Cable Trap is positioned to hold the Cable in place.

Tighten the 3/8” x 2” Bolt (50) and the 3/8” Nylon Locknut (not shown).

23. Wrap the Butterfly Cable (89) around a 3 1/2” Pulley (82) as shown. Attach the Pulley and a Cable Trap (80) to the other side of the bracket on the Leg Press Upright (4) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). The

Cable Trap must be oriented as shown and be positioned to hold the Cable in the groove of the Pulley.

24. Note: The Left Arm (6) is shown removed for easier part identification. Insert a 5/16” x

1” Bolt (97) through the bracket on the Left Arm. Fully tighten a 5/16” Nylon Jam Nut (91) onto the Bolt.

Slide the free end of the Butterfly Cable (89) onto the 5/16” x 1” Bolt (97). Thread another 5/16” Nylon Jam Nut (91) onto the Bolt, but

do not fully tighten it. Leave enough room between the two Jam Nuts for the Cable to pivot.

CABLE ASSEMBLY

End with

two holes

should be

down

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25. Find the Rear Cable (87)—this is the shortest Cable. Slide one end of the Rear Cable

onto the 5/16” x 3” Bolt (92). Thread another 5/16” Nylon Jam Nut (91) onto the Bolt, but

do not fully tighten it. Leave enough room between the two Jam Nuts for the Cable to pivot.

26. See the inset drawing. Attach a 3 1/2” Pulley (82) and a Cable Trap (80) to the upper hole in a Large “U” Bracket (84) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). Be

sure that the Cable Trap is inside the Large “U” Bracket. Note: This may come pre-assembled.

Route the Rear Cable (87) through the Large “U” Bracket (84) and the 3 1/2” Pulley (82).

Be sure that the Cable is in the groove of the Pulley and that the Cable and Pulley move smoothly.

27. Wrap the Rear Cable (87) around a 3 1/2” Pulley (82). Attach the Pulley to the Top Frame (2) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). The Cable must be

routed from the direction shown.

28. Attach the Rear Cable (87) to a Small “U” Bracket (32) with a 1/4” Nylon Locknut (44) and a 1/4” Washer (37). Do not completely

tighten the Nylon Locknut. It should be threaded onto the end of the Cable only a couple of turns, as shown in the inset drawing.

Attach the Small “U” Bracket (32) to the indicated Weight Tube (25) with a 5/16” x 1 3/4” Bolt (68) and a 5/16” Nylon Locknut (40).

CABLE ASSEMBLY

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29. Find the Press Cable (88)—this is the longest Cable. Attach the end of the Press

Cable (88) to the Large “U” Bracket (84) with a 1/4” Nylon Locknut (44) and a 1/4” Washer (37). Do not completely tighten the Nylon

Locknut. It should be threaded onto the end of the Cable so only a couple of threads are showing above the Nylon Locknut, as shown in the inset drawing.

30. Wrap the Press Cable (88) around a 3 1/2” Pulley (82). Attach the Pulley and a Cable Trap (80) to the indicated bracket on the Press Base (13) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). Be sure that the

Cable Trap is turned to hold the Cable in place.

31. Wrap the Press Cable (88) around a 3 1/2” Pulley (82). Attach the Pulley and a Cable Trap (80) to the other bracket on the Press Base (13) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). Be sure that the Cable

Trap is turned to hold the Cable in place.

CABLE ASSEMBLY

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32. Route the Press Cable (88) over the indicated 3 1/2” Pulley (82) attached to the Pulley Plates (31). The Cable must be routed from the direction shown. Refer to the inset drawing. Be sure that the Cable is between the

Cable Trap (80) and the Pulley, and that the Cable Trap is positioned to hold the Cable in place.

Tighten the 3/8” x 2” Bolt (50) and the 3/8” Nylon Locknut (not shown).

33. Route the Press Cable (88) around a 3 1/2” Pulley (82). Attach the Pulley and a Cable Trap (80) to the Leg Press Upright (4) with a 3/8” x 3 1/2” Bolt (66), a 3/8” Washer (38) and a 3/8” Nylon Jam Nut (43). Be sure that the

Cable Trap is turned to hold the Cable in place.

34. Route the Press Cable (88) over the indicated 3 1/2” Pulley (82) attached to the Press Frame (12). Tighten the 3/8” x 3 1/2” Bolt (66) and the 3/8” Nylon Locknut (not shown).

35. Wrap the Press Cable (88) around a “V” Pulley (81). Attach the “V” Pulley to the upper bracket on the Leg Press Upright (4) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Jam Nut (43).

CABLE ASSEMBLY

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36. Route the Press Cable (88) over the indicated 3 1/2” Pulley (82) attached to the Press Frame (12). Be sure that the Cable Trap

(80) is turned to hold the Cable in place and that the Cable is between the Pulley and the crossbar on the Press Frame.

Tighten the 3/8” Nylon Locknut (42) and the 3/8” x 3 1/2” Bolt (not shown).

37. Wrap the Press Cable (88) around a “V” Pulley (81). Attach the “V” Pulley to the lower bracket on the Leg Press Upright (4) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Jam Nut (43).

38. Wrap the Press Cable (88) around a 3 1/2” Pulley (82). Attach the Pulley and a Cable Trap (80) to the Leg Press Arm (9) with the 3/8” x 4 1/2” Bolt (74).

Slide another 3 1/2” Pulley (82) with a Cable Trap (80) onto the 3/8” x 4 1/2” Bolt (74). Hand tighten a 3/8” Nylon Jam Nut (43) onto the Bolt. Do not tighten the Nylon Jam Nut

until step 40.

39. Wrap the Press Cable (88) around a “V” Pulley (81). Attach the “V” Pulley and a Large Cable Trap (83) to the bracket on the Front Seat Frame (8) with a 3/8” x 2 1/2” Bolt (65) and a 3/8” Nylon Locknut (42). Be sure that

the Large Cable Trap is turned to hold the Cable in place and that the Cable and Pulley move smoothly.

CABLE ASSEMBLY

Crossbar

Page 17

40. Note: The 3 1/2” Pulley (82) used in this step was attached in step 38. It is shown removed for easier part identification.

Route the Press Cable (88) around the 3 1/2” Pulley (82). Be sure that the Cable Trap (80)

is turned to hold the Cable in place and that the Cable is routed as shown. Tighten

the 3/8” x 4 1/2” Bolt (74) and the 3/8” Nylon Jam Nut (43).

41. Slide a 5/16” Washer (20) onto a 5/16” x 2 3/4” Bolt (55). Insert the Bolt into the Front Seat Frame (8). Fully tighten a 5/16” Nylon Jam Nut (91) onto the Bolt. Slide the end of the Press Cable (88) onto the Bolt. Thread another 5/16” Nylon Jam Nut (91) onto the Bolt, but

do not fully tighten it. Leave enough room between the two Jam Nuts for the Cable to pivot.

42. Locate the High Cable (85)—this is the shortest remaining cable. Wrap the High

Cable around a 3 1/2” Pulley (82). Attach the Pulley to the Top Frame (2) with a 3/8” x 3 1/2” Bolt (66), a 3/8” Washer (38), and a 3/8” Nylon Locknut (42). 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 post.

43. Wrap the High Cable (85) around a 3 1/2” Pulley (82). Attach the Pulley and a Cable Trap (80) to the Top Frame (2) with a 3/8” x 3 1/2” Bolt (66), a 3/8” Washer (38), and a 3/8” Nylon Jam Nut (43). Be sure that the

Cable Trap is positioned to hold the Cable in place.

CABLE ASSEMBLY

Post

Page 18

44. Locate the remaining preassembled pair of Pulley Plates (31) and 3 1/2” Pulleys (82).

Route the High Cable (85) under the indicated 3 1/2” Pulley (82). The end of the Pulley Plates (31) with two holes should be downward. Refer to the inset drawing. Be sure

that the Cable is between the Cable Trap (80) and the Pulley, and that the Cable Trap is positioned to hold the Cable in place.

Tighten the 3/8” x 2” Bolt (50) and the 3/8” Nylon Locknut (not shown).

45. Wrap the High Cable (85) around a 3 1/2” Pulley (82). Attach the Pulley to the Top Frame (2) with a 3/8” x 2” Bolt (50) and a 3/8” Nylon Locknut (42). The Cable must be

routed from the direction shown.

46. Attach the High Cable (85) to a Small “U” Bracket (32) with a 1/4” Nylon Locknut (44) and a 1/4” Washer (37). Do not completely

tighten the Nylon Locknut. It should be threaded onto the end of the Cable only a couple of turns, as shown in the inset drawing.

Attach the Small “U” Bracket (32) to the indicated Weight Tube (25) with a 5/16” x 1 3/4” Bolt (68) and a 5/16” Nylon Locknut (40).

47. Lay the Low Cable (86) over a 3 1/2” Pulley (82). Attach the Pulley and both Pulley Covers (94) to the Ab Upright (1) with the 3/8” x 4” Bolt (95), two 3/8” Washers (38), and a 3/8” Nylon Locknut (42). Do not overtighten the

Nylon Locknut; the Pulley should turn easily. Make sure that the Cable is between the Pulley and the post, and that the Pulley Covers are turned so the wide tabs are on the indicated side.

CABLE ASSEMBLY

Post

Wide Tabs

must be on

this side

End with two

holes should

be down

Page 19

48. Wrap the Low Cable (86) around a 3 1/2” Pulley (82). Attach the Pulley and a Cable Trap (80) to the Ab Upright (1) with the 3/8” x 3 3/4” Bolt (76) and a 3/8” Nylon Locknut (42).

Be sure that the Cable Trap is in the indicated position.

49. Remove the indicated 3/8” x 2” Bolt (50), the 3/8” Nylon Locknut (42), the 3 1/2” Pulley (82), and the Cable Trap (80) from the indicated Pulley Plates (31). Lay the Low Cable (86) over the Pulley. Reattach the Pulley and the Cable Trap to the lowest hole in the Pulley Plates with the Bolt and the Nylon Locknut.

Make sure that the Cable Trap is turned to hold the Cable in place.

50. Wrap the Low Cable (86) around a 3 1/2” Pulley (82). Attach the Pulley to the Ab Upright (1) with the 3/8” x 3 1/2” Bolt (66), a 3/8” Washer (38), and a 3/8” Nylon Locknut (42). The ball on the Cable must be on the

indicated side of the Pulley. Be sure that the Cable and Pulley move smoothly and that the Cable is between the Pulley and the post.

CABLE ASSEMBLY

Post

Page 20

51. Locate and open the parts bag labeled

“SEAT ASSEMBLY.”

Attach the Small Backrest (18) to the Ab Upright (1) with two 1/4” x 2 1/2” Machine Screws (64) and two 1/4” Washers (37).

52. Press a 1 1/2” Square Inner Cap (57) into the Rear Seat Frame (16).

Insert a 1/4” x 2” Carriage Bolt (61) through the center hole in a Seat Plate (41). Attach the Seat Plate to the Seat (17) with two 1/4” x 1/2” Screws (59).

Insert the 1/4” x 2” Carriage Bolt (61) through the indicated hole in the Rear Seat Frame (16). Tighten a 1/4” Nylon Locknut (44) with a 1/4” Washer (37) onto the Carriage Bolt.

Attach the other end of the Seat (17) to the Rear Seat Frame (16) with a 1/4” Washer (37) and a 1/4” x 2” Machine Screw (63).

53. Press a 1 1/2” Square Inner Cap (57) into the Leg Lever (15).

Lubricate the 5/16” x 2 1/4” Bolt (62). Attach the Leg Lever (15) to the Rear Seat Frame (16) with the Bolt and a 5/16” Nylon Locknut (40). Do not overtighten the Nylon

Locknut; the Leg Lever must pivot freely.

Insert the 5/16” x 2” Eyebolt (79) into the Leg Lever (15) from the direction shown. Tighten a 5/16” Nylon Locknut (40) with a 5/16” Washer (20) onto the Eyebolt.

54. Rest the slot in the Rear Seat Frame (16) on the indicated post in the Ab Upright (1). Attach the Rear Seat Frame to the Ab Upright with a 5/16” x 2 3/4” Carriage Bolt (77) and the Seat Knob (30).

SEAT ASSEMBLY

Slot

Post

62—Lubricate

Page 21

SEAT ASSEMBLYMISC

58. Make sure that all parts have been properly tightened. The use of the remaining parts will be explained in HOW TO USE THE HOME GYM SYSTEM, beginning on page 22 of this manual.

Before using the home gym system, pull each cable a few times to be 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 page 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 TROUBLE-SHOOTING AND MAINTENANCE on page 25.

55. Press two 3/4” Round Inner Caps (78) into each Pad Tube (28).

Insert a Pad Tube (28) into the Rear Seat Frame (16). Slide a Foam Pad (29) onto each end of the Pad Tube.

Insert the other Pad Tube (28) into the Leg Lever (15). Slide a Foam Pad (29) onto each end of the Pad Tube.

56. Attach the Large Backrest (19) to the Leg Press Upright (4) with two 1/4” x 2 1/2” Machine Screws (64) and two 1/4” Washers (37).

57. Insert a 1/4” x 2 1/2” Carriage Bolt (60) through the center hole in a Seat Plate (41). Attach the Seat Plate to the Seat (17) with two 1/4” x 1/2” Screws (59).

Insert the 1/4” x 2 1/2” Carriage Bolt (60) through the indicated hole in the Front Seat Frame (8). Tighten a 1/4” Nylon Locknut (44) with a 1/4” Washer (37) onto the Carriage Bolt.

Attach the other end of the Seat (17) to the Front Seat Frame (8) with a 1/4” Washer (37) and a 1/4” x 2 1/2” Machine Screw (64).

Page 22

HOW TO USE THE HOME GYM SYSTEM

The instructions below describe how each part of the home gym system can be adjusted. Refer to the exercise poster accompanying this manual to see how the home gym system should be set up for each exercise.

IMPORTANT: When attaching the lat bar or nylon strap, make sure that the attachments are in the correct starting position for the exercise to be performed. If there is any slack in the cables or chain as an exercise is performed, the effectiveness of the exercise will be reduced.

CHANGING THE WEIGHT SETTING

The WEIDER 8630 features two weight stacks. The one weight stack is connected to the ab, upper, and lower pulley stations. The other weight stack is connected to the fly and press arms and the leg press.

To change the weight setting of either weight stack, insert a Weight Pin (93) under the desired Weight (90). Insert the Weight Pin until the bent end of the Weight Pin is touching the Weights, and turn the bent end downward. The weight setting of either weight stack can be changed from 6.5 pounds to 106.5 pounds, in increments of 12.5 pounds. 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 24 to find the approximate amount of resistance at each weight station.

ATTACHING THE LAT BAR OR NYLON STRAP TO THE HIGH PULLEY STATION

Attach the Lat Bar (36) to the High Cable (85) with a Cable Clip (33). For some exercises, the Chain (34) should be attached between the Lat Bar and the High Cable with two Cable Clips. Adjust the length of the

Chain between the Lat Bar and the High Cable so the Lat Bar is in the correct starting position for the exercise to be performed.

The Nylon Strap (96) can be attached in the same manner.

ATTACHING THE LAT BAR OR NYLON STRAP TO THE LOW PULLEY STATION

Attach the Lat Bar (36) to the Low Cable (86) with a Cable Clip (33). For some exercises, the Chain (34) should be attached between the Lat Bar and the Low Cable with two Cable Clips. Adjust the length of the

Chain between the Lat Bar and the Low Cable so the Lat Bar is in the correct starting position for the exercise to be performed.

The Nylon Strap (96) can be attached in the same manner.

Page 23

ATTACHING THE AB STRAP TO THE AB PULLEY STATION

Attach the Ab Strap (35) to the Low Cable (86) at the ab pulley station with a Cable Clip (33).

ATTACHING AND REMOVING THE SEAT

To attach the Seat (17), set the bracket on the Rear Seat Frame (16) onto the pins on the Ab Upright (1). Attach the Rear Seat Frame to the Ab Upright with the 5/16” x 2 3/4” Carriage Bolt (77) and the Seat Knob (30).

For some exercises, the Seat (17) must be removed. First, be sure that the chain is not attached to the leg lever. Next, remove the Seat Knob (30) and the 5/16” x 2 3/4” Carriage Bolt (77) from the Rear Seat Frame (16). Lift the Rear Seat Frame off the Ab Upright (1).

ATTACHING THE LEG LEVER TO THE LOW PULLEY STATION

To use the Leg Lever (15), the seat must be attached to the front upright (see ATTACHING AND REMOVING THE SEAT above).

Attach one end of the Chain (34) to the Low Cable (86) with a Cable Clip (33). Attach the other end of the Chain to the Eyebolt (79) with a Cable Clip.

ADJUSTING THE LEG PRESS PLATE

Remove the Lock Pin (73) from the Adjustment Tube (10).

Align the holes in the Leg Press Arm (9) with the desired set of holes in the Adjustment Tube (10). Reinsert the Lock Pin (73) through the holes in the Leg Press Arm and the holes in the Adjustment Tube. Be

sure that the hook on the Lock Pin is clipped in place on the Adjustment Tube.

Hook

Page 24

WEIGHT RESISTANCE CHART

This chart shows the approximate weight resistance at each weight station. “Top” refers to the 6.5 lb. top weight. The other numbers refer to the 12.5 lb. weight plates. The butterfly arm resistance listed is the resistance for each butterfly arm.

WEIGHT PRESS BUTTERFLY LEG HIGH LOW LEG AB

ARM ARM LEVER PULLEY PULLEY PRESS PULLEY

PLATES (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.)

Top 27 20 9 10 10 52 10

1 53 371824249425

2 79 5033404114140

3 101 65 38 53 53 180 53

4 125 83 48 66 63 228 68

5 148 103 58 80 80 263 83

6 175 120 68 96 91 310 96

7 205 143 76 107 101 358 110

8 240 173 90 123 120 410 124

The actual resistance at each weight station may vary due to differences in individual weight plates, as well as friction between the cables, pulleys, and weight guides.

Page 25

TROUBLE-SHOOTING AND MAINTENANCE

Inspect and tighten all parts each time you use the home gym system. Replace any worn parts immediately. The home gym system can be cleaned using a damp cloth and mild non-abrasive detergent. Do not use solvents.

TIGHTENING THE CABLES

Woven cable, the type of cable used on the home gym 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. If any slack is felt when using the weight stack closest to the ab upright, both the High Cable (85) and the Low Cable (86) will need to be tightened. If any slack is felt when using the other weight stack, the Rear Cable (87), the Press Cable (88), and the Butterfly Cable (89) will need to 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 1/4” Nylon Locknut (44) that connects the end of the Press Cable (88) to the Large “U” Bracket (84).

• See drawing 1. Remove the 3/8” Nylon Locknut (42) and the 3/8” x 2” Bolt (50) from the Cable Trap (80), Pulley, and Large “U” Bracket (84). Reattach the Pulley and Cable Trap to the other hole in the Large “U” Bracket. Be sure that the Cable Trap is in the proper position and that the Cable and Pulley move smoothly.

• See drawing 2. Tighten the 1/4” Nylon Locknut (44) that connects the end of the High Cable (85) to the Small “U” Bracket (32).

The Rear Cable (87) can be tightened in the same manner.

• See Drawing 3. If you feel additional slack while using the home gym system, the Low Cable (86) and the Press Cable (88) can be tightened further.

Remove the 3/8” x 2” Bolts (50), the 3/8” Nylon Locknuts (42), the 3 1/3” Pulleys (82), and the Cable Traps (80) from the Pulley Plates (31). Reattach the upper Pulley without the Cable Trap. Reattach the lower Pulley to the higher hole in the Pulley Plates without the Cable Trap. Keep the Cable Traps for future use. Be sure that the Cable and Pulley move smoothly.

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 ORDERING REPLACEMENT PARTS on the back cover of this manual.

86, 88

Page 26

CABLE DIAGRAMS

The cable diagrams on this page and the next page show the proper routing of the High Cable (85), the Low Cable (86), the Rear Cable (87), the Press Cable (88), and the Butterfly Cable (89). Use the diagrams to be sure that the Cables have been assembled correctly. The starting and ending points of each Cable have been labeled. The numbers show the proper route for each Cable. IMPORTANT: If the Cables have not been cor-

rectly routed, the WEIDER 8630 will not function properly and damage may occur.

Low Cable (86)

Butterfly Cable (89)

Press Cable (88)

1—Right Arm

5—Left Arm

4—Low Pulley

1—Long “U” Bracket

Leg Press—13

Ab Pulley—1

Page 27

High Cable (85) Rear Cable (87)

Weight Stack—5

High Pulley—1

1—Top Frame

4—Weight Stack

Page 28

PART IDENTIFICATION CHART—Model No. WESY86301 R0899B

1/4" Washer (37)

5/16" x 1" Bolt (97)

5/16" Washer (20)

3/8" Washer (38)

1/4" Nylon Locknut (44)

5/16" Nylon Locknut (40)

5/16" Nylon Jam Nut (91)

1" Retainer (45)

5/16" x 1 3/4" Bolt (68)

3/8" x 2" Bolt (50)

5/16" x 2 1/4" Bolt (62)

5/16" x 2 1/2" Bolt (39)

3/8" x 2 1/2" Bolt (65)–1

3/8" Nylon Locknut (42)

3/8" Nylon Jam Nut (43)

1" Tap Screw (72)

5/16" x 2 3/4" Bolt (55)

5/16" x 3" Bolt (92)

3/8" x 3 1/4" Bolt (71)

3/8" x 3 1/2" Bolt (66)1/4" x 1/2" Screw (59)

Page 29

1/4" x 2" Machine Screw (63)

1/4" x 2" Carriage Bolt (61)

1/4" x 2 1/2" Machine Screw (64)

1/4" x 2 1/2" Carriage Bolt (60)

5/16" x 2 1/2" Carriage Bolt (49)

Cable Clip (33)

"V" Pulley (81)

(Not shown to scale)

3 1/2" Pulley (82)

(Not shown to scale)

5/16" x 2 3/4" Carriage Bolt (77)

5/16" x 2" Eyebolt (79)

3/8" x 3 3/4" Bolt (76)

3/8" x 4 1/2" Bolt (74)

3/8" x 8" Bolt (52)

5/16" x 6" Bolt (67)

3/8" x 4" Bolt (95)

Page 30

1/2" x 3/4" Spacer (69)

1" x 7/8" Plastic Bushing (54)

1 1/8" x 2 1/2" Plastic Bushing (47)

1" Round Inner Cap (70)

1 1/2" Square Inner Cap (57)

3/4" Round Inner Cap (78)

1" Round Outer Cap (46)

1 3/4" Square Inner Cap (48)

2" Square Inner Cap (56)2" Square Outer Cap (58)

Page 31

PART LIST—Model No. WESY86301 R0899B

Note: “#” indicates a non-illustrated part. Specifications are subject to change without notice.

Key No. Qty. Description

1 1 Ab Upright 2 1 Top Frame 3 1 Butterfly Frame 4 1 Leg Press Upright 5 1 Right Fly Arm 6 1 Left Fly Arm 7 2 Press Arm 8 1 Front Seat Frame

9 1 Leg Press Arm 10 1 Adjustment Tube 11 1 Leg Press Plate 12 1 Press Frame 13 1 Press Base 14 1 Weight Base 15 1 Leg Lever 16 1 Rear Seat Frame 17 2 Seat 18 1 Small Backrest 19 1 Large Backrest 20 13 5/16” Washer 21 4 5” Plastic Grip 22 2 10” Pad 23 4 Weight Guide 24 2 Top Weight 25 2 Weight Tube 26 2 Weight Tube Bumper 27 4 Weight Bumper 28 2 Pad Tube 29 4 Foam Pad 30 1 Seat Knob 31 4 Pulley Plate 32 2 Small “U” Bracket 33 4 Cable Clip 34 1 Chain 35 1 Ab Strap 36 1 Lat Bar 37 11 1/4” Washer 38 8 3/8” Washer 39 5 5/16” x 2 1/2” Bolt 40 28 5/16” Nylon Locknut 41 2 Seat Plate 42 20 3/8” Nylon Locknut 43 5 3/8” Nylon Jam Nut 44 5 1/4” Nylon Locknut 45 4 1” Retainer 46 2 1” Round Outer Cap 47 2 1 1/8” x 2 1/2” Plastic Bushing 48 7 1 3/4” Square Inner Cap 49 6 5/16” x 2 1/2” Carriage Bolt 50 13 3/8” x 2” Bolt

Key No. Qty. Description

51 – Not Used 52 1 3/8” x 8” Bolt 53 1 Leg Press Bumper 54 2 1” x 7/8” Plastic Bushing 55 10 5/16” x 2 3/4” Bolt 56 8 2” Square Inner Cap 57 2 1 1/2” Square Inner Cap 58 2 2” Square Outer Cap 59 4 1/4” x 1/2” Screw 60 1 1/4” x 2 1/2” Carriage Bolt 61 1 1/4” x 2” Carriage Bolt 62 1 5/16” x 2 1/4” Bolt 63 1 1/4” x 2” Machine Screw 64 5 1/4” x 2 1/2” Machine Screw 65 1 3/8” x 2 1/2” Bolt 66 6 3/8” x 3 1/2” Bolt 67 4 5/16” x 6” Bolt 68 2 5/16” x 1 3/4” Bolt 69 8 1/2” x 3/4” Spacer 70 4 1” Round Inner Cap 71 1 3/8” x 3 1/4” Bolt 72 1 1” Tap Screw 73 1 Lock Pin 74 1 3/8” x 4 1/2” Bolt 75 2 Press Bushing 76 1 3/8” x 3 3/4” Bolt 77 1 5/16” x 2 3/4” Carriage Bolt 78 4 3/4” Round Inner Cap 79 1 5/16” x 2” Eyebolt 80 16 Cable Trap 81 3 “V” Pulley 82 21 3 1/2” Pulley 83 1 Large Cable Trap 84 1 Large “U” Bracket 85 1 High Cable 86 1 Low Cable 87 1 Rear Cable 88 1 Press Cable 89 1 Butterfly Cable 90 16 Weight 91 8 5/16” Nylon Jam Nut 92 1 5/16” x 3” Bolt 93 2 Weight Pin 94 2 Pulley Cover 95 1 3/8” x 4” Bolt 96 1 Nylon Strap 97 2 5/16” x 1” Bolt

# 1 User’s Manual # 1 Exercise Poster

Page 32

EXPLODED DRAWING—Model No. WESY86301 R0899B

42 42

Page 33

ORDERING REPLACEMENT PARTS

To order replacement parts, simply call our Customer Service Department toll-free at 1-800-999-3756, Monday through Friday, 6 a.m. until 6 p.m. Mountain Time (excluding holidays). To help us assist you, please be prepared to give the following information:

1. The MODEL NUMBER of the product (WESY86301).

2. The NAME of the product (WEIDER

8630 Training System).

3. The SERIAL NUMBER of the product (see the front cover of this manual).

4. The KEY NUMBER and DESCRIPTION of the part(s) (see the PART LIST and EXPLODED DRAWING attached at the center of this manual).