Sears 831.15946 User's Manual
Contents
1. CABLE ASSEMBLY 28 Attach the Backrest 41 to the Front Upright 42 with two 1 4 x 2 1 2 Screws 43 and two 1 4 Flat Washers 10 The Backrest must be turned so the thickest end is at the bottom SEAT ASSEMBLY Thickest End 13 SEAT ASSEMBLY 29 30 31 32 Press a 1 1 2 Square Inner Cap 32 into the Seat Frame 36 Insert the 1 4 x 2 Carriage Bolt 38 into the center hole in the Seat Plate 37 Attach the Seat Plate to the Seat 13 with two 1 4 x 1 2 Screws 18 Insert the 1 4 x 2 Carriage Bolt 38 into the indicated hole in the Seat Frame 36 Tighten a 1 4 Nylon Locknut 2 with a 1 4 Flat Washer 10 onto the Carriage Bolt Attach the other end of the Seat 13 to the Seat Frame 36 with a 1 4 Flat Washer 10 and a 1 4 x 2 Screw 24 Lubricate the 5 16 x 2 1 4 Bolt 33 Attach the Leg Lever 29 to the Seat Frame 36 with the 5 16 x 2 1 4 Bolt and a 5 16 Nylon Locknut 3 Attach the Short Cable 35 to one of the three holes in the Leg Lever 29 with a 5 16 x 3 4 Bolt 89 a 5 16 Washer 8 and a 5 16 Nylon Locknut 3 Note The three holes are for cable adjustment Insert the Short Cable between the welded rod and the Leg Lever Press a 1 Round Inner Cap 49 into each end of the Curl Bar 86 Slide the 1 2 x 3 8 Bushing 91 the Curl Bar and the Short Cable 35 onto the 5 162. Route the Long Cable 23 around the 3 1 2 Pulley 15 attached to the bracket on the Top Frame 55 Tighten the 3 8 x 2 Bolt 12 and the 3 8 Nylon Locknut 21 Be sure that the Cable is in the groove of the Pulley and that the Cable and Pulley move smoothly 10 CABLE ASSEMBLY 19 Assembly steps 19 through 21 show how to complete the assembly of several pre attached parts The 5 8 x 9 16 Spacer 73 has been pre attached on the outside of the 3 1 2 Low Pulley 92 for shipping purposes Remove the 3 8 Nylon Locknut 21 the Spacer and the Pulley from the 3 8 x 3 3 4 Bolt 71 Do not remove the Bolt The Bolt has been shown removed for part identification Reattach the 3 1 2 Low Pulley 92 with the 5 8 x 9 16 Spacer 73 between the Pulley and the Press Frame 17 Do not tighten the 3 8 Nylon Locknut 21 yet Be sure that the 3 8 x 3 3 4 Bolt 71 the 3 8 Flat Washer 9 the 5 8 x 9 16 Spacer 73 the 3 1 2 Low Pulley and the 3 8 Nylon Locknut 21 are oriented as shown Ne 20 The indicated 3 8 x 3 3 4 Bolt 71 has been inserted from the wrong side for shipping pur poses Remove the Bolt and the 3 8 Nylon Locknut 21 Slide the Cable Trap 66 and the 3 1 2 Pulley 15 onto the 3 8 x 3 3 4 Bolt 71 Re insert the Bolt into the Front Upright 42 from the direction shown Hand tighten the 3 8 Nylon Locknut 21 with
3. 10 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 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 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 t
4. x 1 1 4 Carriage Bolt 90 Hand tighten a 5 16 Nylon Locknut 3 onto the Carriage Bolt Rest the Seat Frame 36 on the indicated pin in the Front Upright 42 Attach the Seat Frame to the Front Upright with a 5 16 x 2 3 4 Carriage Bolt 14 and the Seat Knob 40 14 SEAT ASSEMBLY 33 34 35 Press 3 4 Round Inner Caps 34 into the ends of both 12 1 2 Pad Tubes 28 Insert one 12 1 2 Pad Tube 28 into the Seat Frame 36 Slide a 5 1 2 Pad 30 onto each end of the Pad Tube Insert the other 12 1 2 Pad Tube 28 into the Leg Lever 29 Slide a 5 1 2 Pad 30 onto each end of the Pad Tube See the left inset drawing Insert the head of the 5 16 x 1 1 4 Carriage Bolt 90 into the keyhole in the Leg Lever 29 Be sure that the shoulder of the Carriage Bolt is firmly seated in the square part of the keyhole See the right inset drawing Orient the Short Cable 35 and the Curl Bar 86 as shown Tighten the indicated 5 16 Nylon Locknut 3 Do not overtighten the Nylon Locknut This is the storage position for the Curl Bar Keyhole 90 Attach the Curl Pad 82 to the Curl Frame 84 with four 1 4 x 1 2 Screws 18 Insert a 1 1 2 Square Inner Cap 32 into each end of the Curl Frame 84 Note These Square Inner Caps may come pre assem bled Attach the Curl Frame 84 to the Seat Frame 36 by inserting the pin on the Curl Frame into the upper hole in
5. To adjust the Short Cable 35 remove the 5 16 x 3 4 Bolt 89 5 16 Flat Washer 8 and 5 16 Nylon Locknut 3 Re attach the Short Cable 35 to one of the other holes in the Leg Lever 29 with the 5 16 x 3 4 Bolt 89 5 16 Flat Washer 8 and 5 16 Nylon Locknut 3 Note The Short Cable should be attached so that the Curl Bar 86 is in the correct starting position for the exercise to be performed WEIGHT RESISTANCE CHART This chart shows the approximate weight resistance at each exercise station Top refers to the 6 5 Ib 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 ARM BUTTERFLY ARM LEG LEVER HIGH PULLEY LOW PULLEY CURL BAR PLATES Ibs Ibs Ibs Ibs Ibs Ibs 20 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 Slack can be removed from the cables by tightening the 1 4 Nylon Locknuts 2 at the end of the Long Cable 23 see drawing 1 and at the end o
6. around the 3 1 2 Pulley 15 attached to the upper hole in the Press Frame 17 Be sure that the Cable Trap 66 is turned to hold the Cable in place and that the Cable is routed around the Pulley as shown Tighten the 3 8 Nylon Locknut 21 and the 3 8 x 3 1 2 Bolt not shown Route the Medium Cable 58 around the 3 1 2 Pulley 15 attached to the upper hole in the Front Upright 42 See the inset drawing Be sure that the Cable Trap 66 is turned to hold the Cable in place and that the Cable is routed around the Pulley as shown Tighten the 3 8 Nylon Locknut 21 and the 3 8 x 3 3 4 Bolt 71 12 Inset shows view from other side Inset shows view from other side 26 Attach the end of the Medium Cable 58 to the Long U Bracket 57 with a 1 4 Nylon Locknut 2 and a 1 4 Flat Washer 10 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 Locknut as shown in the inset drawing 27 Attach the Long Cable 23 to the Small U Bracket 67 with a 1 4 Nylon Locknut 2 and a 1 4 Flat Washer 10 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 67 to the Weight Tube 63 with the 5 16 x 1 3 4 Bolt 72 and a 5 16 Nylon Locknut 3
7. the Seat Frame Secure the Curl Frame with the Curl Knob 85 15 VKR ASSEMBLY 36 Press 1 1 2 Sguare Inner Caps 32 into the ends of the Left VKR Arm 79 and the Right VKR Arm 80 Press 1 Round Inner Caps 49 into the ends of the handles on the Left VKR Arm and the Right VKR Arm Attach the Left VKR Arm 79 and the Right VKR Arm 80 to the Rear Upright 56 with two 5 16 x 3 Bolts 81 and two 5 16 Nylon Locknuts 3 37 Attach a VKR Armrest 78 to the Right VKR Arm 80 with two 1 4 x 2 Screws 24 and two 1 4 Flat Washers 10 Attach a VKR Armrest 78 to the Left VKR Arm 79 in the same manner Attach the VKR Backrest 77 to the Rear Upright 56 with two 1 4 x 2 1 2 Screws 43 and two 1 4 Flat Washers 10 16 38 Remove the decals from the decal sheet not shown and apply them to the home gym system in the loca tions shown in the illustration below HIGH PULLEY OTHER SIDE BUTTERFLY LIFESTYLER SYSTEM 200 VERTICAL KNEE RAISE BENCH PRESS PREACHER CURL LEG EXTENSION LOW PULLEY 39 Make sure that all parts have been properly tightened The use of the remaining parts will be explained in ADJUSTMENT beginning on page 18 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 I
8. 22 128275 23 127064 24 128276 25 127505 26 122693 27 108874 28 127065 29 127053 30 127066 31 119702 32 103833 33 121421 34 119170 35 127067 36 127054 37 127055 38 128281 39 115177 40 119192 41 127056 42 127057 43 128283 44 113666 45 127180 46 127058 47 127059 OONDOARWNDN Qty FANMNOAARAABAAAAADAUTHDAANNADANAAHANDAANWAWAHAMWWA ANww Description 5 16 x 2 1 2 Carriage Bolt 1 4 Nylon Locknut 5 16 Nylon Locknut Base Stabilizer V Pulley 3 8 x 2 1 2 Bolt 5 16 Flat Washer 3 8 Flat Washer 1 4 Flat Washer 5 16 x 2 3 4 Bolt 3 8 x 2 Bolt Seat 5 16 x 2 3 4 Carriage Bolt 3 1 2 Pulley 3 8 x 3 1 2 Bolt Press Frame 1 4 x 1 2 Screw Weight Bumper Pulley Bracket 3 8 Nylon Locknut 5 16 x 2 1 2 Bolt Long Cable 1 4 x 2 Screw Weight Weight Pin 2 Sguare Inner Cap 12 1 2 Pad Tube Leg Lever 5 1 2 Pad Hand Grip 1 1 2 Square Inner Cap 5 16 x 2 1 4 Bolt 3 4 Round Inner Cap Short Cable Seat Frame Seat Plate 1 4 x 2 Carriage Bolt Nylon Strap Seat Knob Backrest Front Upright 1 4 x 2 1 2 Screw 1 3 4 Square Inner Cap 10 Pad Press Arm Left Arm Key Part No 48 49 50 51 No 127060 120733 126799 105723 116868 103087 127061 127068 127069 127070 127071 128292 128293 122688 122719 127167 122691 120696 127168 127169 128297 108778 120808 118588 1020
9. 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 Pin Grooves FRAME ASSEMBLY ARM ASSEMBLY 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 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 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 Pd Lubricate Welded Spacers ARM ASSEMBLY
10. 73 121845 121828 126891 127506 127170 127171 127172 127173 126145 127175 127517 127176 127177 127178 115648 126883 013211 013480 130313 124590 127242 127243 Qty a E A ROG96A Description Right Arm 1 Round Inner Cap Long Cable Trap 2 Square Outer Cap Chain Cable Clip Lat Bar Top Frame Rear Upright Long U Bracket Medium Cable 3 8 x 8 Bolt 5 16 x 6 Bolt 1 2 x 3 4 Spacer Weight Guide Weight Tube Weight Tube Bumper 1 Square Inner Cap Cable Trap Small U Bracket 5 16 x 5 Bolt 1 Retainer 1 Round Cover Cap 3 8 x 3 3 4 Bolt 5 16 x 1 3 4 Bolt 5 8 x 9 16 Spacer 1 1 4 x 2 1 2 Plastic Bushing 1 x 7 8 Plastic Bushing Top Weight VKR Backrest VKR Arm Rest Left VKR Arm Right VKR Arm 5 16 x 3 Bolt Curl Pad Foot Rest Curl Frame Curl Knob Curl Bar 1 2 x 1 2 Bushing Brace 5 16 x 3 4 Bolt 5 16 x 1 1 4 Carriage Bolt 1 2 x 3 8 Bushing 3 1 2 Low Pulley User s Manual Exercise Guide Note indicates a non illustrated part Specifications are subject to change without notice EXPLODED DRAWING Model No 831 159460 R0696A R0995A EXPLODED DRAWING Model No 831 159460 The model number and serial number of your SEARS Model No 831 159460 LIFESTYLER SYSTEM 200 are listed on a decal attached to the frame See the front cover of this manual to fin
11. AP TO THE HIGH PULLEY STATION Attach the Lat Bar 54 to the Long Cable 23 with a Cable Clip 53 For some exercises the Chain 52 should be attached between the Lat Bar and the Long Cable with two Cable Clips Adjust the length of the Chain between the Lat Bar and the Long Cable so the Lat Bar is in the correct starting position for the exercise to be performed The Nylon Strap 39 can be attached in the same manner ATTACHING THE LAT BAR OR NYLON STRAP TO THE LOW PULLEY STATION Attach the Lat Bar 54 to the Medium Cable 58 with a Cable Clip 53 For some exercises the Chain 52 should be attached between the Lat Bar and the Pulley Cable with two Cable Clips Adjust the length of the Chain between the Lat Bar and the Medium Cable so the Lat Bar is in the correct starting position for the exercise to be performed The Nylon Strap 39 can be attached in the same manner 7 Y a NU 9 IN 25 18 ATTACHING AND REMOVING THE SEAT Set the bracket on the Seat Frame 36 on the indicat ed pins on the Front Upright 42 Attach the Seat Frame to the Front Upright with the 5 16 x 2 3 4 Carriage Bolt 14 and the Seat Knob 40 For some exercises the Seat Frame 36 must be re moved First be sure that the chain is not attached to the leg lever Next remove the Seat Knob 40 and the 5 16 x 2 3 4 Carriage Bolt 14 from the Seat Frame 36 Lift the Seat Frame off the Front Up
12. EZ SYSTEN 2 SEARS Model No 831 159460 Serial No The serial number can be found in the location shown below Write the serial number in the space above E Serial Number Decal under seat ExERCISE E QUIPMENT QUESTIONS HELPLINE 1 800 736 6879 CAUTION Read all precautions and instruc tions in this manual before using this equipment Save this manual for future reference USER S MANUAL PATENT PENDING TABLE OF CONTENTS FULL 90 DAY WARRANTY sso lo dei rlel kele ce ee ela dee e pai 2 IMPORTANT PRECAUTIONS orei ai eee al EA Ere ta gie i 3 BEFORE YOU BEGIN ius oc aaa pietre iaia a 4 ASSEMBLY yee awd wong be LO e LEV e SPL dea eles pia RE te nee a 5 ADJUSTMENT r SRE E OR AI TE tr 18 TROUBLE SHOOTING AND MAINTENANCE 21 CABLE DIAGRAM Lirio pad darlo daa paras iaia 22 ORDERING REPLACEMENT PARTS Li 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 i
13. Pulley 22 O Mp OL OL 1 2 x 1 2 Bushing 87 1 eee 5 8 x 9 16 Spacer 73 9 1 2 x 3 4 Spacer 61 OL 2 ON 1 x 7 8 Plastic Bushing 75 1 Square Inner Cap 65 E 1 3 4 Square Inner Cap 44 1 1 2 Square Inner Cap 32 Mw 2 Square Inner Cap 27 2 Square Outer Cap 51 O H 1a nyon Lodi 2 8 u 1 4 x 2 Screw 24 5 eee MO O y 1 4 x 2 Carriage Bolt 38 i 3 8 x 2 Bolt 12 5 16 x 2 1 4 Bolt 33 5 16 Flat Washer 8 8 1 4 x 2 1 2 Screw 43 HO 5 16 x 2 1 2 Bolt 22 3 8 Flat Washer 9 4 5 16 x 2 1 2 Carriage Bolt 1 3 1 4 x 1 2 Screw 18 3 8 x 2 1 2 Bolt 7 5 16 x 3 Bolt 81 5 16 x 1 1 4 Carriage Bolt 90 HO 5 16 x 1 3 4 Bolt 72 5 16 x 2 3 4 Carriage Bolt 14 3 MW 3 8 x 3 1 2 Bolt 16 MO 3 8 x 3 3 4 Bolt 71 Y 5 16 x 5 Bolt 68 1 5 16 x 6 Bolt 60 1 OL 1 1 4 x 2 1 2 Plastic Bushing 74 gt Cable Clip 53 3 1 Retainer 69 4 on ON OL 3 4 Round Inner Cap 34 4 Peona Cap 49 nep 1 Round Cover Cap 70 4 ra a x 8 Boit 59 1 38 PART LIST Model No 831 159460 Key Part No No 100291 012139 012056 127049 127050 115164 013581 014073 014132 10 014063 11 119377 12 013601 13 126875 14 123385 15 115370 16 120003 17 127051 18 127937 19 122690 20 127052 21 012149
14. d the location of the decal All replacement parts are available for immediate purchase or QUESTIONS special order when you visit your nearest SEARS Service Center To request service or to order parts by telephone call the toll free If you find that numbers listed at the left you need help assembling or When requesting help or service or ordering parts please be pre operating the LIFESTYLER pared to provide the following information SYSTEM 200 a partis missing The MODEL NUMBER of the product 831 159460 or you need to schedule repair service The NAME of the product SEARS LIFESTYLER SYSTEM 200 call our toll free HELPLINE 1 800 736 6879 Monday Saturday 7 am 7 pm Central Time excluding holidays The PART NUMBER of the PART see the PART LIST EXPLOD ED DRAWING attached at the center of this manual The DESCRIPTION of the PART see the PART LIST EXPLOD ED DRAWING attached at the center of this manual REPLACEMENT PARTS If parts become worn and need to be replaced call the following toll free number 1 800 FON PART 1 800 366 7278 SEARS ROEBUCK AND CO HOFFMAN ESTATES IL 60179 Part No 127242 RO696A Printed in Canada 1996 Sears Roebuck and Co
15. 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 FRAME ASSEMBLY 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 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 sc
16. f the cables are not properly installed they may be damaged when heavy weight is used See the CABLE DIAGRAM on page 22 of this manual for proper cable routing If there is any slack in the cables you will need to remove it by tightening the cables See TROUBLE SHOOTING AND MAINTE NANCE on page 21 17 ADJUSTMENT The instructions below describe how each part of the home gym system can be adjusted Refer to the exercise guide accompanying this manual to see how the home gym system should be set up for each exercise IMPOR TANT When attaching the lat bar or nylon strap make sure that the attachments are in the correct start ing 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 To change the weight setting of the weight stack insert the Weight Pin 26 under the desired Weight 25 Be sure to 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 the 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 actual amount of resistance at each exercise station may vary from the weight setting Use the WEIGHT RESISTANCE CHART on page 20 to find the approximate amount of resistance at each weight station ATTACHING THE LAT BAR OR NYLON STR
17. f the Short Cable 58 see drawing 2 To do this you may need to remove the Small U Bracket 67 from the Weight Tube 63 or remove the 3 1 2 Pulley 15 from the Long U Bracket 57 Make sure that the cables are not too tight or the Top Weight 76 will be lifted off the weight stack Additional slack can be removed by moving the 3 1 2 Pulley 15 to the other hole in the Long U Bracket 57 Remove the 3 8 Nylon Locknut 21 and the 3 8 x 2 Bolt 12 from the Cable Trap 66 Pulley and Long U Bracket Re attach the Pulley and Cable Trap Be sure that the Cable trap is in the proper position and that the Cable and Pulley move smoothly If the cables need to be replaced see the back cover of this manual 21 CABLE DIAGRAM The diagram below shows the proper routing of the Short Cable 35 the Medium Cable 58 and the Long Cable 23 Use the diagram to be sure that the cables and the cable traps have been assembled correctly If the cables have not been correctly routed the home gym system will not function properly and damage may occur The inset drawings show the proper positioning of the cable traps The cable traps should be positioned so that the cables will not come off the pulleys Be sure that the cable traps do not touch or bind the cables 1 High Pulley 5 Long U Bracket Medium Cable 58 Short Cable 35 8 Weight Stack 1 Low
18. f the pulleys 6 The home gym system is designed to be 13 Always disconnect the lat bar from the home used by only one person at a time gym system when performing an exercise that does not use the lat bar 7 Keep small children and pets away from the home gym system at all times 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 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 guestions please call ASSEMBLED DIMENSIONS Height 74 in Width 40 in Length 58 in 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 cal
19. he lower end of each Arm with soapy water Slide a 10 Pad 45 onto the lower end of each Arm Welded Brackets 48 55 Bracket Lubricate Axle CABLE ASSEMBLY 11 12 13 14 During steps 11 through 27 refer to the CABLE DIAGRAM on page 22 of this manual to verify proper cable routing Before begin ning 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 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 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 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 posi t
20. ioned to hold the Cable in place Tighten the 3 8 x 2 1 2 Bolt 7 and the 3 8 Nylon Locknut not shown CABLE ASSEMBLY 15 Route the Long Cable 23 around the V Pulley 6 on the Right Arm 48 Be sure that the Cable is in the groove of the V Pulley and that the Long Cable Trap 50 is turned to hold the Cable in place Tighten the 3 8 x 2 1 2 Bolt 7 and the 3 8 Nylon Locknut not shown 16 Route the Long Cable 23 around the 3 1 2 Pulley 15 attached to the Pulley Bracket 20 Be sure that the Cable is in the groove of the Pulley and that the Cable Trap 66 is turned to hold the Cable in place Tighten the 3 8 x 2 Bolt 12 and the 3 8 Nylon Locknut not shown Make sure that the 5 16 x 5 Bolt 68 is properly tightened and that the Pulley Bracket 20 can move freely 17 See the inset drawing Attach a 3 1 2 Pulley 15 and a Cable Trap 66 to the indicated hole in the Long U Bracket 57 with a 3 8 x 2 Bolt 12 and a 3 8 Nylon Locknut 21 Be sure that the Cable Trap is inside the U Bracket Note This may come pre assem bled Route the Long Cable 23 around the 3 1 2 Pulley 15 and through the Long U Bracket 57 Be sure that the Cable is in the groove of the Pulley and that the Cable and Pulley move smoothly 18 Note The Pulley in this drawing is pre assembled It is shown disassembled for easy part identification
21. ling The model number is 831 159460 The serial number can be found on a decal attached to the SYS TEM 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 Lat Bar High Pulley Station Butterfly Arms Vertical Knee Raise VKR Arm Backrest Press Arm Weight Stack Weight Pin Curl Pad Curl Frame Leg Lever Curl Bar Low Pulley Station Foot Plate 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 back rest assembly and 5 VKR assembly The hard ware 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 1 Before beginning assembly be sure that you have read and understand the infor mation in the box above Press a 2 Sguare Outer Cap 51 onto
22. rewdriver One 1 rubber mallet E 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 High Side of Bracket Slotted Hole FRAME ASSEMBLY 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 Press a 2 Square Inner Cap 27 into the indi cated 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 Set two Weight Bumpers 19 on the indicated bracket on the Base 4 as shown Stack eight Weights
23. right 42 ATTACHING THE LEG LEVER TO THE LOW PULLEY STATION To use the Leg Lever 29 the seat must be attached to the front upright see ATTACHING AND REMOV ING THE SEAT above Attach one end of the Chain 52 to the Medium Cable 58 with a Cable Clip 53 Attach the other end of the Chain to the indicated bracket on the Leg Lever 29 with a Cable Clip ATTACHING AND REMOVING THE CURL FRAME For some exercises the Curl Frame 84 must be attached to the Seat Frame 36 To attach the Curl Frame to the Seat Frame insert the pin on the Curl Frame into the upper hole in the Seat Frame Secure the Curl Frame with the Curl Knob 85 To remove the Curl Frame 84 from the Seat Frame 36 remove the Curl Knob 85 Lift the Curl Frame off the Seat Frame USING THE CURL BAR For most exercises that use the Curl Bar 86 the curl frame must be attached see ATTACHING AND REMOVING THE CURL FRAME above Remove the Curl Bar 86 from the keyhole in the Leg Lever 29 Hold the Curl Bar as described for the exercise you are about to perform Be sure that the Short Cable 35 remains in the groove on the underside of the Leg Lever while you are using the Curl Bar It may be necessary to adjust the Short Cable 35 in order to perform certain exercises To do so see ADJUSTING THE SHORT CABLE on page 20 19 ADJUSTING THE SHORT CABLE The position of the Curl Bar 86 can be changed by adjusting the Short Cable 35
24. s 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 IMPORTANT PRECAUTIONS WARNING To reduce the risk of serious injury read the following important precautions before using the home gym system 1 Read all instructions in this manual and in 8 Keep hands and feet away from moving the accompanying literature before using the parts home gym system 9 Always wear athletic shoes for foot protection 2 Itis the responsibility of the owner to ensure that all users of the home gym system are 10 Always stand on the foot plate when perform adequately informed of all precautions ing an exercise that could cause the home gym system to tip 3 If you feel pain or dizziness at any time while exercising stop immediately and begin cool 11 Never release the press arm butterfly arms ing down leg lever lat bar or nylon strap while weights are raised The weights will fall with great 4 Use the home gym system only on a level force surface Place a mat beneath the home gym system to protect the floor or carpet 12 Make sure that the cables remain on the pul leys at all times If the cables bind while you 5 Inspect and tighten all parts often Replace are exercising stop immediately and make any worn parts immediately sure that the cables are on all o
25. the 3 8 Flat Washer 9 onto the Bolt Be sure that all parts are oriented as shown Do not tight en the Nylon Locknut yet 21 The indicated 3 8 x 3 3 4 Bolt 71 has also been inserted from the wrong side for ship ping purposes Remove the Bolt and the 3 8 Nylon Locknut 21 Slide the Cable Trap 66 and the 3 1 2 Pulley 15 onto the 3 8 x 3 3 4 Bolt 71 Re insert the Bolt into the Front Upright 42 from the direction shown Hand tighten the 3 8 Nylon Locknut 21 with the 3 8 Flat Washer 9 onto the Bolt Be sure that all parts are oriented as shown Do not tight en the Nylon Locknut yet 11 CABLE ASSEMBLY 22 23 24 25 Locate the Medium Cable 58 Route the Medium Cable 58 under the 3 1 2 Low Pulley 92 attached to the lower hole in the Press Frame 17 Be sure that the end of the Cable with the ball is on the indicated side of the Press Frame and that the Cable is between the Pulley and the crossbar on the Press Frame Tighten the 3 8 Nylon Locknut 21 and the 3 8 x 3 3 4 Bolt not shown Route the Medium Cable 58 around the 3 1 2 Pulley 15 attached to the lower hole in the Front Upright 42 See the inset draw ing Be sure that the Cable Trap 66 is turned to hold the Cable in place and that the Cable is routed around the Pulley as shown Tighten the 3 8 Nylon Locknut 21 and the 3 8 x 3 3 4 Bolt 71 Route the Medium Cable 58
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