Weider 831.159833 Home Gym User Manual
Contents
1. Low Cable 71 PART IDENTIFICATION CHART Model No 831 159833 R1203A M10 x 69mm Bolt 92 gt M6 Nylon Locknut 103 M10 x 63mm Carriage Bolt 76 M8 Nylon Locknut 86 O M10 Nylon Locknut 90 M10 x 67mm Bolt 82 M6 Washer 99 M8 x 63mm Carriage Bolt 113 M8 x 61mm Carriage Bolt 75 8 x 66mm Bolt 89 C M6 x 65mm Bolt 79 M8 Washer 100 8 x 62mm Bolt 87 M10 x 58mm Bolt 114 M8 x 58mm Bolt mo M10 x 48mm Bolt 93 C H 6 x 16mm Bolt 98 M10 x 45mm Bolt 94 C 89 4 25mm Screw 80 8 x 20mm Shoulder Bolt 84 M10 Washer 97 M8 x 45mm Bolt 96 7 M6 x 62mm Carriage Bolt 91 3 M8 x 68mm Shoulder Bolt 108 H m M10 x 72mm Bolt 105 Y S x gt e gt gt M10 x 76mm Bolt 88 M10 x 78mm Bolt 107 M10 x 81mm Bolt 104 M10 x 84mm Bolt 78 M10 x 89mm Bolt 111 M10 x 91mm Bolt 101 M10 x2. o Tx T 2 S 7 o WEIGHT SYSTEM EXERCISER Write the serial number in the space above for reference User s Manual Serial Number Decal under seat Sears Roebuck and Co Hoffman Estates IL 60179 tions in this manual before using this equipment Save this manu Read all precautions and instruc al for future reference Assembly Adjustments Troubleshooting Part List and Drawing CAUTION TABLE OF CONTENTS IMPORTANT PRECAUTIONS e rr 3 BEFORE YOU BEGIN Renee Ege ee A AE 4 ASSEMBLY EMT 5 ADJUSTMEN Seri een e baal e Qua SN Ae wah ee a od ee eee ee a eee eee 25 WEIGHT RESISTANCE CHAT 27 TROUBLESHOOTING AND MAINTENANCE eens 28 CABLE DIAGRAMS eoim RU enc a aa ee cee ee s en 30 ORDERING REPLACEMENT PARTS Back Cover FULL 90 DAY WARRANTY mt Back Cover Note A PART LIST EXPLODED DRAWING and a PART IDENTIFICATION CHART are attached in the center of this manual Remove the PART LIST EXPLODED DRAWING and the PART IDENTIFICATION CHART before beginning assembly IMPORTANT PRECAUTIONS A WARNING To reduce the risk of serious injury read the following important precautions before using the weight system 1 10 Read all instructions in this manual and in the accompanying literature before using the weight system It is
3. The warning decal shown here has been placed on the weight system in the location shown on page 4 If a decal is missing or illegible please call toll free 1 800 999 3756 Monday through Friday 6 a m until 6 p m Mountain Time to order a free replacement decal Place the decal on the weight system in the location shown Misuse of this roduct may result In serious injury Read user s man ual and follow all warnings and op erating instructions prior to use Do not allow child ren on or around machine or removed A 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 innovative and versatile WEIDER PRO POWER STACK weight system The weight system offers a unique selection of weight sta tions 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 weight system will help you to achieve the results you want For your benefit read this manual carefully before using the weight system If you have questions after Butterfly Arm Ab Pulley Statio
4. Trademark SM Service Mark of Sears Roebuck and Co Marca Registrada TM Marca de F brica SM Marca de Servicio de Sears Roebuck and Co FULL 90 DAY WARRANTY N 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 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 Part No 202725 R1203A Printed in China 2003 Sears Roebuck and Co
5. the Center Top Frame 8 with an M10 x 67mm Bolt 82 two M10 Washers 97 and an M10 Nylon Locknut 90 29 Wrap the Rear Cable 70 under a 90mm Pulley 30 31 32 35 Attach the Pulley and a Cable Trap 38 to the top hole in the pair of Pulley Plates 32 with an M10 x 48mm Bolt 93 and an M10 Nylon Locknut 90 Make sure the Cable Trap is posi tioned to hold the Cable in the groove of the Pulley Wrap the Rear Cable 70 over a 115mm Pulley 36 in the direction shown Attach the Pulley inside the indicated bracket on the Center Top Frame 8 with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 Attach the end of the Rear Cable 70 to a U bracket 33 with an M8 Washer 100 and an M8 Nylon Locknut 86 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 Attach the U bracket 33 to the Short Weight Tube 44 with an M8 x 45mm Bolt 96 and an M8 Nylon Locknut 86 Identify the Ab Cable 74 It is approximately 226 1 2 long and it has a ball on one end and an eyelet on the other H Large tabs on this side rss Wrap the Ab Cable 74 over a 90mm Pulley 35 as shown Place two Pulley Covers 39 over the Pulley so that the large tabs are on the indicated side Attach the Pulley a
6. 20 21 Arm Assembly Locate and open the parts bag labeled ARM ASSEMBLY Press two 50mm Square Inner Caps 67 into the ends of the Leg Lever 13 Lubricate an M10 x 84mm Bolt 78 with grease Attach the Leg Lever 13 to the Butterfly Leg 11 with the Bolt and an M10 Nylon Locknut 90 Do not overtighten the Locknut the Leg Lever must be able to pivot easily Lubricate the M10 x 76mm Bolt 88 with grease Attach the Leg Press Lever 14 to the Press Base 3 with the Bolt and an M10 Nylon Locknut 90 Do not overtighten the Locknut the Leg Press Lever must pivot easily Lubricate See the inset drawing Press a Plastic Bushing 60 onto each welded tube on the Press Frame 17 Slide the Press Frame into place on the Press Base 3 Note This will be a tight fit the Plastic Bushings should fit onto each end of the welded tubes in the Base Lubricate the M10 x 207mm Bolt 106 with grease Attach the Press Frame 17 to the Press Base 3 with the Bolt and an M10 Nylon Locknut 90 Do not overtighten the Locknut the Press Frame must pivot easily 90 Lubricate Press a 45mm Square Inner Cap 68 into the top of a Press Arm 18 Press a 25mm Round Inner Cap 66 into the Press Arm Attach the Press Arm 18 to the Press Frame 17 with two M8 x 62mm Bolts 87 and two 8 Nylon Locknuts 86 Repeat this step with the other Press Arm 18 22 Identify the Right an
7. 39 40 Wrap the Ab Cable 74 under a 90mm Pulley 35 Attach the Pulley to the indicated bracket on the Center Base 2 with an M10 x 97mm Bolt 77 and an M10 Nylon Locknut 90 Note The M10 x 97mm Bolt 77 must be inserted through both brackets on the Center Frame 2 Tighten the M10 Nylon Locknut 90 only a few turns onto the Bolt it will need to be removed in step 39 Wrap the Ab Cable 74 over a 90mm Pulley 35 in the direction shown Attach the Pulley anda Cable Trap 38 to the second set of holes from the bottom in the indicated pair of Pulley Plates 32 with an M10 x 48mm Bolt 93 and an M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Remove the M10 x 97mm Bolt 77 and the M10 Nylon Locknut 90 used in step 37 Wrap the Ab Cable 74 under a 90mm Pulley 35 as shown Attach the Pulley to the indicated brack et on the Center Base 2 and the 90mm Pulley 35 used in step 37 to its bracket with the M10 x 97mm Bolt 77 and the M10 Nylon Locknut 90 Note Make sure the Pulley used in step 37 is attached as shown Wrap the Ab Cable 74 around a 90mm Pulley 35 as shown Slide the Pulley and a Cable Trap 38 onto the M10 x 89mm Carriage Bolt 95 in the Center Base 2 Secure the Pulley with an M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley
8. 51 Insert a Pad Tube 51 into the indicated hole in the Leg Lever 13 Slide two Foam Pads 52 onto the ends of the Pad Tube Insert a Pad Tube 51 into the welded tube on the Butterfly Leg 11 Slide two Foam Pads 52 onto the ends of the Pad Tube 67 Attach the Curl Pad 22 to the Curl Post 21 with two M6 x 16mm Bolts 98 68 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 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 pages 30 and 31 for proper cable routing If there is any slack in the cables you will need to remove it by tightening the cables see TROUBLESHOOTING AND MAINTENANCE on page 28 24 ADJUSTMENTS The instructions below describe how each part of the weight system can be adjusted Refer to the exercise guide accompanying this manual to see how the weight system should be set up for each exercise IMPOR TANT When using an accessory make sure it is 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 reduc
9. 93mm Bolt 85 M10 x 89mm Carriage Bolt 95 M10 x 92mm Carriage Bolt 112 g M10 x 97mm Bolt 77 M10 x 100mm Bolt 115 25mm Retainer 54 25mm Round Cover 55 50mm Square Inner Cap 67 19mm Round Inner Cap 64 25mm Round Inner Cap 66 25mm Square Inner Cap 69 Bi 45mm Square Inner Cap 68 PART LIST Model No 831 159833 R1203A Key No Qty Description Key No Qty Description 1 1 Butterfly Base 60 2 Plastic Bushing 2 1 Center Base 61 2 Large Bushing 3 1 Press Base 62 4 Handgrip 4 1 Butterfly Upright 63 4 M10 Large Washer 5 1 Press Upright 64 4 19mm Round Inner Cap 6 1 Upright Support 65 2 Butterfly Arm Bushing 7 1 Butterfly Top Frame 66 2 25mm Round Inner Cap 8 1 Center Top Frame 67 15 50mm Square Inner Cap 9 1 Press Top Frame 68 7 45mm Square Inner Cap 10 1 Butterfly Seat Frame 69 1 25mm Square Inner Cap 11 1 Butterfly Leg 70 1 Rear Cable 12 1 Press Seat Frame 71 1 Low Cable 13 1 Leg Lever 72 1 Press Cable 14 1 Leg Press Lever 73 1 Butterfly Cable 15 1 Adjustment Tube 74 1 Ab Cable 16 1 Leg Press Plate 75 8 M8 x 61mm Carriage Bolt 17 1 Press Frame 76 1 M10 x 68mm Carriage Bolt 18 2 Press Arm 77 3 M
10. Bolt 96 and the M8 Nylon Locknut 86 The Press Cable 72 can be tightened in the same manner The Pulley Plates 32 have four sets of holes for each 90mm Pulley 35 Slack can be removed from the cables by moving one or both Pulleys to a set of holes closer to the center of the Pulley Plates To move a 90mm Pulley 35 remove the M10 Nylon Locknut 90 and the M10 x 48mm Bolt 93 from the Pulley Plates 32 the Cable Trap 38 and Pulley Re attach the Pulley and Cable Trap to the next set of holes in the Pulley Plates with the Bolt and Locknut 28 Slack can be removed from the Press Cable 72 by moving the V pulley 34 attached to the Press Seat Frame 12 closer to the Press Upright 5 Remove the M10 x 93mm Bolt 85 M10 Washer 97 and M10 Nylon Locknut 90 from the Press Seat Frame 12 the V pulley 34 and the Long Cable Trap 37 Move the V pulley to a hole that is closer to the Press Upright 5 one hole at a time until the slack is removed Reattach the V pulley and Cable Trap to the hole with the Bolt Washer and Locknut If there is still slack in the Press Cable 72 move the V pulley 34 attached to the small tube on the Press Upright 5 to a hole that is closer to the Upright Remove the M10 x 69mm Bolt 92 M10 Washer 97 and M10 Nylon Locknut 90 from the Press Upright 5 the V pulley 34 and the Long Cable Trap 37
11. a V pulley 84 in the direction shown Attach the V pulley and a Long Cable Trap 37 underneath the Press Seat Frame 12 with an M10 x 100mm Bolt 115 an M10 Washer 97 and an M10 Nylon Locknut 90 Note the Press Seat Frame has five adjustment holes The Pulley must attached at the second hole from the Leg Press Lever 14 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Remove the M10 Nylon Locknut 90 used in step 54 Wrap the Press Cable 72 around a 90mm Pulley 35 as shown Slide a Cable Trap 38 and the Pulley onto the M10 x 121mm Bolt 102 in the Leg Press Lever 14 Properly tighten the M10 Nylon Locknut 90 onto the Bolt Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley 21 57 Remove the M10 Nylon Locknut 90 used in step 53 Route the Press Cable 72 through the Press Frame 17 Wrap the Press Cable 72 under a 90mm Pulley 35 Slide a Cable Trap 38 and the Pulley onto the M10 x 121mm Bolt 102 in the bottom of the Press Upright 5 Properly tighten the M10 Nylon Locknut 90 onto the Bolt Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley 58 Wrap the Press Cable 72 around a 90mm Pulley 35 as shown Slide a Cable Trap 38 and the Pulley onto the M10 x 92mm Carriage Bolt 112 in the Press Base 3 Secure the Pulley with an M10 Nylon Locknut
12. and open the parts bag labeled PULLEY BAG 2 Remove one V pulley 34 from the bag Wrap the Butterfly Cable 73 over the V pulley 34 Attach the V pulley and a Long Cable Trap 37 to the bracket on the back of the Butterfly Upright 4 with an M10 x 58mm Bolt 114 and an M10 Nylon Locknut 90 Make sure the Long Cable Trap is oriented to hold the Cable in the groove of the V pulley 25 26 27 28 Wrap the Butterfly Cable 73 under a 90mm Pulley 35 Attach the Pulley to the Double U bracket 31 with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 Remove another V pulley 34 from the bag labeled PULLEY BAG 2 Wrap the Butterfly Cable 73 over the V pulley 84 Attach the V pulley and a Long Cable Trap 37 to the bracket on the back of the Butterfly Upright 4 with an M10 x 58mm Bolt 114 and an M10 Nylon Locknut 90 Make sure the Long Cable Trap is oriented to hold the Cable in the groove of the V pulley Attach the Butterfly Cable 73 to the bracket on the Right Butterfly Arm 19 with an M8 x 20mm Shoulder Bolt 84 and an M8 Nylon Locknut 86 Make sure that the flat side of the eyelet on the cable see the inset drawing is against theButterfly Arm Identify the Rear Cable 70 It is approximately 95 1 8 long and it has an eyelet on one end and a threaded shaft on the other Attach the eyelet on the Rear Cable 70 inside
13. 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 that all parts are oriented exactly as shown in the draw ings Tightening Parts Tighten all parts as you assemble them unless instructed to do otherwise Questions If you have questions after reading the assembly instructions please call 1 800 4 MY HOME 1 800 469 4663 Cable Assembly During this stage you will attach the cables and pulleys that connect the weight stations to the weight stacks Seat Assembly During the final stage you will assemble the seats and the backrests Frame Assembly Before beginning be sure that you have read and understood the information on page 5 Locate and open the parts bag labeled FRAME ASSEMBLY Press a 50mm Square Inner Cap 67 into each end of the Butterfly Base 1 Insert four M8 x 61mm Carriage Bolts 75 and an M10 x 89mm Carriage Bolt 95 up through the indicated holes in the Butterfly Base 1 Place the Butterfly Base flat on the floor Note If the Bolts fall out secure them by putting a small piece of tape over the head of each Bolt Press three 50mm Square Inner Caps 67 into the Center Base 2 Insert an M10 x 89mm Carriage Bolt 95 up through the indicated hole in the Center Base Note There are three kinds of support p
14. is oriented as shown Wrap the Press Cable 72 around a 90mm Pulley 85 in the direction shown Attach the Pulley and a Cable Trap 38 at the indicated hole in the Press Frame 17 with an M10 x 81mm Bolt 104 an M10 Washer 97 and an M10 Nylon Locknut 90 Make sure the Pulley is attached on the inside of the Press Frame Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley 20 53 54 55 56 Wrap the Press Cable 72 around a 90mm Pulley 35 in the direction shown Attach the Pulley and a Cable Trap 38 to the indicated hole on the right side of the Press Upright 5 with an M10 x 121mm Bolt 102 and an M10 Nylon Locknut 90 Note Thread the Locknut only two turns onto the Bolt another Pulley will be attached to the Bolt in step 57 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Route the Press Cable 72 through the Press Frame 17 and around a 90mm Pulley 35 as shown Attach the Pulley and a Cable Trap 38 to the indicated hole on the right side of the Leg Press Lever 14 with an M10 x 121mm Bolt 102 and an M10 Nylon Locknut 90 Note Thread the Locknut only two turns onto the Bolt another Pulley will be attached to the Bolt in step 56 Make sure the Cable Trap is posi tioned to hold the Cable in the groove of the Pulley Wrap the Press Cable 72 around
15. six Weights 41 onto the Right Weight Guides 26 Make sure the Weights are turned so the pin grooves are on the bottom Press a Weight Tube Bumper 45 into the lower end of the Short Weight Tube 44 Slide the Short Weight Tube into the center holes in the Weights 41 Lubricate the indicated holes in a Top Weight 42 with grease Slide the Top Weight onto the Right Weight Guides 26 Note Make sure the Top Weight is turned so the groove fits over the welded pin on the Short Weight Tube 44 Slide the Bottom Weight 47 and seven Weights 41 onto the Left Weight Guides 27 Make sure the decal on the Bottom Weight is in the indi cated location and the Weights are oriented with the pin grooves on the bottom Press a Weight Tube Bumper 45 into the lower end of the Long Weight Tube 43 Slide the Long Weight Tube into the center holes in the Weights 41 Lubricate the indicated holes in the other Top Weight 42 with grease Slide the Top Weight onto the Left Weight Guides 27 Note Make sure the Top Weight is turned so the groove fits over the welded pin on the Long Weight Tube 43 Lubricate Pin Grooves Lubricate Pin Groove 15 Press a 50mm Square Inner Cap 67 into the 16 17 Center Top Frame 8 Place the Center Top Frame on the indicated brackets on the Uprights 4 5 Note The tops of the four Weight Guides 26 27 must be behind the Center Top Frame as shown in step 16 A
16. to the Seat 23 with the serial number decal Insert the M6 x 62mm Carriage Bolt 91 into the indicated hole in the Butterfly Seat Frame 10 Secure the other end of the Seat 23 to the Seat Frame with an M6 x 65mm Bolt 79 and an M6 Washer Secure the M6 x 62mm Carriage Bolt with another M6 Washer 99 and an M6 Nylon Locknut 103 Aitach the other Seat 23 to the Press Seat Frame 12 not shown in the same manner W T H TT1I Z 64 Insert an M6 x 62mm Carriage Bolt 91 through the center hole in a Seat Plate 30 Attach the Seat Plate to the Press Backrest 24 with two M6 x 16mm Bolt 98 Insert the M6 x 62mm Carriage Bolt 91 into the indicated hole in the Press Upright 5 Secure the other end of the Press Backrest 24 with an M6 x 65mm Bolt 79 and an M6 Washer Secure the M6 x 62mm Carriage Bolt with an M6 Washer 99 and an M6 Nylon Locknut 103 65 Press a 45mm Square Inner Cap 68 into the indicated end of the Adjustment Tube 15 Orient the Leg Press Plate 16 and Adjustment Tube 15 as shown in the inset drawing Attach the Adjustment Tube to the Leg Press Plate 16 with an M8 x 58mm Bolt 110 two M8 Washers 100 and an M8 Nylon Locknut 86 Place the Adjustment Tube 15 in the bracket on top of the Leg Press Lever 14 and secure it with the Adjustment Pin 40 66 Press four 19mm Round Inner Caps 64 into the ends of the two Pad Tubes
17. 10 x 97mm Bolt 19 1 Right Butterfly Arm 78 1 M10 x 84mm Bolt 20 1 Left Butterfly Arm 79 5 M6 x 65mm Bolt 21 1 Curl Post 80 2 M4 x 25mm Screw 22 1 Curl Pad 81 2 Weight Pin 23 2 Seat 82 3 M10 x 67mm Bolt 24 1 Press Backrest 83 1 Nylon Strap 25 1 Butterfly Backrest 84 2 M8 x 20mm Shoulder Bolt 26 2 Right Weight Guide 85 1 M10 x 93mm Bolt 27 2 Left Weight Guide 86 36 M8 Nylon Locknut 28 2 Small Support Plate 87 4 M8 x 62mm Bolt 29 2 Large Support Plate 88 1 M10 x 76mm Bolt 30 3 Seat Plate 89 14 M8 x 66mm Bolt 31 1 Double U bracket 90 52 M10 Nylon Locknut 32 4 Pulley Plate 91 3 M6 x 62mm Carriage Bolt 33 2 U bracket 92 4 M10 x 69mm Bolt 34 4 V pulley 93 6 M10 x 48mm Bolt 35 27 90mm Pulley 94 7 M10 x 45mm Bolt 36 2 115mm Pulley 95 2 M10 x 89mm Carriage Bolt 37 4 Long Cable Trap 96 2 M8 x 45mm Bolt 38 19 Cable Trap 97 22 M10 Washer 39 2 Pulley Cover 98 8 M6 x 16mm Bolt 40 1 Adjustment Pin 99 8 M6 Washer 41 13 Weight 100 11 M8 Washer 42 2 Top Weight 101 4 M10 x 91mm Bolt 43 1 Long Weight Tube 102 3 M10 x 121mm Bolt 44 1 Short Weight Tube 103 3 M6 Nylon Locknut 45 2 Weight Tube Bumper 104 3 M10 x 81mm Bolt 46 4 Weight Bumper 105 4 M10 x 72mm Bolt 47 1 Bottom Weight 106 1 M10 x 207mm Bolt 48 1 Weight Plate 107 4 M10 x 78mm Bolt 49 1 Curl Knob 108 1 M8 x 68mm Shoulder Bolt 50 2 Bumper 109 4 Medium Support Plate 51 2 Pad Tube 110 1 M8 x 58mm Bolt 52 4 Foam Pad 111 1 M10 x 89mm Bolt 53 2 Large Foam Pad 112 1 M10 x 92mm Carriage Bolt 54 4 25mm
18. 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley 59 Lay the Press Cable 72 in the bracket on the Center Base 2 Attach a 90mm Pulley 35 inside the bracket with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 60 Wrap the Press Cable 72 over a 115mm Pulley 36 Attach the Pulley inside the indicated bracket on the Center Top Frame 8 with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 onto the Cable so that only two threads show 61 Attach the Press Cable 72 to the remaining U bracket 33 with an M8 Washer 100 and an M8 Nylon Locknut 86 Note Do not completely tighten the Locknut it should be threaded 72 96 33 a past the Locknut see the inset drawing ol Attach the U bracket 33 to the Long Weight Tube 43 with an M8 x 45mm Bolt 96 and an 8 Nylon Locknut 86 Important Follow all five cables from end to end and make sure that they rest in the grooves of all of the pulleys and that the cables and the pulleys move smoothly Seat Assembly 62 Locate and open the parts bag labeled SEAT ASSEMBLY Attach the Butterfly Backrest 25 to the Butterfly Upright 4 with two M6 x 65mm Bolts 79 and two M6 Washers 99 63 Insert an M6 x 62mm Carriage Bolt 91 through the center hole in a Seat Plate 30 Using two M6 x 16mm Bolt 98 attach the Seat Plate
19. Lay the Ab Cable 74 inside the indicated bracket on the Center Base 2 Attach a 90mm Pulley 35 inside the bracket with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 Bracket 41 42 43 44 Locate the Weight Plate 48 that is attached to the bottom of the Bottom Weight 47 See the inset drawing Attach the end of the Ab Cable 74 to the bottom of the Weight Plate 48 with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 Identify the Low Cable 71 It is approximately 135 long and it has a ball on one end and an eye let on the other Route the eyelet end through the slot in the cable guide on the Butterfly Base 1 Route the Low Cable 71 under a 90mm Pulley 35 Attach the Pulley and a Cable Trap 38 to the bracket on the Butterfly Base 1 with an M10 x 48mm Bolt 93 and an M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Wrap the Low Cable 71 under a 90mm Pulley 35 Attach the Pulley and a Cable Trap 38 to the welded tube on the Butterfly Upright 4 with an M10 x 121mm Bolt 102 and an M10 Nylon Locknut 90 Note Thread the Locknut only two turns onto the Bolt another Pulley will be attached to the Bolt in step 45 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Wrap the Low Cabl
20. Move the V pulley to a hole that is closer to the Press Upright one hole at a time until the slack is removed Reattach the V pulley and Cable Trap to the hole with the Bolt Washer and Locknut If a cable slips off the pulleys often the cable 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 29 ws CABLE DIAGRAMS The Cable Diagrams below and on the next page show the proper routing of the Rear Cable 70 the Low Cable 71 the Press Cable 72 the Butterfly Cable 73 and the Ab Cable 74 The numbers show the correct route for each Cable Make sure that the Cables are routed correctly that the Pulleys move smoothly and that the Cable Traps do not touch or bind the Cables Incorrect cable routing can damage the weight system CABLE ID CHART Press Cable 72 73 52 0 0 OS a 70 95 1 8 POR 71 132 2 8 O FP 1 Sa lt 74 226 1 2 er 1o 72 387 5 8 sg D 2 EK 15 p N cx q A d 0 IG y A 13 0 O 8 25 T Qu Sy IKG 8 d g 1 Wi A 77 A 3 Zl 1 10 11 7 4 30 co N o a D gt gt m Rear Cable 70
21. Retainer 113 2 M8 x 63mm Carriage Bolt 55 2 25mm Cover Cap 114 2 M10 x 58mm Bolt 56 1 Ab Strap 115 1 M10 x 100mm Bolt 57 1 Chain 1 User s Manual 58 3 Cable Clip 1 Exercise Guide 59 1 Lat Bar 2 Grease Packet Note indicates a non illustrated part Specifications are subject to change without notice EXPLODED DRAWING Model No 831 159833 R1203A Get it fixed at your home or ours Your Home For repair in your home of all major brand appliances lawn and garden equipment or heating and cooling systems no matter who made it no matter who sold it For the replacement parts accessories and user s manuals that you need to do it yourself For Sears professional installation of home appliances and items like garage door openers and water heaters 1 800 4 MY HOME Anytime day or night 1 800 469 4663 U S A and Canada www sears com www sears ca Our Home For repair of carry in products like vacuums lawn equipment and electronics call or go on line for the location of your nearest Sears Parts and Repair Center 1 800 488 1222 Anytime day or night U S A only www sears com To purchase a protection agreement U S A or maintenance agreement Canada on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para pedir servicio de reparacion a domicilio y para ordenar piezas 1 888 SU HOGAR 1 888 784 6427 SEARS Registered Trademark
22. d Left Butterfly Arms 19 20 by the positions of the welded brackets Press a 45mm Square Inner Cap 68 into each end of the Right Butterfly Arm 19 Wet the lower end of the Butterfly Arm with soapy water Slide a Large Foam Pad 53 onto the lower end of the Butterfly Arm Lubricate the axles on the Butterfly Top Frame 7 with grease Orient the Right Butterfly Arm 19 as shown and slide it onto the right axle See the inset drawing Place two 25mm Retainers 54 on top of an inverted 25mm Cover Cap 55 Make sure the teeth on the Retainers bend toward the Cover Cap as shown Have a second person gently tap the two 25mm Retainers 54 and the 25mm Cover Cap 55 onto the axle on the Butterfly Top Frame 7 Repeat this step with the Left Butterfly Arm 20 Cable Assembly 23 Locate and open the parts bag labeled CABLE ASSEMBLY For cable identification and routing during steps 23 to 61 refer to the CABLE DIAGRAMS and CABLE ID CHART on pages 30 and 31 Make sure that the cable traps do not touch or bind the cables as you assemble them Identify the Butterfly Cable 73 It is approxi mately 52 long and it has an eyelet on each end Attach the Butterfly Cable to the bracket on the Left Butterfly Arm 20 with an M8 x 20mm Shoulder Bolt 84 and an M8 Nylon Locknut 86 Make sure that the flat side of the eyelet on the cable see the inset drawing is against theButterfly Arm 24 Locate
23. e 71 over a 90mm Pulley 35 Attach the Pulley and a Cable Trap 38 to the second set of holes from the bottom in the Pulley Plates 32 with an M10 x 48mm Bolt 93 and an M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley 18 45 46 47 48 Remove the M10 Nylon Locknut 90 used in step 43 Wrap the Low Cable 71 under a 90mm Pulley 35 Attach the Pulley and a Cable Trap 38 to the M10 x 121mm Bolt 102 used in step 43 with the M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Attach the Low Cable 71 to the Leg Lever 13 with an M8 x 68mm Shoulder Bolt 108 an M8 Washer 100 and an M8 Nylon Locknut 86 Make sure that the flat side of the eyelet on the cable see the inset drawing is against the leg lever Identify the Press Cable 72 It is approximately 387 5 8 long and it has a ball on one end anda threaded shaft on the other Wrap the Press Cable 72 over a 90mm Pulley 35 Attach the Pulley to the Press Top Frame 9 with an M10 x 89mm Bolt 111 an M10 Washer 97 and an M10 Nylon Locknut 90 Make sure the Cable is between the Pulley and the pin on the Press Top Frame Route the Press Cable 72 over the 90mm Pulley 35 that was attached to the Press Top Frame 9 in step 16 Make sure the Cable T
24. ed ATTACHING THE ACCESSORIES Attach the Lat Bar 59 to the Low Cable 71 at the low pulley station with a Cable Clip 58 For some exercises the Chain 57 should be attached between the Lat Bar and the Cable with two Cable Clips Adjust the length of the Chain between the Lat Bar and the Cable so the Lat Bar is in the correct start ing position for the exercise to be performed The Nylon Strap 83 or Ab Strap 56 can be attached in the same manner The accessories can be attached to the ab pulley station or high pulley station in the same manner ADJUSTING THE LEG PRESS PLATE To adjust the position of the Leg Press Plate 16 pull out the Adjustment Pin 40 and slide the Adjustment Tube 15 either backward or forward in the bracket on the Leg Press Lever 14 Line up one of the adjustment holes in the Adjustment Tube with the hole in the bracket and re insert the Adjustment Pin ATTACHING THE CURL PAD To use the Curl Pad 22 remove the 50mm Square Inner Cap 67 from the Butterfly Leg 11 Slide the Curl Post 21 to the desired height in the Butterfly Leg Tighten the Curl Knob 49 into the Butterfly Leg and an adjustment hole in the Curl Post CHANGING THE WEIGHT SETTING To change the setting of a weight stack insert a Weight Pin 81 under the desired Weight 41 Insert the Weight Pin so that the bent end touches the weight stack Turn the bent end down To use the Bottom Weigh
25. eplace any worn parts immedi ately The weight 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 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 Slack can be removed from the cables in several different ways When you are tightening the cables note that they are linked into two distinct groups The Rear Cable 70 the Low Cable 71 the Butterfly Cable 73 and the Ab Cable 74 are all connected to the small weight stack All three cables will be tightened by tightening the Rear Cable at the small weight stack or by adjusting the 90mm Pulleys 35 in either set of Pulley Plates 32 The Press Cable 72 is attached to the large weight stack The Press Cable can be tightened at the large weight stack or by moving the V pulleys 34 on the Press Upright 5 and the Press Seat Frame 12 The threaded ends on the Rear Cable 70 and the Press Cable 72 attached to the weight stacks can be used to tighten the cables To tighten the Rear Cable 70 remove the M8 x 45mm Bolt 96 and the M8 Nylon Locknut 86 from the U bracket 33 and the Short Weight Tube 44 Tighten the M8 Nylon Locknut 86 onto the end of the Rear Cable 70 a few turns Re attach the U bracket 33 to the Short Weight Tube 44 with the M8 x 45mm
26. ght 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 easier we have divided the assembly process into four stages The small hard ware needed for each stage is packaged in sepa rate bags Important Wait until you begin each stage to open the parts bag s for that stage Place all parts of the weight system in a cleared area and remove the packing materials Do not dis pose of the packing materials until assembly is com pleted 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 Make sure that you have the following tools Two adjustable wrenches One standard screwdriver One phillips screwdriver One rubber mallet You will also need grease or petroleum jelly a small amount of soapy water and 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 How to Identify Parts To help you identify the small parts used in assembly a PART IDENTIFICATION CHART is included in the center of this manual Lay the chart on the floor and use it to easily identify parts during
27. lates The main difference between them is the dis tance between the holes When you need a support plate find the kind with holes that will fit over the bolts you are using Attach the Center Base 2 to the Butterfly Base 1 with two M8 x 66mm Bolts 89 a Medium Support Plate 109 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet Press a 50mm Square Inner Cap 67 into the end of the Press Base 3 Insert four M8 x 61mm Carriage Bolts 75 an M10 x 63mm Carriage Bolt 76 and an M10 x 92mm Carriage Bolt 112 up through the indicat ed holes in the Press Base 3 Orient the Press Base 3 with the indents around the indicated holes on the bottom Attach the Press Base to the Center Base 2 with two M8 x 66mm Bolts 89 a Medium Support Plate 109 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 4 Slide the Butterfly Upright 4 over the indicated 8 x 61mm Carriage Bolts 75 in the Butterfly Base 1 Hand tighten two M8 Nylon Locknuts 86 onto the Bolts Do not tighten the Locknuts yet 5 Press three 50mm Square Inner Caps 67 into the Butterfly Top Frame 7 Attach the Butterfly Top Frame 7 to the indicat ed bracket at the top of the Butterfly Upright 4 with two M8 x 66mm Bolts 89 a Medium Support Plate 109 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 6 Press a 50mm Square Inner Cap 67 halfway into the top of the Butterfly Leg 11 A
28. n Backrest Curl Pad Seat Weight Stack Leg Lever Low Pulley Station Foot Plate 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 159833 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 Please use the drawing below to familiarize your self with the major parts and how they fit together ASSEMBLED DIMENSIONS Height 77 in Width 80 in Depth 59 in High Pulley Station Lat Bar Backrest Press Arm Seat Leg Press Plate Leg Press Lever ASSEMBLY Make Assembly Easier Everything in this manual is designed to ensure that the weight system can be assem bled successfully by anyone Before beginning assembly make sure to read the information on this page This brief introduction 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 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 Select a Location for the Weight System Because of its wei
29. nd Pulley Covers to the Butterfly Upright 4 with an M10 x 97mm Bolt 77 two M10 Washers 97 and an M10 Nylon Locknut 90 Make sure the Cable is between the Pulley and the pin on the Upright 33 Wrap the Ab Cable 74 under a 90mm Pulley 35 Attach the Pulley and a Cable Trap 38 to the top hole in the pair of Pulley Plates 32 with an M10 x 48mm Bolt 93 and an M10 Nylon Locknut 90 Make sure the Cable Trap is posi tioned to hold the Cable in the groove of the Pulley 34 Wrap the Ab Cable 74 over a 90mm Pulley 35 in the direction shown Attach the Pulley to the Double U bracket 31 with an M10 x 45mm Bolt 94 and an M10 Nylon Locknut 90 35 Wrap the Ab Cable 74 under a 90mm Pulley 36 35 Attach the Pulley and a Cable Trap 38 to the indicated bracket on the Butterfly Base 1 with an M10 x 48mm Bolt 93 and an M10 Nylon Locknut 90 Make sure the Cable Trap is posi tioned to hold the Cable in the groove of the Pulley Wrap the Ab Cable 74 around a 90mm Pulley 35 in the direction shown Slide a Cable Trap 38 and the Pulley onto the M10 x 89mm Carriage Bolt 95 in the Butterfly Base 1 Secure the Pulley with an M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley 37 38
30. rap 38 is positioned to hold the Cable in the groove of the Pulley Properly tighten the M10 Nylon Locknut not shown attached to the M10 x 97mm Bolt 77 49 50 51 52 Wrap the Press Cable 72 under a 90mm Pulley 35 Attach the Pulley and a Cable Trap 38 to the indicated hole in the Press Upright 5 with an M10 x 93mm Bolt 85 an M10 Washer 97 and an M10 Nylon Locknut 90 Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Route the Press Cable 72 through the opening in the Press Frame 17 and wrap the Cable around a 90mm Pulley 35 in the direction shown Attach the 90mm Pulley 35 and a Cable Trap 38 to the indicated hole in the Press Frame 17 with an M10 x 81mm Bolt 104 an M10 Washer 97 and an M10 Nylon Locknut 90 Make sure the Pulley is attached on the inside of the Press Frame Make sure the Cable Trap is positioned to hold the Cable in the groove of the Pulley Wrap the Press Cable 72 around a V pulley 34 in the direction shown Attach the V pulley and a Long Cable Trap 37 to the small tube on the Press Upright 5 with an M10 x 81mm Bolt 104 an M10 Washer 97 and an M10 Nylon Locknut 90 Note The small tube has four adjustment holes The V pulley must be attached at the hole farthest from the Upright Make sure the Cable Trap
31. t 47 with the press arms or the leg press insert a Weight Pin 81 under the Bottom Weight Remove the other Weight Pin from the small weight stack To use the small weight stack with the press arms or leg press insert a Weight Pin 81 under the Bottom Weight 47 Then insert the other Weight Pin under the desired Weight 41 in the right weight stack 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 27 to find the approximate amount of resistance at each weight station 26 WEIGHT RESISTANCE CHART The chart below shows the approximate weight resistance at each exercise station Left Top and Right Top refer to the 6 Ib top weights Bottom refers to the 12 5 Ib bottom weight The other numbers refer to the 12 5 lb weight plates Weight resistance shown for the butterfly arm station is for each butterfly arm Note The actu al 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 HIGH PRESS LEG BUTTER AB LEG LOW PULLEY ARM PRESS FLYARM PULLEY LEVER PULLEY Ibs Ibs Ibs Ibs Ibs Ibs Ibs Left Top 7 Bottom Right Top 1 2 3 4 5 6 27 TROUBLESHOOTING AND MAINTENANCE Make sure all parts are properly tightened each time the weight system is used R
32. tach a Bumper 50 to the Seat Frame with an M4 x 25mm Screw 80 Slide the Press Seat Frame 12 onto the indicat ed M8 x 61mm Carriage Bolts 75 in the Press Base 3 Hand tighten two M8 Nylon Locknuts 86 onto the Bolts Do not tighten the Locknuts yet Attach the Press Seat Frame 12 to the Press Upright 5 with two M8 x 66mm Bolts 89 two M8 Washers 100 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 10 Press a 50mm Square Inner Cap 67 into the Press Top Frame 9 Attach the Press Top Frame 9 to the indicated bracket at the top of the Press Upright 5 with two M8 x 66mm Bolts 89 a Medium Support Plate 109 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 11 Identify the Left Weight Guides 27 which have welded rings near the bottom Slide two Weight Bumpers 46 onto the Left Weight Guides Insert the Left Weight Guides into the indicated holes in the Center Base 2 Set the other two Weight Bumpers 46 over the indicated holes in the Center Base 2 Insert the Right Weight Guides 26 through the Weight Bumpers and into the holes in the Center Base Make sure the oval holes on the Right Weight Guides are on the top 12 Attach the indicated Weight Guides 26 27 to the Center Base 2 with two M10 x 67mm Bolts 82 four M10 Washers 97 and two M10 Nylon Locknuts 90 13 14 Slide
33. the responsibility of the owner to ensure that all users of the weight system are ade quately informed of all precautions The weight system is intended for home use only Do not use the weight system in any commercial rental or institutional setting Use the weight system only on a level sur face Cover the floor beneath the weight sys tem to protect the floor Make sure all parts are properly tightened each time the weight system is used Replace any worn parts immediately Keep children under 12 and pets away from the weight system at all times Keep hands and feet away from moving parts Always wear athletic shoes for foot protection The weight system is designed to support a a maximum user weight of 250 pounds Always stand on the foot plate when per forming an exercise that could cause the weight system to tip 11 12 13 14 15 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 Always disconnect the lat bar from the weight system when performing an exercise that does not use the lat bar Make sure that the cables remain on the pul leys 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 If you feel pain or dizziness at any time while exercising stop immediately and begin cool ing down
34. ttach a Bumper 50 to the Butterfly Leg with an M4 x 25mm Screw 80 Attach the Butterfly Seat Frame 10 to the Butterfly Leg 11 with two M8 x 66mm Bolts 89 two M8 Washers 100 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 7 Slide the Butterfly Leg 11 onto the two M8 x 61mm Carriage Bolts 75 in the Butterfly Base 1 Hand tighten two M8 Nylon Locknuts 86 onto the Bolts Do not tighten the Locknuts yet Attach the Butterfly Seat Frame 10 to the Butterfly Upright 4 with two M8 x 66mm Bolts 89 two M8 Washers 100 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 8 Press a 25mm Square Inner Cap 69 into the small tube on the Press Upright 5 Slide the Press Upright 5 over the indicated M8 x 61mm Carriage Bolts 75 in the Press Base 3 Hand tighten two M8 Nylon Locknuts 86 onto the Bolts Do not tighten the Locknuts yet Slide the Upright Support 6 over the M10 x 63mm Carriage Bolt 76 and the M10 x 92mm Carriage Bolt 112 in the Press Base 3 Hand tighten an M10 Nylon Locknut 90 onto the M10 x 63mm Carriage Bolt Do not tighten the Locknut yet Note Do not thread a locknut onto the M10 x 92mm Carriage Bolt yet Attach the Upright Support 6 to the Press Upright 5 with two M8 x 63mm Carriage Bolts 113 and two M8 Nylon Locknuts 86 Do not tighten the Locknuts yet 9 Press a 50mm Square Inner Cap 67 into the Press Seat Frame 12 At
35. ttach the Center Top Frame 8 to the Butterfly Top Frame 7 with two M10 x 69mm Bolts 92 a Large Support Plate 29 and two M10 Nylon Locknuts 90 Do not tighten the Locknuts yet Attach the Center Top Frame 8 to the bracket on the Butterfly Upright 4 with two M10 x 72mm Bolts 105 a Small Support Plate 28 and two M10 Nylon Locknuts 90 Do not tighten the Locknuts yet Attach the the rear hole in Center Top Frame 8 to the Press Top Frame 9 with an M10 x 69mm Bolt 92 a Large Support Plate 29 and an M10 Nylon Locknut 90 Do not tighten the Locknut yet Locate the parts bag labeled PULLEY BAG 1 Remove a 90mm Pulley 35 from the bag Slide the Pulley and a Cable Trap 38 onto an M10 x 97mm Bolt 77 Slide the Bolt through the Large Support Plate 29 and Press Top Frame 9 Hand tighten an M10 Nylon Locknut 90 onto it Do not tighten the Locknuts yet Attach the Center Top Frame 8 to the bracket on the Press Upright 5 with two M10 x 72mm Bolts 105 a Small Support Plate 28 and two M10 Nylon Locknuts 90 Do not tighten the Locknuts yet Attach each set of Weight Guides 26 27 to the Center Top Frame 8 with four M10 x 91mm Bolts 101 eight M10 Washers 97 and four M10 Nylon Locknuts 90 Tighten the M10 Nylon Locknuts 90 and the M8 Nylon Locknuts 86 used in steps 2 17 11 18 19
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