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WEIDERPROPOWER STACK Model No . 831.159830 USER'S MANUAL Serial No . The serial number is found in the locationshown below , Write the serial number inthe space above . Serial Number Decal Ex E : R C I _ 5 _ IE _ F - - - - ( _ U I P M E N T HELPLINE ! 1 - 800 - 736 - 6879 Patent Pending SEARS , ROEBUCK AND CO . HOFFMAN ESTATES , IL 60179 www . weiderfitness . com new products , prizes , fitness tips , and much morel
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TABLE OF CONTENTS IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 TROUBLESHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover FULL 90 DAY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . 2
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IMPORTANT PRECAUTIONS 3
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BEFORE YOU BEGIN have additional questions , please call our toll - free Thank you for selectingthe innovative and versatile HELPLINE at 1 - 800 - 736 - 6879 , Monday through WELDER ° PRO POWER STACK weight system . The Saturday , 7 a . m . until 7 p . m . Central Time ( excluding POWER STACK offers a unique selectionof weight holidays ) . To help us assist you , please note the prod - stationsdesigned to develop every major muscle uct model number and serial number before calling . group of the body . Whether your goal is to tone your The model number is 831.159830 . The serial number body , build dramatic musclesize and strength , or can be found on a decal attached to the weight system improve your cardiovascularsystem , the POWER STACK willhelp youto achievethe resultsyouwant . ( see the front cover of this manual ) . Please use the drawing below to familiarize your - For your benefit , read this manual carefully before self with the major parts and how they fit together . using the POWER STACK weight system . If you ASSEMBLED DIMENSIONS : Height : 77 in . Width : 80 in . Depth : 55 in . ButterflyArm Ab Pulley Station High Pulley Station Backrest Lat Bar Warningl Curl Pad - - Deca Seat , Backrest Leg Level Press Arm Seat Low Pulley Station Foot Plate - - Leg Press Lever Leg Press 4
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ASSEMBLY Make sure you have the following tools : • Two adjustable wrenches • One standard screwdriver • One phillips screwdriver • One rubber mallet • Youwill also need grease or petroleum jelly , a small amount of soapywater , and clear tape or masking tape . Assembly Requires Two Persons Note : Assembly will be more convenient if you have For your convenience and safety , assemble the a socket set , a set of open - end or closed - end weight system withthe help of another person . wrenches , or a set of ratchetwrenches . Set Aside Enough Time How to Identify Parts Due to the many features of the weight system , the To help you identifythe smallpartsused inassembly , assembly process will require several hours . By we have includeda PART IDENTIFICATION CHART setting aside plenty of time and by decidingto in the center of thismanual . Place the charton the make the task enjoyable , assemblywill gosmoothly . floor and use it to easily identifyparts duringeach You may want to assemble the weight systemover assembly step . Note : Some small parts may have a coupleof evenings . been pre - attached . If a part Is not In the parts bag , check to see If It has been pre - attached . Select a Location for the Weight System How to Orient Parts Because of its weight and size , the weight isystemll As you assemble the weight system , make sure that should be assembled in the locationwhere it w be all parts are oriented exactly as shown in the draw - used . Make sure that there is enough room to walk ings . around the weight system as you assemble it . Tightening Parts How to Unpack the Box " 13ghtenall parts as you assemble them , unless To make assembly as easy as possible , we have instructedto do otherwise . divided the assembly process intofour stages . The parts needed for each stage are found in individual Questions ? bags . Important : Walt unUl you begin each stage to open the parts bag for that stage . Place all If you have questionsafter readingthe assembly parts of the weight system in a cleared area and instructions , please sail our toll - free HELPLINE at remove the packing materials . Do not disposeof 1 - 800 - 736 - 6879 , Monday through Saturday , 7 a . m . the packingmaterials untilassemblyis completed . until7 p . m . Central " 13me ( excludingholidays ) . The Four Stages of the Assembly Process Frame Assembly - - You will begin by assembling Cable Assembly - - During this stage you will the base and the uprightsthat form the skeleton of attach the cables and pulleysthat connect the arms to the weights . the weight system . Arm Assembly - - During this stage you will Seat Assembly - - Dudng the final stage you will assemble the seats and the backrests . assemble the arms and the leg lever . 5
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1 . Before beginning , be sure that you have read and understood the Information on page 6 . 67 Locate and open the parts bag labeled " FRAME ASSEMBLY . " 95 Press a 2 " Square Inner Cap ( 67 ) into each end 75 of the ButterflyBase ( 1 ) . 75 Insert four 5 / 16 " x 2 1 / 2 " Carriage Bolts ( 75 ) and a a 3 / 8 " x 3 1 / 2 " Carriage Bolt ( 95 ) up through the 67 indicatedholes 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 heed of each Bolt . 2 . Press three 2 " Square Inner Caps ( 67 ) intothe 2 Center Base ( 2 ) . Insert a 3 / 8 " x 3 1 / 2 " Carriage Bolt ( 95 ) up through the indicated hole in the Center Base . 89 109 Attachthe Center Base ( 2 ) to the ButterflyBase ( 1 ) 86 withtwo 5 / 16 " x 2 3 / 4 " Bolts ( 89 ) , a Medium 67 Support Plate ( 109 ) , and two 5 / 16 " Nylon Locknuts ( 86 ) . Do not tighten the Nylon Locknuts yet . Note : There are three kinds of Support Plates . 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 . 3 , Press a 2 " Square Inner Cap ( 67 ) into the end of the Press Base ( 3 ) . Insert four 5 / 16 " x 2 1 / 2 " Carriage Bolts ( 75 ) up through the indicated holes in the Press Base ( 3 ) . Insert a 3 / 8 " x 2 1 / 2 " Carriage Bolt ( 76 ) and a 3 / 8 " x 4 " Carriage Bolt ( 112 ) up through the indicated holes at the end of the Press Base . 86 67 2 Attachthe Press Base ( 3 ) to the Center Base ( 2 ) 109 withtwo 5 / 16 " x 2 3 / 4 " Bolts ( 89 ) , a Medium Support Plate ( 109 ) , and two 5 / 16 " NylonLocknuts ( 86 ) . Do not tighten the Nylon Locknuts yet . 3 112 75 78
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Slidethe ButterflyUpright ( 4 ) over the indicated 4 . 4 5 / 16 " x 2 112 " Carriage Bolts ( 75 ) in the Butterfly Base ( 1 ) . Hand tighten two 5 / 16 " Nylon Locknuts ( 86 ) onto the Bolts . Do not Ughten the Nylon Locknuts yet . 86 86 \ 1 75 5 . Press three 2 " Square Inner Caps ( 67 ) into the 5 ButterflyTop Frame ( 7 ) . Press two Round Inner Caps ( 63 ) intothe top of the Butterfly Top Frame . Attach the ButterflyTop Frame ( 7 ) to the indicat - ed bracket at the top of the Butterfly Updght ( 4 ) with two 5 / 16 " x 2 3 / 4 " Bolts ( 89 ) , a Medium Support Plate ( 109 ) , and two 5 / 16 " Nylon Locknuts ( 86 ) . 6 . Press a 2 " Square Inner Cap ( 67 ) halfwayinto the top of the ButterflyLeg ( 11 ) . Attach a Bumper ( 50 ) to the ButterflyLeg witha 1 " Tap Screw ( 80 ) . Attachthe ButterflySeat Frame ( 10 ) to the ButterflyLeg ( 11 ) with two 5 / 16 " x 2 3 / 4 " Bolts ( 89 ) , two 5 / 16 " Washers ( 100 ) , and two 5 / 16 " Nylon Locknuts ( 86 ) . Do not Ughten the Nylon Locknuts yet . , _ " - 11 8O 7
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7 . Slide the ButterflyLeg ( 11 ) onto the two 5116 " x 2 1 / 2 " Carriage Bolts ( 75 ) inthe ButterflyBase 10 ( 1 ) . Hand tighten two 5 / 16 " Nylon Locknuts ( 86 ) onto the Bolts . Attachthe Butterfly Seat Frame ( 10 ) to the ButterflyUpright ( 4 ) with two 5 / 16 " x 2 3 / 4 " Bolts 11 ( 89 ) , two 5116 " Washers ( 100 ) , and two 5 / 16 " Nylon Lccknuts ( 86 ) . Do not tighten the 5 / 16 " Nylon Locknuts ( 86 ) yet . 8 . Press a 1 " Square Inner Cap ( 69 ) into the small 8 tube on the Press Upright ( 5 ) . Slide the Press Upright ( 5 ) over the indicated 5 / 16 " x 2 112 " Carriage Bolts ( 75 ) in the Press Base ( 3 ) . Hand tighten two 5 / 16 " Nylon Locknuts 5 ( 86 ) onto the Bolts . Do not tighten the Nylon Locknuts yet . Slide the Updght Support ( 6 ) over the 3 / 8 " x 2 1 / 2 " Cardege Bolt ( 76 ) and the 318 " x 4 " Carriage Bolt ( 112 ) in the Press Base ( 3 ) . Hand tighten a 3 / 8 " Nylon Jamnut ( 92 ) onto the 3 / 8 " x 2 112 " Carriage Bolt . Do not tighten the Nylon Jamnut yet . Note : Do not thread a Nylon Jamnut onto the 3 / 8 " x 4 " Carriage Bolt yet . Attach the UprightSupport ( 6 ) to the Press Upright ( 5 ) with two 5 / 16 " x 2 1 / 2 " Carriage Bolts ( 75 ) and two 5 / 16 " Nylon Locknuts ( 86 ) . Do not Ughten the Nylon Locknuts yet . 9 . Press a 2 " Square Inner Cap ( 67 ) into the Press 89 , / 1 / III Seat Frame ( 12 ) . Attach a Bumper ( 50 ) to the Press Seat Frame with a 1 " Tap Screw ( 80 ) . Slide the Press Seat Frame ( 12 ) onto the indicat - ed 5116 " x 2 1 / 2 " Carriage Bolts ( 75 ) in the Press Base ( 3 ) . Hand tightentwo 5 / 16 " Nylon Locknuts 50 . 5 ( 86 ) onto the Bolts . Do not tighten the Nylon Locknuts yet . Attach the Press Seat Frame ( 12 ) to the Press Upright ( 5 ) with two 5 / 16 " x 2 3 / 4 " Bolts ( 89 ) , two 5 / 16 " Washers ( 100 ) , and two 5 / 16 " Nylon _ 75 Locknuts ( 86 ) . Do not tighten the Nylon Locknuts yet . 8
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10 . Press a 2 " Square Inner Cap ( 67 ) into the Press 10 Top Frame ( 9 ) . Attachthe Press Top Frame ( 9 ) to the indicated bracket at the top of the Press Upright ( 5 ) with two 5 / 16 " x 2 314 " Bolts ( 89 ) , a Medium Support Plate ( 109 ) , and two 5 / 16 " Nylon Locknuts ( 86 ) . Do not tighten the Nylon Locknuts yet . 11 . Identifythe Left Weight Guides ( 27 ) , which have 11 welded ringsnear the bottom . Slide two Weight Bumpers ( 46 ) onto the Left Weight Guides . Note : The wide end of the Weight Bumpers must be on bottom . Insert the Left Weight Guides into the indicated holes inthe Center Base ( 2 ) . Set the other two Weight Bumpers ( 46 ) over the indicated holes in the Center Base ( 2 ) . Note : The wide end of the Weight Bumpers must be on bottom . Insert the Right Weight Guides ( 26 ) throughthe Weight Bumpers and into the holes in the Center Base . 26 < 27 < Welded _ . Rings 12 . Attachthe indicatedWeight Guides ( 26 , 27 ) to the Center Base ( 2 ) withtwo 3 / 8 " x 2 3 / 4 " Bolts ( 82 ) , four 3 / 8 " Washers ( 97 ) , and two 3 / 8 " Nylon Locknuts ( 90 ) . 9
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13 . Slide six Weights ( 41 ) onto the Right Weight 13 Guides ( 26 ) . Make sure the Weights are turned so the pin grooves are on the bottom . f _ 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 ) . Slide a Top Weight ( 42 ) onto the RightWeight Guides ( 26 ) . Note : Make sure the Top Weight Is turned so the groove fits over the welded pin on the Short Weight Tube ( 44 ) . 14 . Slide the BottomWeight ( 47 ) and seven Weights ( 41 ) onto the Left Weight Guides ( 27 ) . 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 Long Weight Tube ( 43 ) . Slide the Long Weight Tube intothe center holes in the Weights ( 41 ) . Pin Slide the other Top Weight ( 42 ) onto the Left Weight Guides ( 27 ) . Note : Make sure the Top Weight Is tumed so the groove fits over the welded pin on the Long Weight Tube ( 43 ) . 41 10
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15 . Press a 2 " Square Inner Cap ( 67 ) into the Center 15 82 Top Frame ( 8 ) . Place the Center Top Frame on the indicated bracketson the Uprights ( 4 , 5 ) . Note : The tops of the four Weight Guides ( 26 , 28 67 27 ) must be behind the Center Top Frame , as 82 90 shown In step 16 . Attachthe Center Top Frame ( 8 ) to the Butterfly 8 Top Frame ( 7 ) with two 3 / 8 " x 2 3 / 4 " Bolts ( 82 ) , a Large Support Plate ( 29 ) , and two 318 " Nylon Locknuts ( 90 ) . Do not tighten the Nylon Locknuts yet . Attach the Center Top Frame ( 8 ) to the bracket on the ButterflyUpright ( 4 ) with two 3 / 8 " x 2 3 / 4 " Bolts ( 82 ) , a Small Support Plate ( 28 ) , and two 3 / 8 " NylonJamnuts ( 92 ) . Do not tighten the Nylon Locknuts yet . 16 . Attachthe Center Top Frame ( 8 ) to the rear hole in 16 the PressTop Frame ( 9 ) witha 3 / 8 " x 2 3 / 4 " Bolt f ( 82 ) , a Large SupportPlate ( 29 ) , and a 3 / 8 " Nylon f Locknut ( 90 ) . Do not tighten the Locknut yet . 82 _ < Locate the parts bag labeled " PULLEY BAG 28 1 . " Remove a 3 1 / 2 " Pulley ( 35 ) from the bag . t 90 92 Slide a 3 1 / 2 " Pulley ( 35 ) and a Cable Trap ( 38 ) onto a 3i8 " x 4 " Bolt ( 78 ) . Slide the Boltthrough the Large SupportPlate ( 29 ) and Press Top Frame ( 9 ) , and hand tightena 3 / 8 " NylonLocknut ( 90 ) onto it . T ' - 35 " 5 38 _ 178 Attachthe Center Top Frame ( 8 ) to the bracketon the Press Upright ( 5 ) with two 3 / 8 " x 2 3 / 4 " Bolts ( 82 ) , a Small Support Plate ( 28 ) , and two 3 / 8 " NylonJamnuts ( 92 ) . Do not tighten the Nylon Locknuts yet . 17 . Attach each set of Weight Guides ( 26 , 27 ) to the 17 Center Top Frame ( 8 ) withtwo 3 / 8 " x 3 314 " Bolts ( 101 ) , two 3 / 8 " SAE Washers ( 113 ) , and two 318 " " _ 8 90 Nylon Locknuts ( 90 ) . Tighten the 3 / 8 " Nylon Locknuts ( 90 ) , the " ' " ° 113 u / _ 5 / 16 " Nylon Locknuts ( 86 ) , and the 3 / 8 " Nylon Jamnut ( 92 ) used In steps 2 - 17 . 11
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18 92 11 18 . Locate and open the parts bag labeled " ARM ASSEMBLY . " Press two 2 " Square Inner Caps ( 67 ) intothe ends of the Leg Lever ( 13 ) . Lubricate a 3 / 8 " x 3 1 / 4 " Bolt ( 104 ) . Attach the Leg Lever ( 13 ) to the ButterflyLeg ( 11 ) with the Bolt and a 3 / 8 " Nylon Jamnut ( 92 ) . Do not over - tighten the Nylon Jamnut ; the Leg Lever must be able to pivot easily . 19 . Lubricatethe 3 / 8 " x 3 " Bolt ( 88 ) . Attach the Leg 19 Press Lever ( 14 ) to the Press Base ( 3 ) withthe Bolt and a 3 / 8 " Nylon Locknut ( 90 ) . Do not over - tighten the Nylon Locknut ; the Leg Press Lever must pivot easily . Lubricate 88 - _ . 20 . See the insetdrawing . 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 PleaUc Bushings should fit onto each end of the welded tubes In the Base . Lubricatethe 318 " x 8 " Bolt ( 106 ) . Attach the Press Frame ( 17 ) to the Press Base ( 3 ) withthe Bolt and a 3 / 8 " Nylon Jamnut ( 92 ) . Do not over - tighten the Nylon Jamnut ; the Press Frame must pivot easily . 21 . Press a 1 3 / 4 " Square Inner Cap ( 68 ) into the top 21 of a Press Arm ( 18 ) . Press a 1 " Round Inner Cap ( 66 ) into the Press Arm . Attach the Press Arm ( 18 ) to the Press Frame ( 17 ) with two 5 / 16 " x 2 112 " Bolts ( 87 ) and two 5 / 16 " Nylon Locknuts ( 86 ) . Repeat this step withthe other Press Arm ( 18 ) . 12
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22 . Identify the Rightand Left ButterflyArms ( 19 , 20 ) 22 by the positions of the welded brackets . Press a 1 3 / 4 " Square Inner Cap ( 68 ) into each end of the Right ButterflyArm ( 19 ) . Wet the lower end of the Butterfly Arm withsoapy water . Slide a Large Foam Pad ( 53 ) onto the lower end of the Butterfly Arm . Lubricatethe axles on the Butterfly Top Frame ( 7 ) . Orient the Right ButterflyArm ( 19 ) as shown and slide it onto the right axle . Have a second person secure the Butterfly Arm with two 1 " Retainers ( 54 ) and a 1 " Cover Cap ( 55 ) . Note : Place the Retainers on top of the Inverted = _ = = , Cover Cap . Make sure the teeth on the Retainers bend toward the Cover Cap , as 53 20 - - - shown In the Inset drawing . Gently tap the Cover Cap onto the axle with a hammer . : / I 68 Repeat this step with the Left Butterfly Arm ( 20 ) . Teet _ hif 55 _ 23 23 . Locate and open the parts beg labeledtification " CABLE ASSEMBLY . " For cable Iden 77 and routing during steps 23 to 61 , refer to the CABLE DIAGRAMS and CABLE ID CHART on " - . . ' Bracket pages 30 and 31 . Identify the Butterfly Cable ( 73 ) . It is approxi - mately 52 " long and it has an eyelet on each end . Attachthe ButterflyCable to the bracket on the Left ButterflyArm ( 20 ) with a 5 / 16 " x 1 " Shoulder Jh , . J , , , Bolt ( 84 ) and a 5 / 16 " Nylon Jamnut ( 77 ) . 24 24 . Locate and open the parts bag labeled " PULLEY BAG 2 . " Remove one " V " - Pulley ( 34 ) from the bag . Leave the remalnlng pulleys In the bag for IdentlflcaUon of the Pro Pulleys . Wrap the ButterflyCable ( 73 ) around a = V " - Pulley ( 34 ) inthe direction shown . Attach the Pulley and a Long Cable Trap ( 37 ) to the bracket on the back of the Butterfly Upright ( 4 ) with a 3 / 8 " x 2 1 / 2 " Bolt ( 105 ) and a 3 / 8 " Nylon Locknut ( 90 ) . Make sure the Long Cable Trap Is oriented as shown . 13
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25 . Remove the 3 1 / 2 " Pulleys ( 35 ) fromthe Double 25 " U " - Bracket ( 31 ) . Wrap the ButterflyCable ( 73 ) around a 3 1 / 2 " Pulley ( 35 ) . Attach the Pulley to the Double " U " - Bracket ( 31 ) with a 3 / 8 " x 1 314 " Bolt ( 94 ) and a 3 / 8 " Nylon Locknut ( 90 ) . 26 . Remove another " V " - Pulley ( 34 ) from the bag 26 labeled " PULLEY BAG 2 . " 105 34 Wrap the Butterfly Cable ( 73 ) around the " 4 " - 73 , , / 37 Pulley ( 34 ) in the directionshown . Attach the Pulley and a Long Cable Trap ( 37 ) to the bracket on the back of the Butterfly Upright ( 4 ) with a 3 / 8 " x 2 1 / 2 " Bolt ( 105 ) and a 3 / 8 " NylonLocknut ( 90 ) . Make sure the Long Cable Trap Is orient - ed as shown . 27 . Attach the ButterflyCable ( 73 ) to the bracket on 27 the RightButterflyArm ( 19 ) witha 5 / 16 " x 1 " 77 ShoulderBolt ( 84 ) and a 5 / 16 " NylonJamnut ( 77 ) . 28 . Identify the Rear Cable ( 70 ) . It is approximately 28 95 1 / 8 " long . and it has an eyelet on one end and 90 8 a threaded shaft on the other . 97 Attachthe eyelet on the Rear Cable ( 70 ) inside 82 the Center Top Frame ( 8 ) with a 3 / 8 " x 2 3 / 4 " Bolt ( 82 ) , two 3 / 8 " Washers ( 97 ) , and a 3 / 8 " Nylon Locknut ( 90 ) . 14
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29 . Remove the 3 112 " Pulleys ( 35 ) from a pair of pre - assembled Pulley Plates ( 32 ) . Wrap the Rear Cable ( 70 ) around a 3 1 / 2 " Pulley ( 35 ) in the direction shown . Attach the Pulley and a Cable Trap ( 38 ) to the top hole in the pair of Pulley Plates ( 32 ) with a 3 / 8 " x 2 " Bolt ( 93 ) and a 3 / 8 " Nylon Locknut ( 90 ) . Make sure the Cable Trap Is positioned to hold the Cable In the groove of the Pulley . 30 . Wrap the Rear Cable ( 70 ) around a 4 1 / 2 " Pulley 30 Bracket ( 36 ) in the directionshown . Attach the Pulley 9O inside the indicated bracket on the Center Top Frame ( 8 ) with a 3 / 8 " x 1 3 / 4 " Bolt ( 94 ) and a 3 / 8 " , ! . 3o Nylon Locknut ( 90 ) . 31 . Attach the end of the Rear Cable ( 70 ) to a " U " - Bracket ( 33 ) with a 1 / 4 " Washer ( 99 ) and a 1 / 4 " Nylon Locknut ( 103 ) . / Attach the " U " - Bracket ( 33 ) to the Short Weight Tube ( 44 ) with a 5 / 16 " x 1 3 / 4 " Bolt ( 96 ) and a 5 / 16 " Nylon Locknut ( 86 ) . 32 . Identify the Ab Cable ( 74 ) . It is approximately 32 226 1 / 2 " long , and it has a ball on one end and an eyelet on the other . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley 92 _ 9 _ / / _ 9 on this side ( 35 ) as shown . Place two Pulley Covers ( 39 ) over the Pulley , so that the large tabs are on the side shown . Attach the Pulley and Pulley Covers to the Butterfly Updght ( 4 ) with a 3 / 8 " x 3 3 / 4 " Bolt ( 101 ) , two 3 / 8 " Washers ( 97 ) , and a 3 / 8 " Nylon Jamnut ( 92 ) . Make sure the Cable Is between the Pulley end the pin on the Upright . 15
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33 . Remove the 3 112 " Pulleys ( 35 ) from the other pair of pre - assembled Pulley Plates ( 32 ) . Wrap the Ab Cable ( 74 ) around a 3 112 " Pulley ( 35 ) in the directionshown . Attach the Pulley and a Cable Trap ( 38 ) to the top hole in the pair of Pulley Plates ( 32 ) with a 3 / 8 " x 2 " Bolt ( 93 ) and a 318 " Nylon Locknut ( 90 ) . Make sure the Cable Trap Is positioned to hold the Cable In the groove of the Pulley . 34 . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Attach the Pulley to the Double " U " - Bracket ( 31 ) with a 3 / 8 " x 1 3 / 4 " Bolt ( 94 ) and a 3 / 8 " Nylon Locknut ( 90 ) . 35 . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley 35 ( 35 ) in the directionshown , Attach the Pulley and a Cable Trap ( 38 ) to the indicated bracketon the ButterflyBase ( 1 ) with a 3 / 8 " x 2 " Bolt ( 93 ) and a 3 / 8 " Nylon Locknut ( 90 ) . Make sure the Cable Trap Is positioned to hold the Cable In the groove of the Pulley . 1 90 36 . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Slide a Cable Trap ( 38 ) and the Pulleyonto the 3 / 8 " x 3 1 / 2 " Carriage Bolt ( 95 ) inthe ButterflyBase ( 1 ) . Secure the Pulleywith a 3 / 8 " NylonJamnut ( 92 ) . Make sure the Cable Trap Is positioned to hold the Cable In the groove of the Pulley . 16
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37 . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Attach the Pulley to the indicatedbracket on the Center Base ( 2 ) with a 3 / 8 " x 3 3 / 4 " Bolt ( 101 ) and a 318 " Nylon Locknut ( 90 ) . Make sure the Cable Is routed In 37 . i 351714101 " the direction shown . Note : The 3 / 8 " x 3 3 / 4 " Bolt ( 101 ) must be Inserted through both brackets on the Center Frame ( 2 ) . Tighten the 3 / 8 " Nylon Locknut ( 90 ) only a few turns onto the Bolt ; It will need to be removed In step 39 . 38 . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley 38 ( 35 ) in the directionshown . Attachthe Pulley and a Cable Trap ( 38 ) to the forth set of holesfrom the bottom in the indicatedpair of Pulley Plates ( 32 ) with a 3 / 8 " x 2 " Bolt ( 93 ) and a 318 " Nylon Locknut ( 90 ) . Make sure the Cable Trap Is posi - tioned to hold the Cable In the groove of the Pulley . 39 . Remove the 3 / 8 " x 3 3 / 4 " Bolt ( 101 ) and the 3 / 8 " 39 Nylon Locknut ( 90 ) used in step 37 . Wrap the Ab Cable ( 74 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Attach the Pulleyto the indi - cated bracketon the Center Base ( 2 ) , and the 3 1 / 2 " Pulley ( 35 ) used in step 37 to itsbracket , withthe 3i8 " x 3 3 / 4 " Bolt ( 101 ) and the 3 / 8 " Nylon Locknut ( 90 ) . Note : Make sure the Pulley used In step 37 Is attached as shown . Wrap the At ) Cable ( 74 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Slide the Pulley and a Cable Trap ( 38 ) onto the 3 / 8 " x 3 1 / 2 " Carriage Bolt ( 95 ) in the Center Base ( 2 ) . Secure the Pulleywith a 3 / 8 " Nylon Jamnut ( 92 ) . Make sure the Cable Trap Is poslUoned to hold the Cable 35 In the groove of the Pulley . 40 . Lay the Ab Cable ( 74 ) inside the indicatedbracket on the Center Base ( 2 ) . Attach a 3 112 " Pulley ( 35 ) insidethe bracketwith a 3 / 8 " x I 3 / 4 " Bolt ( 94 ) and a 3 / 8 " Nylon Jamnut ( 92 ) . 17
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41 . Locate the Weight Plate ( 48 ) that Is attached 41 to the bottom of the Bottom Weight ( 47 ) . See the Inset drawing . Attachthe end of the Ab Cable ( 74 ) to the bottom of the Weight Plate ( 48 ) with a 5 / 16 " x 1 3 / 4 " Bolt ( 96 ) and a 5 / 16 " Nylon Locknut ( 86 ) . 42 . Remove a Pro Pulley ( 110 ) from the bag 42 labeled " PULLEY BAG 2 . " Identify the Low Cable ( 71 ) . It is approximately 142 1 / 8 " longand it has a ball on one end and an 93 110 eyelet on the other . Route the eyelet end through the slot in the cable guide on the ButterflyBase ( 1 ) . Route the Low Cable ( 71 ) under the Pro Pulley 9O ( 110 ) . Attachthe Pro Pulley and a Cable Trap ( 38 ) to the bracket on the ButterflyBase ( 1 ) with a 3 / 8 " x 2 " Bolt ( 93 ) and a 318 " Nylon Locknut Cable ( 90 ) . Make sure the Cable Trap Is positioned to Guide hold the Cable In the groove of the Pulley . 43 . Wrap the Low Cable ( 71 ) around a 3 112 " Pulley 43 102 ( 35 ) in the directionshown . Attach the Pulley and a Cable Trap ( 38 ) to the indicatedhole in the ButterflyUpdght ( 4 ) with a 3 / 8 " x 4 3 / 4 " Bolt ( 102 ) and a 3 / 8 " NylonJamnut ( 92 ) . Note : Thread the Jamnut 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 . 44 . Wrap the Low Cable ( 71 ) over a 3 1 / 2 " Pulley 44 ( 35 ) in the dire _ ion shown . Attach the Pulley and a Cable Trap ( 38 ) to the forthset of holes from the bottom inthe Pulley Plates ( 32 ) with a 3 / 8 " x 2 " Bolt ( 93 ) and a 3 / 8 " Nylon Locknut ( 90 ) . Make sure the Cable " l _ ap Is positioned to hold the Cable In the groove of the Pulley . 90 - ! 35 18
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45 . Remove the 3 / 8 " Nylon Jamnut ( 92 ) from the 3 / 8 " x 4 3 / 4 " Bolt ( 102 ) inserted intothe Butterfly Upright ( 4 ) in step 43 . Wrap the Low Cable ( 71 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Attach the Pulley and a Cable Trap ( 38 ) to the 3 / 8 " x 4 3 / 4 " Bolt ( 102 ) with the 3 / 8 " Nylon Jamnut ( 92 ) . Make sure the Cable Trap Is positioned to hold the Cable in the groove of the Pulley . 46 . Attach the Low Cable ( 71 ) to the Leg Lever ( 13 ) 46 with a 5 / 16 " x 2 314 " Shoulder Bolt ( 108 ) , a 5 / 16 " Washer ( 100 ) , and a 5 / 16 " NylonJamnut ( 77 ) . 100 77 \ 71 47 . Remove a Pro Pulley ( 110 ) from the bag 47 labeled " PULLEY BAG 2 . " Identify the Press Cable ( 72 ) . It is approximately 387 5 / 8 " longand it has a ball on one end and a threaded shaft on the other . Wrap the Press Cable ( 72 ) around the Pro Pulley ( 110 ) in the directionshown . Attach the Pulley to the Press Top Frame ( 9 ) with a 3 / 8 " x 3 112 " Bolt ( 111 ) , a 3 / 8 " Washer ( 97 ) , and a 3 / 8 " Nylon Jamnut ( 92 ) . Make sure the Cable Is between the Pulley and the pin on the Press Top Frame . / II IH 48 . Route the threaded end of the Press Cable ( 72 ) 48 around the 3 112 " Pulley ( 35 ) that was attached to the Press Top Frame ( 9 ) in step 16 . Make sure 38 the Cable Trap ( 38 ) Is positioned to hold the Cable In the groove of the Pulley . Properly tightenthe 3 / 8 " Nylon Locknut ( not shown ) attached to the 3 / 8 " x 4 " Bolt ( 78 ) . 19
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49 . Wrap the Press Cable ( 72 ) around a 3 1 / 2 " Pulley ( 35 ) in the direction shown . Attach the Pulley and a Cable Trap ( 38 ) to the indicated hole in the Press Upright ( 5 ) with a 3 / 8 " x 3 3 / 4 " Bolt ( 101 ) , a 3 / 8 " Washer ( 97 ) and a 3 / 8 " Nylon Locknut ( 90 ) . Make sure the Cable Trap Is positioned to hold the Cable In the groove of the Pulley , 50 . Route the Press Cable ( 72 ) throughthe opening in the Press Frame ( 17 ) and wrap the Cable around a 3 1 / 2 " Pulley ( 35 ) inthe direction shown . Attach the 3 112 " Pulley ( 35 ) and a Cable Trap ( 38 ) to the indicated hole inthe Press Frame ( 17 ) witha 3 / 8 " x 3 1 / 4 " Bolt ( 104 ) , a 3 / 8 " Washer ( 97 ) and a 3 / 8 " 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 . 51 . Wrap the Press Cable ( 72 ) around a " V " - Pulley 51 ( 34 ) inthe direction shown . Attach the Pulley and a Long Cable Trap ( 37 ) to the small tube on the Press Upright ( 5 ) with a 318 " x 3 1 / 4 " Bolt ( 104 ) , a 3 / 8 " Washer ( 97 ) and a 318 " Nylon Locknut ( 90 ) . Note : The small tube has four adjustment holes . Attach the " V " - Pulley In the hole far - thest from the Upright . Make sure the Cable Trap Is oriented as shown . 34 37 104 52 . Wrap the Press Cable ( 72 ) around a 3 1 / 2 " Pulley ( 35 ) in the directionshown . Attachthe Pulley to the indicated hole in the Press Frame ( 17 ) with a 3 / 8 " x 3 1 / 4 " Bolt ( 104 ) , a 3 / 8 " Washer ( 97 ) , and a 3 / 8 " 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
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53 . Wrap the Press Cable ( 72 ) around a 3 1 / 2 " Pulley 53 ( 35 ) in the directionshown . Attach the Pulley and a Cable Trap ( 38 ) to the indicated hole on the right side of the Press Upright ( 5 ) witha 3 / 8 " x 4 3 / 4 " Bolt ( 102 ) and a 3 / 8 " Nylon Jamnut ( 92 ) . Note : Thread the Jamnut 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 5 the Pulley . 38 54 . Route the Press Cable ( 72 ) throughthe Press Frame ( 17 ) and around a 3 1 / 2 " Pulley ( 35 ) as shown . Attachthe Pulley and a Cable Trap ( 38 ) to the indicatedhole on the right side of the Leg Press Lever ( 14 ) with a 318 " x 4 3 / 4 " Bolt ( 102 ) and a 3 / 8 " NylonJamnut ( 92 ) . Note : Thread the 54 _ • e Jamnut only two turns onto the Bolt ; another Pulley will be attached to the Bolt In step 56 . Make sure the Cable " Nap Is poslUoned to hold the Cable In the groove of the Pulley . 38 14 " 55 . Wrap the Press Cable ( 72 ) around a = V " - Pulley ( 34 ) inthe direction shown . Attach the Pulley and a Long Cable Trap ( 37 ) underneaththe Press 85 Seat Frame ( 12 ) with a 318 " x 4 114 " Bolt ( 85 ) , a 97 3 / 8 " Washer ( 97 ) , and a 3 / 8 " Nylon Locknut ( 90 ) . Note : the Press Seat Frame has five adjust - 12 ment holes . Attach the Pulley to 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 , 14 56 . Remove the 318 " Nylon Jamnut ( 92 ) used in step 56 54 . Wrap the Press Cable ( 72 ) around a 3 1 / 2 " Pulley 14 - ( 35 ) inthe directionshown . Slide a Cable Trap ( 38 ) and the Pulleyonto the 3 / 8 " x 4 3 / 4 " Bolt ( 102 ) in the Leg Press Lever ( 14 ) . Properlytight - 102 - _ en the 3 / 8 " Nylon Jamnut ( 92 ) onto the Bolt . Make sure the Cable Trap Is positioned to _ 38 35 hold the Cable In the groove of the Pulley . 21
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57 . Remove the 3 / 8 " Nylon Jamnut ( 92 ) used in step 53 . Route the Press Cable ( 72 ) throughthe Press Frame ( 17 ) . Wrap the Press Cable ( 72 ) around a 3 1 / 2 " Pulley 38 ( 35 ) in the directionshown . Slide a Cable Trap ( 38 ) and the Pulley onto the 3 / 8 " x 4 314 " Bolt 57 2 ( 102 ) in the bottom of the Press Updght ( 5 ) . Properlytightenthe 3 / 8 " NylonJamnut ( 92 ) onto the Bolt . Make sure the Cable Trap Is posi - W 1023 ' 592 tioned to hold the Cable In the groove of the Pulley . 17 58 . Wrap the Press Cable ( 72 ) around a 3 112 " Pulley ( 35 ) in the directionshown . Slide a Cable Trap ( 38 ) and the Pulley onto the 3 / 8 " x 4 " Carriage Bolt ( 112 ) in the Press Base ( 3 ) . Secure the Pulley 92 witha 318 " Nylon Jamnut ( 92 ) . Make sure the Cable Trap Is positioned to hold the Cable In the groove of the Pulley . . 112 59 . Lay the Press Cable ( 72 ) in the bracketon the Center Base ( 2 ) . Attach a 3 1 / 2 " Pulley ( 35 ) inside the bracketwith a 3 / 8 " x 1 3 / 4 " Bolt ( 94 ) and a 318 " NylonJamnut ( 92 ) . 60 . Wrap the Press Cable ( 72 ) around a 4 112 " Pulley ( 36 ) inthe directionshown . Attach the Pulley 90 72 insidethe indicated bracketon the Center Top Frame ( 8 ) with a 3 / 8 " x 1 3 / 4 " Bolt ( 94 ) and a 3 / 8 " Nylon Locknut ( 90 ) . 22
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61 . Attach the Press Cable ( 72 ) to the remaining = U " - Bracket ( 33 ) with a 1 / 4 " Washer ( 99 ) and a 1 / 4 " / / / / Nylon Locknut ( 103 ) . Note : Do not completely Ughten the Nylon Locknut ; It should be 96 threaded only two turns onto the end of the Cable , as shown In the Inset drawing • Attachthe = U " - Bracket ( 33 ) to the LongWeight Tube ( 43 ) with a 5116 " x 1 3 / 4 " Bolt ( 96 ) and a 5116 " 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 . 62 62 . Locate and open the parts bag labeled " SEAT . o ASSEMBLY . " 25 _ Attachthe ButterflyBackrest ( 25 ) to the Butterfly Upright ( 4 ) with two 114 " x 2 1 / 2 " Bolts ( 79 ) and two 1 / 4 " Washers ( 99 ) . o . " 63 . Insert a 1 / 4 " x 2 112 " Carriage Bolt ( 91 ) through 63 the center hole in a Seat Plate ( 30 ) . Attach the Seat Plate to a Seat ( 23 ) with two 1 / 4 " x 3 / 4 " Bolt ( 98 ) . Insertthe 1 / 4 " x 2 112 " Carriage Bolt ( 91 ) intothe indicated hole in the ButterflySeat Frame ( 10 ) and secure it with a 1 / 4 " Washer ( 99 ) and a 1 / 4 " Nylon Locknut ( 103 ) . Secure the other end of the Seat ( 23 ) with a 1 / 4 " x 2 1 / 2 " Bolt ( 79 ) and a 1 / 4 " Washer . Attachthe other Seat ( 23 ) to the Press Seat Frame ( 12 , not shown ) inthe same manner . 64 . Insert a 1 / 4 " x 2 1 / 2 " Carriage Bolt ( 91 ) through 64 the center hole in a Seat Plate ( 30 ) . Attachthe . . . . " " _ ' _ 79 Seat Plate to the Press Backrest ( 24 ) with two 99 1 / 4 " x 3 / 4 " Bolt ( 98 ) . Insert the 114 " x 2 112 " Carriage Bolt ( 91 ) into the indicatedhole in the Press Upright ( 5 ) and secure it with a 114 " Washer ( 99 ) and a 1 / 4 " Nylon Locknut ( 103 ) . Secure the other end of the Press Backrest ( 24 ) with a 1 / 4 " x 2 112 " Bolt ( 79 ) and another 114 " Washer . 23
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65 . Press a 1 3 / 4 " Square Inner Cap ( 68 ) into the 65 indicated end of the Adjustment Tube ( 15 ) . Attach the AdjustmentTube ( 15 ) to the bracket ( not visiblein the drawing ) on the back of the Leg lO0 lI Press Plate ( 18 ) with a 5 / 16 " x 2 1 / 2 " Bolt ( 87 ) , two 5 / 16 " Washers ( 100 ) , and a 5 / 16 " Nylon Locknut ( 86 ) . 14 100 86 Place the AdjustmentTube ( 15 ) in the bracketon top of the Leg Press Lever ( 14 ) and secure it with 16 the Adjustment Pin ( 40 ) . Note : The lip on the Leg Press Plate ( 16 ) must be on the upper edge . 66 . Press four 3 / 4 " Round Inner Caps ( 64 ) into the 66 ends of the two Pad Tubes ( 51 ) . Insert a Pad Tube ( 51 ) intothe indicated hole in 52 the Leg Lever ( 13 ) . Slide two Foam Pads ( 52 ) onto the ends of the Pad Tube . Insert a Pad Tube ( 51 ) into the indicated hole in the ButterflyLeg ( 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 67 two 1 / 4 " x 3 / 4 " Bolts ( 98 ) . 98 68 . Make sure that all parts have been properly tightened . The use of the remaining parts will be explained in ADJUSTMENTS , beginningon the following page . Before usingthe weight system , pull each cable a few times to be surethat the cables move smoothlyover the pulleys . If one of the cables does not move smoothly , find and correctthe problem . IMPORTANT : If the cables are not properly Installed , they may be damaged when heavy weight Is used . Sea 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
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ADJUSTMENTS The instructionsbelow describe how each part o ! the weight system can be adjusted . Refer to the exemise guide accompanyingthis 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 cor _ = ct starting position for the exercise to be performed . If there Is any slack In the cables or chain as an exercise Is performed , the effecUveness of the exercise will be reduced . ATTACHING THE ACCESSORIES TO A PULLEY STATION Attachthe I _ atBar ( 59 ) to the Low Cable ( 71 ) at the 71 low pulleystationwith a Cable Clip ( 58 ) . For some 83 57 exercises , the Chain ( 57 ) shouldbe attached between the Lat Bar and the Low Cable withtwo Cable Clips . Adjust the length of the Chain between the Lat Bar end the Low Cable so the Lat Bar Is In the correct starting position for the exercise to be performed . 59 The Nylon Strap ( 83 ) or Ab Strap ( 56 ) can be attached in the same manner . The accessoriescan be attached to the ab pulleystationor highpulleystation inthe same manner . ADJUSTING THE LEG PRESS PLATE 40 To adjust the positionof the Leg Press Plate ( 16 ) , pull out the Adjustment Pin ( 40 ) and slide the Adjustment 15 Tube ( 15 ) either backward or forward inthe bracket on the Leg Press Lever ( 14 ) . Line up one of the adjustmentholes in the AdjustmentTube with the hole in the bracketand re - insertthe Adjustment Pin . ATTACHING THE CURL PAD To use the Curl Pad ( 22 ) , removethe 2 " Square Inner Cap ( 67 ) from the ButterflyLeg ( 11 ) . Slide the Curl Post ( 21 ) to the desired height inths ButterflyLeg . 22 Tighten the Curl Knob ( 49 ) intothe ButterflyLeg and an adjustment hole in the Curl Post . 25
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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 Weight ( 47 ) withthe press arms or the leg press , insert the Weight Pin ( 81 ) under the Bottom Weight . Remove the other Weight Pin from the small weight stack . To use the small weight stack withthe press arms or leg press , insert a Weight Pin ( 81 ) underthe Bottom Weight ( 47 ) . Then , insert the other Weight Pin under the desired Weight ( 41 ) in the rightweight 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
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WEIGHT RESISTANCE CHART The chart below shows the approximate weight resistance at each exercise station . " Left Top " and = RightTop " refer to the 6 lb . top weights . = Bottom " refers to the 12.5 lb . bottomweight . The other numbers refer to the 12,5 lb . weight plates . Weight resistance shown for the butterflyarm station is for each butterflyarm . 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 FLY ARM PULLEY LEVER PULLEY ( Ibs . ) ( Ibs . ) ( Ibs . ) ( Ibs . ) ( Ibs . ) ( Ibs . ) ( Ibs . ) Le _ Top 32 35 34 6 133 164 243 7 150 180 278 165 205 307 Bottom 25 30 28 170 210 315 25 RlghtTop 41 48 42 187 230 350 40 1 27
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TROUBLESHOOTING AND MAINTENANCE Make sure all parts are properlytightened each time you use the weightsystem . Replace any worn partsimmedi - 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 stretchslightlywhen 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 differentways . When you are tighteningthe cables , note that they are linked intotwo 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 3 1 / 2 " 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 Pulley Plates ( 32 ) have four sets of adjustment holes for each 3 1 / 2 " 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 3 112 " Pulley ( 35 ) , remove the 318 " Nylon Locknut ( 90 ) and the 318 " x 2 " Bolt ( 93 ) from the Pulley Plates ( 32 ) , the Cable Trap ( 38 ) , and Pulley . 9O Re - attach the Pulley and Cable Trap to the next set of holes in the Pulley Plates with the Bolt and Nylon Locknut . Note : Begin by moving the bottom Pulley up one set of holes . If the cables are still too loose , move the top Pulley down one set of holes , until the slack In the cables has been removed . The threaded ends on the Rear Cable ( 70 ) and the Press Cable ( 72 ) attachedto the weight stackscan be used to tightenthe cables . To tighten the Rear Cable ( 70 ) , remove the 5 / 16 " x 1 3 / 4 " Bolt ( 96 ) and the 5 / 16 " Nylon Locknut ( 86 ) from the " U " - Bracket ( 33 ) and the Short WeightTube ( 44 ) . Tighten the 1 / 4 " Nylon Locknut ( 103 ) at the end of the Rear Cable ( 70 ) a few tums . Re - attach the " U " - Bracket ( 33 ) to the Short Weight Tube ( 44 ) withthe 5 / 16 " x 1 3 / 4 " Bolt ( 96 ) and the 5 / 16 " Nylon Locknut ( 86 ) . The Press Cable ( 72 ) can be tightened inthe same manner .
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Slack can be removed from the Press Cable ( 72 ) by movingthe = V " - Pulley ( 34 ) attached to the Press Seat Frame ( 12 ) closer to the Press Upright ( 5 ) . Remove the 3 / 8 " x 4 1 / 4 " Bolt ( 85 ) , 3 / 8 " Washer ( 97 ) , and 3 / 8 " Nylon Locknut ( 90 ) from the Press Seat Frame ( 12 ) , the " V " - Pulley ( 34 ) , and the LongCable Trap ( 37 ) . Move the Pulley to a hole that is closer to the Press Upright ( 5 ) , one hole at a time , untilthe slack is removed . Reattach the Pulley and Cable Trap to the hole with the Bolt , Washer , and Nylon Locknut . I { there is still slack in the Press Cable ( 72 ) , move the " V " - PuUey ( 34 ) attached to the small tube on the Press Upright ( 5 ) to a hole that is closerto the Upright . Remove the 3 / 8 " x 3 114 " Bolt ( 104 ) , 318 " Washer ( 97 ) , and 3 / 8 " Nylon Locknut ( 90 ) from the Press Updght ( 5 ) , the " V " - Pulley ( 34 ) , and the Long Cable Trap ( 37 ) . Move the Pulley to a hole that is closer to the Press Upright , one hole at a time , untilthe slack is removed . Reattach the Pulley and Cable Trap to the hole with the Bolt , Washer , and Nylon 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 o ! this manual . 29
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CABLE DIAGRAMS The Cable Diagrams below and on the next page show the proper mutingof the Rear Cable ( 70 ) , the Low Cable ( 71 ) , the Press Cable ( 72 ) , the ButterflyCable ( 73 ) , and the Ab Cable ( 74 ) . The numbers showthe 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 . I Press Cable ( 72 ) 2 12 3 11 7 4 30
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Low Cable ( 71 ) 2 Rear Cable ( 70 ) 1 Butterfly Cable ( 73 ) 5 31
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This chart is provided to help you identifythe small parts used in assembly . The number in parenthesis below each part refersto the key number of the part from the PART LIST in the center of this manual . Important : Some parts may have been pre - assembled for shipping purposes . If you cannot find a part In the parts bags , check to sea If It has bean pl _ - assembled . Note : Assembly Is divided into four stages : 1 ) frame assembly ; 2 ) arm assembly ; 3 ) cable assembly ; and 4 ) seat assembly . The hardware for each assembly stage Is packaged separately . Walt until you begin each stage to open that parts bag .
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PART IDENTIFICATION CHART - - Model No . 831.159830 Ro402A 3 / 8 " x 1 314 " Bolt ( 94 ) 1 / 4 " Nylon Locknut ( 103 ) 318 " x 2 " Bolt ( 93 ) 5 / 16 " Nylon Jamnut ( 77 ) _ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ 1 / 4 " x 2 1 / 2 " Bolt ( 79 ) 5 / 16 " Nylon Locknut ( 86 ) _ , \ \ \ \ \ \ l _ 5 / 16 " x 2 112 " Bolt ( 87 ) 3 / 8 " Nylon Jamnut ( 92 ) 3 / 8 " x 2 1 / 2 " Bolt ( 105 ) _ \ \ \ \ \ \ _ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ _ 3 / 8 " Nylon Locknut ( 90 ) 1 / 4 " x 2 1 / 2 " Carriage Bolt ( 91 ) _ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ I 5 / 16 " x 2 1 / 2 " Carriage Bolt ( 75 ) 114 " Washer ( 99 ) 318 " x 2 1 / 2 " Carriage Bolt ( 5116 " Washer ( 100 ) _ \ \ \ \ \ \ 1 5 / 16 " x 2 3 / 4 " Bolt ( 89 ) 3 / 8 " x 2 314 " Bolt ( 82 ) 3 / 8 " SAE Washer ( 113 ) 3 / 8 " Washer ( 97 )
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3 / 4 " Round Inner Cap ( 64 ) Round Inner Cap ( 63 ) 1 " Retainer ( 54 ) 1 " Round Inner Cap ( 66 ) 1 " Square Inner Cap ( 69 ) 1 " Cover Cap ( 55 ) ( - i ! J 1 3 / 4 " Square Inner Cap ( 68 ) 2 " Square Inner Cap ( 67 )
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_ \ \ \ \ \ \ 1 _ ] 5116 " x 3 " Bolt ( 107 ) 5116 " x 1 3 / 4 " Bolt ( 96 ) _ \ \ \ \ \ \ l [ _ 5116 " x 1 " Shoulder Bolt ( 84 ) 5116 " x 2 3 / 4 " Shoulder Bolt ( 108 ) 1 " Tap Screw ( 80 ) 318 " x 3 " Bolt ( 88 ) 1 / 4 " x 3 / 4 " Bolt ( 98 ) 318 " x 3 114 " Bolt ( 104 ) O o m 318 " x 3 1 / 2 " Bolt ( 111 ) x O3 3 / 8 " x 3 1 / 2 " Carriage Bolt ( 95 ) [ _ 318 " x 3 3 / 4 " Bolt ( 101 ) 318 " x 4 " Bolt ( 78 ) 318 " x 4 " Carriage Bolt ( 112 ) 318 " x 4 114 " Bolt ( 85 ) 3 / 8 " x 4 3 / 4 " Bolt ( 102 )
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SAVE THIS PART LIST / EXPLODED DRAWING FOR FUTURE REFERENCE
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PART LIST - - Model No . 831.159830 Ro . o2A Description Key No . Qty . Description Key No . Qty . Let Bar 1 1 Butterfly Base 59 1 PlasticBushing 2 1 Center Base 60 2 3 1 Press Base 61 2 LargeBushing Handgrip 4 1 Butterfly Upright 62 4 RoundInnerCap 5 1 Press Upright 63 2 3 / 4 " RoundinnerCap 6 1 Updght Support 64 4 ButterflyArm Bushing 7 1 Butterfly Top Frame 65 2 1 " Round InnerCap 8 1 Center Top Frame 66 2 2 " Square Inner Cap 9 1 Press Top Frame 67 15 1 3 / 4 " Square InnerCap 10 1 Butterfly Seat Frame 68 7 1 " Square inner Cap 11 1 Butterfly Leg 69 1 Rear Cable 12 1 Press Seat Frame 70 1 LowCable 13 1 Leg Lever 71 1 Press Cable 14 1 Leg Press Lever 72 1 ButterflyCable 15 1 Adjustment Tube 73 1 Ab Cable 16 1 Leg Press Plate 74 1 17 1 Press Frame 75 10 5 / 16 " x 2 112 " Cardage Bolt 18 2 Press Arm 76 1 3 / 8 " x 2 112 " Carriage Bolt 5 / 16 " NylonJamnut 19 1 Right Butterfly Arm 77 3 3 / 8 " x 4 " Bolt 20 1 Left Butterfly Arm 78 1 1 / 4 " x 2 1 / 2 " Bolt 21 1 Curl Post 79 5 22 1 Cud Pad 80 2 1 " Tap Screw 23 2 Seat 81 2 Weight 3Pin / 3 / 8 " x 2 4 " Bolt 24 1 Press Backrest 82 10 25 1 Butterfly Backrest 83 1 Nylon StrapShoulder 5 / 16 " x 1 " Bolt 26 2 Right Weight Guide 84 2 3 / 8 " x 4 114 " Bolt 27 2 Left Weight Guide 85 1 5 / 16 " Nylon Locknut 28 2 Small Support Plate 86 36 5 / 16 " x 2 1 / 2 " Bolt 29 2 Large Support Plate 87 5 3 / 8 " x 3 " Bolt 30 3 Seat Plate 88 1 5 / 16 " x 2 3 / 4 " Bolt 31 1 Double = U ' - Bracket 89 14 3 / 8 " Nylon Locknut 32 4 Pulley Plate 90 30 33 2 " U " - Bracket 91 3 1 / 4 " x 2 1 / 2 " Carriage Bolt 34 4 = V - Pulley 92 16 3 / 8 " Nylon Jamnut 3 / 8 " x 2 " Bolt 35 25 3 1 / 2 " Pulley 93 6 3 / 8 " x 1 314 " Bolt 36 2 4 1 / 2 " Pulley 94 6 3 / 8 " x 3 1 / 2 " Cerriege Bolt 37 4 Long Cable Trap 95 2 5 / 16 " x 1 3 / 4 " Bolt 38 19 Cable Trap 96 3 3 / 8 " Washer 39 2 Pulley Cover 97 18 1 / 4 " x 3 / 4 " Bolt 40 1 Adjustment Pin 98 8 1 / 4 " Washer 41 13 Weight 99 10 3 / 16 " Washer 42 2 Top Weight 100 9 3 / 8 " x 3 3 / 4 " Bolt 43 1 Long Weight Tube 101 7 3 / 8 " x 4 3 / 4 " Bolt 44 1 Short Weight Tube 102 3 114 " Nylon Locknut 45 2 Weight Tube Bumper 103 5 3 / 8 " x 3 1 / 4 " Bolt 46 4 Weight Bumper 104 4 3 / 8 " x 2 lt2 " Bolt 47 1 Bottom Weight 105 2 3 / 8 " x 8 " Bolt 48 1 Weight Plate 106 1 5 / 16 x 3 " Bolt 49 1 Cud Knob 107 4 5 / 16 " x 2 3 / 4 " ShoulderBolt 50 2 Bumper 108 1 51 2 Pad Tube 109 4 MediumSupportPlate 52 4 Foam Pad 110 2 Pro 1Pulley12 " 3 / 8 " x 3 Bolt 53 2 Large Foam Pad 111 1 54 4 1 " Retainer 112 1 3 / 8 " x 4 " Carriage Bolt 3 / 8 " SAE Washer 55 2 1 " Cover Cap 113 4 User's Manual 56 1 Ab Strap # 1 Exercise Guide 57 1 Chain # 1 58 3 Cable Clip Note : = # " indicatesa non - illustratedpart . Specificationsare subjectto change withoutnotice .
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38 112 86 75 76 16 : 23 ( : 3 4 _ C : )
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SEARS The model number and serial numberof your WELDERe PRO Model No . 831.189830 POWER STACK weight system are listedon a decal attached to the frame . See the front cover of this manual to find the location of the decal . QUESTIONS ? All replacement parts are available for immediate purchase or if you find that : special order when you visityour nearest SEARS Service Center . To request service or to order parts by telephone , call the toll - free • you need help assembling or numbers listed at the left . operating the WELDER * PRO POWER STACK weight system When requestinghelp or service , or ordering parts , please be • a part Is missing prepared to provide the followinginformation : • or you need to schedule repair • The MODEL NUMBER of the product ( 831.159830 ) service call our toll - free HELPLINE • The NAME of the product ( WELDERe PRO POWER STACK weight system ) 1 - 800 - 736 - 6879 Monday - Saturday , 7 am - 7 pm • The KEY NUMBER and DESCRIPTION of the PART ( see the Central Time ( excluding holidays ) PART LIST / EXPLODED DRAWING in the centerof thismanual ) . REPLACEMENT PARTS If parts become worn and need to SEARS , ROEBUCK AND CO . , HOFFMAN ESTATES , IL 60179 be replaced , call the following toll - free number 1 - 800 - FON - PART ( 1 - 800 - 366 - 7278 ) l FULL 90 DAY WARRANTY J For 90 days from the date of purchase , if failure occurs due to defect in material or workmanshipin this SEARS WEIGHT SYSTEM EXERCISER , contactthe nearest SEARS Service Center throughoutthe United States and SEARS will repairor replace the WEIGHT SYSTEM EXERCISER , free of charge . This warranty does not apply when the WEIGHT SYSTEM EXERCISER is usedcommerciallyor for rental purposes . This warranty givesyou specificlegal rights , and you may also have other rightswhich vary from state to state . SEARS , ROEBUCK AND CO . , DEPT . 817WA , HOFFMAN ESTATES , IL 60179 Part No . 183713 R0402A Pdnted in Canada © 2002 Seam , Roebuck and Co .