Weider 831159822 User Manual PRO 4100 Manuals And Guides L0902436

WEIDER Weight System Manual L0902436 WEIDER Weight System Owner's Manual, WEIDER Weight System installation guides

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Model No. 831.159822
Serial No.
Write the serial number in the
space above for reference,

WEIGHT SYSTEM EXERCISER
User's Manual

Serial Number Decal (under seat)

o Assembly
Adjustments
Part List and Drawing

e

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

Sears, Roebuck

and Co., Hoffman

Estates,

IL 60179

TABLE OF CONTENTS
IMPORTANT PRECAUTIONS ................................................................
BEFORE YOU BEGIN ......................................................................
ASSEMBLY ..............................................................................
ADJUSTMENTS ..........................................................................
WEIGHT RESISTANCE CHART ..............................................................
CABLE DIAGRAM .........................................................................
EXERCISE GUIDELINES ...................................................................
ORDERING REPLACEMENT PARTS ..................................................
FULL 90 DAY WARRANTY ..........................................................

3
4
5
21
23
24
26
Back Cover
Back Cover

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

2

iMPORTANT PRECAUTIONS
A WARNING: To,educe
the
.skofse.ous
injury, read
the
following
tions
before using the weight system.

important

precau-

Read all instructions in this manual and in
the accompanying literature before using the
weight system. Use the weight system only
as described in this manual,

11. Make sure that the cables remain on the pulleys at all times. If the cables bind while you
are exercising, stop immediately and make
sure that the cables are on all of the pulleys.

2.

it is the responsibility
of the owner to ensure
that all users of the weight system are adequately informed of all precautions,

12. Always stand on the foot plate when performing an exercise that could cause the
weight system to tip.

3.

The weight system is intended for home use
only. Do not use the weight system in a cornmercial, rental, or institutional setting,

13. Always disconnect the lat bar from the
weight system when performing
an exercise
that does not use the lat bar.

4.

Use the weight system only on a level surface. Cover the floor or carpet beneath the
weight system to protect the floor.

14. If you feel pain or dizziness while exercising,
stop immediately and begin cooling down.

5.

Make sure all parts are properly tightened
each time the weight system is used.
Replace any worn parts immediately.

.

6.

Keep children under the age of 12 and pets
away from the weight system at all times.

7.

Keep hands and feet away from moving parts.

8.

Always wear athletic shoes for foot protection when using the weight system.

9.

The weight system is designed to support a
maximum user weight of 300 pounds.

15. The warning decals
shown here have been
placed on the weight
system in the locations
hown on page 4. If a
decal is missing or
illegible, please call
1-800-999-3756 to order
a free replacement
decal. Place the decal
on the weight system
in the location shown.

• Misuseof thisproducl
mayresultin serious
injury.
• Readuser'smanual
and followall warnings
and operatinginstructions priorto use.
• Donot allowchildren
on or aroundmachine.
• Replacelabelif
damaged,illegible,or
removed.
Decal 1

10. Never release the press arm, butterfly arms,
leg lever, leg press base, lat bar, ab strap, or
handle while weights are raised; the weights
will fall with great force.
Decal 2

WARNING: Before
beginning
thisoranyexercise
program,
consu,
yourphysician.
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.

3

BEFORE YOU BEGIN
Thank you for selecting the versatile WELDER _'_PRO
4100 weight system. The PRO 4100 weight system
offers a selection of weight stations designed to develop every major muscle group of the body. Whether
your goal is to tone your body, build dramatic muscle
size and strength, or improve your cardiovascular system, the weight system will help you to achieve the
results you want.

reading this manual, call 1-800-4-MY-HOMF _
(1-800-469-4663). To help us assist you, please note
the product model number and serial number before
calling. The model number is 831.1 59822. The serial
number can be found on a decal attached to the
weight system (see the front cover of this manual).
Before reading further, please review the drawing
below and familiarize yourself with the parts that are
labeled.

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

ASSEMBLED
DIMENSIONS:
Height: 77 in.
Width:
81 in.
Length: 59 in.

Warning Decal 2
(One on each side
of the right upright.)

Lat Bar
--

Butterfly Arm
Press Arm

High Pulley Station

Left Side
Warning
Decal 1

Ab Pulley
Station

Backrest
Backrest
Seat
Right Side
--

Leg Press
Plate

Seat
Weight -Leg Lev_

Pulley
Station

Note: The terms "right side" and "left side" are determined rel=
ative to a person facing away from the weight system; they do
not correspond to right and left in the pictures in the manual.

4

Foot Plate

ASSEMBLY
As you assemble the weight system, make sure
all parts are oriented as shown in the drawings.

Make Things Easier for Yourself
Everything in this manual is designed to ensure
that the weight system can be assembled successfully by most people. However, it is important to realize that the versatile weight system
has many parts and that the assembly process
will take time. Most people find that by setting
aside plenty of time, assembly will go smoothly.

• For help identifying smafl parts, use the PART
IDENTIFICATION CHART.
An Allen wrench W(included) and the following
tools (not included) are needed for assembly:
two adjustable

wrenches

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

one standard

screwdriver

one Phillips screwdriver

o Assembly requires two people.

lubricant, such as grease or petroleum
and soapy water.

Place all parts in a cleared area and remove the
packing materials. Do not dispose of the packing
materials until assembly is completed.

jelly,

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.

Tighten all parts as you assemble them, unless
instructed to do otherwise.

FRAME ASSEMBLY
81
.

Before beginning assembly, be sure that you
understand the information in the box above.
Attach the Base Cap (28) to the Right Base (1)
with two M4 x 20mm Self-tapping Screws (77).
Attach the Center Base (67) to the Right Base with
two M8 x 70mm Bolts (81), two M8 Washers (75),
and two M8 Nylon Locknuts (71). Do not tighten
the Locknuts yet.

28
102
57
77

Insert two M8 x 70mm Carriage Bolts (102) up
through a Support Plate (21) and the Right Base
(1). Insert two M8 x 65ram Carriage Bolts (57) up
through the Right Base. If the Bolts fall out,
place a piece of tape over the Bolt heads.
.

75

33

Press two 50mm Square Inner Caps (33) into the
ends of the Left Base (2). Insert two M8 x 70mm
Carriage Bolts (102) up through a Support Plate
(21) and the Left Base. Insert two M8 x 65mm
Carriage Bolts (57) up through the Left Base. If the
Bolts fall out, place tape over the Bolt heads.

71

75 81

81

67

33
102

Attach the Left Base (2) to the Right Base (1) and
the Center Base (67) with three M8 x 70mm Bolts
(81), three M8 Washers (75), and three M8 Nylon
Locknuts (71). Tighten the Locknuts used in
steps 1 and 2.

5

3.

3

Attach the Base Plate (37) to the Left Base (2)
with an M10 x 135mm Bolt (58) and an M10
Nylon Locknut (70). Be sure that the textured
side is on top.

"

Attach the Left Upright (7) to the Left Base (2)
with the two M8 x 70mm Carriage Bolts (102),
two M8 Washers (75), and two M8 Nylon
Locknuts (71).

ii

i

Attach the Left Leg (36) to the Left Base (2) with
the two indicated M8 x 65mm Carriage Bolts (57)
and two M8 Nylon Locknuts (71). Be sure the
large upper hole in the Left Leg is on the side
shown,

i

i

i

i

',

Do not tighten the IVl8 Nylon Locknuts (71) yet.
71

36
e

71

Hole
71

102

57
58

.

Press a 50ram x 63mm Inner Cap (22) into the
top of the Right Leg (73).
Attach the Right Leg (73) to the Right Base (1)
with the two M8 x 65mm Carriage Bolts (57) and
two M8 Nylon Locknuts (71).
Attach the Right Upright (6) to the Right Base (1)
with the two M8 x 70mm Carriage Bolts (102),
two M8 Washers (75), and two M8 Nylon
Locknuts (71).
Do not tighten the IVl8 Nylon Locknuts (71) yet.

22
71

71
71
102
1
57

6

5.

Attach the Right Seat Frame (5) to the Right Leg
(73) with two M8 x 80mm Bolts (60), two M8
Washers (75), and two M8 Nylon Locknuts (71).

5
60

75

5

Attach the Right Seat Frame (5) to the Right
Upright (6) with two M8 x 80mm Bolts (60), a
Large Support Plate (101), two M8 Washers (75),
and two M8 Nylon Locknuts (71).

75
101

Do not tighten the IVl8 Nylon Locknuts (71) yet.

75

,

Press a 50mm Square Inner Cap (33) into the
end of the Left Seat Frame (29).

6

75

60

81

71
Attach the Left Seat Frame (29) to the Left Leg
(36) with two M8 x 70mm Bolts (81), two M8
Washers (75), and two M8 Nylon Locknuts (71).

29
101

Attach the Left Seat Frame (29) to the Left
Upright (7) with two M8 x 80mm Bolts (60), a
Large Support Plate (101), two M8 Washers (75),
and two M8 Nylon Locknuts (71).
Do not tighten the IVl8 Nylon Locknuts

,

6O
7
71

71

(71) yet.

Set two Weight Bumpers (83) over the indicated
holes in the Center Base (67). Insert the two
Weight Guides (20) into the holes. Attach the
Weight Guides to the Center Base with two M8 x
65ram Bolts (63), four M8 Washers (75), and two
M8 Nylon Locknuts (71).

i

20_

i

,,

'ii i
'i i

83

83
\

/71

63

7

33

.

Slide the eight Weights (72) onto the Weight
Guides (20) with the pin grooves on the side
shown.

Lubricate

Press the Weight Tube Bumper (32) into the bottom of the Weight Tube (82). Insert the Weight
Tube into the center hole in the stack of Weights
(72). Be sure the Weight Tube is oriented as
shown,
Lubricate the indicated holes in the Top Weight
(74). Slide the Top Weight onto the Weight
Guides (20), with the pin groove on the bottom.

.

Press two 50mm x 63mm Inner Caps (22) into
the ends of the Left Top Frame (3).
22

Attach the Left Top Frame (3) to the Left Upright
(7) with two M8 x 85ram Bolts (59), a Support
Plate (21), and two M8 Nylon Locknuts (71). Do
not tighten the Locknuts yet.

59

21

\

10. Press a 50mm x 63mm Inner Cap (22) into the
end of the Right Top Frame (8).

10

71

59

Attach the Right Top Frame (8) to the Right
Upright (6) with two M8 x 85mm Bolts (59), a
Support Plate (21), and two M8 Nylon Locknuts
(71).

21

75
22

Attach the Right Top Frame (8) to the Left Top
Frame (3) with two M8 x 70mm Bolts (81), two
M8 Washers (75), and two M8 Nylon Locknuts
(71).
Do not tighten the IVl8 Nylon Locknuts (71) yet.

8

11. Press the two Weight Guide Bushings (44) into
the Center Top Frame (14). Slide the Center Top
Frame onto the Weight Guides (20).

11

71
Attach the Center Top Frame (14) to the Right
Top Frame (8) with two M8 x 70ram Bolts (81),
two M8 Washers (75), and two M8 Nylon
Locknuts (71).

14

71
44

_,

\

81

81

Attach the Center Top Frame (14) to the Left Top
Frame (3) with two M8 x 70mm Bolts (81), two
M8 Washers (75), and two M8 Nylon Locknuts
(71).

75

Tighten all of the M8 Nylon Locknuts (71)
used in steps 3-11.

ARM

12

ASSEMBLY

12. Press a 38mm Square Inner Cap (41) into the
Right Upright (6). Press a 50mm x 63mm Inner
Cap (22) into the Butterfly Frame (9).
Lubricate an M10 x 80mm Bolt (61) with grease.
Attach the Butterfly Frame (9) to the Right Top
Frame (8) with the Bolt and an M10 Nylon Locknut
(70). Do not overtighten the Locknut; the
Butterfly Frame must be able to pivot easily.

13. Lubricate an M10 x 55mm Bolt (89) with grease.
Attach the Pivot Bracket (48) to the Right Butterfly
Arm (11) with the Bolt and an M10 Nylon Locknut
(70). Do not overtighten the Locknut; the Pivot
Bracket must be able to pivot easily.

13

Press a 38mm x 50mm Inner Cap (23) into the
indicated end of the Right Butterfly Arm (11). Wet
the lower end of the Arm with soapy water. Slide
a Large Foam Pad (19) onto the Arm.

11
75

Slide a Foam Grip (76) onto a Press Handle (12).
Press a 25mm Round Inner Cap (24) into the end
of the Handle. Attach the Handle to the Right
Butterfly Arm (11) with two M8 x 16mm Button
Head Bolts (64) and two M8 Washers (75).

7o
#_

76

Slide the Large Foam Pad (19) down so that the
bottom of the Foam Pad is even with the lower
end of the Right Butterfly Arm (11),
12

Repeat this step with the Left Butterfly Arm
(10).

9

23

64
24

14. Lubricate an M10 x 80mm Button Head Bolt (97)
and both sides of two Plastic Washers (55) with
grease. Attach the Right Butterfly Arm (11) to the
Butterfly Frame (9) with the Bolt, the two Plastic
Washers, two Butterfly Caps (54), and an M10
Nylon Locknut (70). Do not overtighten the
Locknut; the Butterfly Arm must be able to
pivot easily. Be sure the indented sides of the
Plastic Washers fit over the welded bushing in
the Butterfly Arm.
Repeat this step with the Left Butterfly
(10).

14

97

Lubricate
Welded
Bushing
11

7O

Arm

15. Attach the Bumper (25) to the Right Leg (73) with
an M4 x 20mm Self-tapping Screw (77).

15
73

Press two 38mm x 50mm Inner Caps (23) into
the ends of the Leg Lever (4).

23

Lubricate

Lubricate an M10 x 65mm Bolt (99) with grease.
Attach the Leg Lever (4) to the Right Leg (73)
with the Bolt and an M10 Nylon Locknut (70). Do
not overtighten the Locknut; the Leg Lever
must be able to pivot easily.

16. Press a 50mm x 63mm Inner Cap (22) into the
top of the Leg Press Frame (30).

16
_---22

Lubricate an M10 x 80mm Bolt (61) with grease.
Attach the Leg Press Frame (30) to the Left Base
(2) with the Bolt and an M10 Nylon Locknut (70).
Do not overtighten the Locknut; the Leg Press
Frame must be able to pivot easily.

61
,,_ Lubricate

10

CABLE

17

ASSEMBLY

17.
iMPORTANT: While assembling the cables,
do not overtighten the iocknuts attaching
the pulleys; the pulleys must be able to
turn freely. Refer to the CABLE DIAGRAMS
and CABLE ID CHART on pages 24 and 25
for proper cable routing and help identifying the cables.

70

Locate the High Cable (45). Route the Cable up
through the Left Top Frame (3) and around a
90mm Pulley (38). Attach the Pulley inside the
Top Frame with an M10 x 70mm Bolt (100), two
M10 Washers (50), two 13mm Spacers (34), and
an M10 Nylon Locknut (70).

18
91

38

34

70

50 \

lOO

18. Route the High Cable (45) around a 90mm Pulley
(38) and down through the Left Top Frame (3).
Attach the Pulley and a Cable Trap (91) inside
the Top Frame with an M10 x 70mm Bolt (100),
two M10 Washers (50), two 13mm Spacers (34),
and an M10 Nylon Locknut (70). Be sure the
Cable Trap is turned to hold the Cable in the
groove of the Pulley.

\

Note: To complete this step, it may be neces=
sary to loosen the indicated M8 Nylon
Locknuts (71). Retighten the Locknuts when
this step is completed.

19

19. Wrap the High Cable (45) around a 90mm Pulley
(38). Attach the Pulley to the single hole side of a
Double "U"-Bracket (56) with an M10 x 45mm
Bolt (66) and an M10 Nylon Locknut (70).
38
70
66

20. Note: The following drawings are shown from
the left side of the weight system, with the
Left Top Frame (3) removed for clarity.

20
70

Wrap the High Cable (45) around a 90mm Pulley
(38). Attach the Pulley at the rear hole, inside of
the bracket on the Center Top Frame (14) with an
M10 x 45mm Bolt (66) and an M10 Nylon Locknut
(70).

11

21. Wrap the High Cable (45) around a 90mm Pulley
(38). Attach the Pulley at the forward hole, inside
of the bracket on the Center Top Frame (14) with
an M10 x 45mm Bolt (66) and an M10 Nylon
Locknut (70).

21

7O

38

66

22. Attach the end of the High Cable (45) to the
Small "U"-Bracket (79) with an M6 Nylon Locknut
(26). Note: Do not completely tighten the
Locknut; it should be threaded only two turns
onto the end of the Cable, as shown in the
inset drawing.

22

Attach the Small "U"-Bracket (79) to the Weight
Tube (82) with an M8 x 45mm Bolt (69) and an
M8 Nylon Locknut (71). Do not overtighten the
Locknut; the Weight Tube should be able to
pivot in the "U'=Bracket.

il

23. Locate the Leg Press Cable (95). Attach the
Cable inside the Left Leg (36) with an M10 x
70mm Bolt (100), two M10 Washers (50), two
Long Spacers (80), and an M10 Nylon Locknut
(70).

50

8O
95

5O
36
24. Wrap the Leg Press Cable (95) around a 90mm
Pulley (38). Attach the Pulley inside the Leg
Press Frame (30) with an M10 x 70mm Bolt
(100), two M10 Washers (50), two 13ram Spacers
(34), and an M10 Nylon Locknut (70).

24

34
95

100

12

70

ii

25. Route the Leg Press Cable (95) through the Left
Leg (36) and the Left Upright (7) as shown. Wrap
the Cable around a 90mm Pulley (38). Attach the
Pulley inside the Upright with an M10 x 70mm
Bolt (100), two M10 Washers (50), two 13ram
Spacers (34), and an M10 Nylon Locknut (70).

26. Wrap the Leg Press Cable (95) around a 90mm
Pulley (38). Attach the Pulley inside the bracket
on the Left Top Frame (3) with an M10 x 45mm
Bolt (66) and an M10 Nylon Locknut (70).

26

3

II ;3'
27. Attach the end of the Leg Press Cable (95) to the
"U"-Bracket (85) with an M6 Nylon Locknut (26).
Note: Do not completely tighten the Locknut;
it should be threaded only two turns onto the
end of the Cable, as shown in the inset draw=
ing.

28. Locate the Butterfly Cable (46). Attach the
Cable to the Pivot Bracket (48) on the Left
Butterfly Arm (10) with an M8 x 20ram Shoulder
Bolt (78) and an M8 Nylon Locknut (71).

13

29. Wrap the Butterfly Cable (46) around a "V"-Pulley
(39). Attach the Pulley and a Long Cable Trap
(40) to the bracket on the Right Upright (6) with
an M10 x 60mm Bolt (65) and an M10 Nylon
Locknut (70). Be sure the Cable Trap is turned
to hold the Cable in the groove of the Pulley.

29

30. Wrap the Butterfly Cable (46) around a 90mm
Pulley (38). Attach the Pulley to the single hole
side of the other Double "U"-Bracket (56) with an
M10 x 45mm Bolt (66) and an M10 Nylon Locknut
(70).

/
31. Wrap the Butterfly Cable (46) around a "V"-Pulley
(39). Attach the Pulley and a Long Cable Trap
(40) to the bracket on the Right Upright (6) with
an M10 x 60mm Bolt (65) and an M10 Nylon
Locknut (70). Be sure the Cable Trap is turned
to hold the Cable in the groove of the Pulley.

56

31
_/65
46
X

39

32. Attach the Butterfly Cable (46) to the Pivot
Bracket (48) on the Right Butterfly Arm (11) with
an M8 x 20mm Shoulder Bolt (78) and an M8
Nylon Locknut (71).

6

32
78

46

71

14

33. Locate the Leg Lever Cable (96). Route the
eyelet end of the Cable through the Right Leg
(73) and attach it to the Leg Lever (4) with an M8
x 20ram Shoulder Bolt (78) and an M8 Nylon
Locknut (71).

33

71

96

34. Attach a 90mm Pulley (38) inside the Right Leg
(73) with an M10 x 70ram Bolt (100), two M10
Washers (50), two 13ram Spacers (34), and an
M10 Nylon Locknut (70).

78

34

34

34
100

35. Route the Leg Lever Cable (96) through the Right
Upright (6) and under a 90mm Pulley (38). Attach
the Pulley inside the Upright with an M10 x 70mm
Bolt (100), two M10 Washers (50), two 13mm
Spacers (34), and an M10 Nylon Locknut (70).

35

100
36. Wrap the Leg Lever Cable (96) around a 90mm
Pulley (38). Attach the Pulley and a Cable Trap
(91) to the second set of holes from the bottom of
the indicated Double "U"-Bracket (56) with an
M10 x 50mm Bolt (62) and an M10 Nylon Locknut
(70). Be sure the Cable Trap is turned to hold
the Cable in the groove of the Pulley.

36

15

37. Attach the end of the Leg Lever Cable (96) to the
other "U"-Bracket (85) with an M6 Nylon Locknut
(26). Note: Do not completely tighten the
Locknut; it should be threaded only two turns
onto the end of the Cable, as shown in the
inset drawing.

!

38. Locate the Low Cable (47). Route the small ball
on the Cable through the cage on the Leg Press
Frame (30).

-i

Attach a 90mm Pulley (38) inside the Leg Press
Frame (30) with an M10 x 70ram Bolt (100), two
M10 Washers (50), two 13mm Spacers (34), and
an M10 Nylon Locknut (70).

._--.

38

_:_

_--44__

100_'_':0

,0

(85) with an M10 x 50mm Bolt (62) and an M10
Nylon Locknut (70). Be sure the Cable Trap is
turned to hold the Cable in the groove of the
Pulley.

16

d 70

" ':l_-_Cage

"_

39. Route the Low Cable (47) through the Left Leg
(36) and the Left Upright (7). Attach a 90mm
Pulley (38) inside the Upright with an M10 x
70mm Bolt (100), two M10 Washers (50), two
13mm Spacers (34), and an M10 Nylon Locknut
(70).

40. Wrap the Low Cable (47) around a 90ram Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the lower set of holes in the indicated "U"-Bracket

\34

0!'/

__._

47

41. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley to the indicated bracket on
the Left Base (2) with an M10 x 45mm Bolt (66)
and an M10 Nylon Locknut (70).

\

66

2

42. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley to the indicated bracket on
the Left Base (2) with an M10 x 45mm Bolt (66)
and an M10 Nylon Locknut (70).
38
2

43. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the second set of holes from the bottom of the

43

indicated Double "U"-Bracket (56) with an M10 x
50mm Bolt (62) and an M10 Nylon Locknut (70).
Be sure the Cable Trap is turned to hold the
Cable in the groove of the Pulley.

44. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley to the indicated bracket on
the Right Base (1) with an M10 x 45mm Bolt (66)
and an M10 Nylon Locknut (70).

44

66

17

45. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley to the indicated bracket on
the Right Base (1) with an M10 x 45mm Bolt (66)
and an M10 Nylon Locknut (70).

,.
46. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the lower set of holes in the indicated "U"-Bracket
(85) with an M10 x 50mm Bolt (62) and an M10
Nylon Locknut (70). Be sure the Cable Trap is
turned to hold the Cable in the groove of the
Pulley.

47. Wrap the Low Cable (47) around a 90mm Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the side of the Right Upright (6) with an M10 x
95ram Bolt (98), an M10 Washer (50), and an
M10 Nylon Locknut (70). Be sure the Cable Trap
is turned to hold the Cable in the groove of
the Pulley.

48. Wrap the Low Cable (47) around a 90ram Pulley
(38). Attach the Pulley and a pair of Pulley
Covers (92) to the Right Upright (6) with an M10
x 100ram Bolt (84), two M10 Washers (50), and
an M10 Nylon Locknut (70). Be sure the small
tabs on the Pulley Covers are on the side
shown, and the Cable is between the Pulley
and the rod on the Upright.

48

_ 7-

50

_-____

18

Sambaj,' _

k7 47

92

-

_

"tK'/-.@/70

--

49

SEAT ASSEMBLY
49. Attach a Seat (16) to the Right Seat Frame (5)
with an M6 x 65mm Bolt (90), three M6 Washers
(35), and two M6 x 16ram Bolts (13).
Repeat this step with the other Seat (16) and
the Left Seat Frame (not shown).

50. Attach a Backrest (15) to the Right Upright (6)
with four M6 x 16mm Bolts (13) and four M6
Washers (35).
Repeat this step with the other Backrest
and the Left Upright (not shown).

5O

(15)
35
13

15..

35

/

(

51. Slide the Long Pad Tube (17) through the hole in
the Right Leg (73). Slide two Foam Pads (18)
onto the ends of the Pad Tube. Press two 19mm

51

Round Inner Caps (27) into the ends of the Pad
Tube.

18
27
1

Repeat this step with the Short Pad Tube (94)
and the Leg Lever (4).

4

94

52. Press a 50mm x 63mm Inner Cap (22) into the
indicated end of the Adjustment Tube (88).

73

52

Attach the Leg Press Plate (31) to the Adjustment
Tube (88) with an M8 x 65mm Bolt (63), two M8
Washers (75), and an M8 Nylon Locknut (71).

87

22
88

Attach the Adjustment Tube (88) to the Leg Press
Frame (30) with the Leg Press Pin (87). Be sure
the Pin is in the locked position around the
Leg Press Frame.

75

71

75
31

19

53. Insert the two Locking Pins (53) into the Butterfly
Frame (9). Attach the tether on the Pins to the
Butterfly Frame with an M4 x 10ram Self-tapping
Screw (68). Do not fully tighten the Screw.

53
53
68

54. Make sure that all parts have been properly tightened. The use of all remaining parts will be explained in
ADJUSTMENTS, starting on the following page.
Before using the weight system, pull each cable a few times to make sure that the cables move smoothly
over the pulleys. If one of the cables does not move smoothly, find and correct the problem. IMPORTANT." If
the cables are not properly routed, they may be damaged when heavy weight is used. See the CABLE
DIAGRAM on pages 24 and 25 of this manual for proper cable routing, if there is any slack in the
cables, you will need to remove it by tightening the cables; see TIGHTENING THE CABLES on page
22.

2O

ADJUSTMENTS
This section explains how to adjust the weight system. See the EXERCISE GUIDELINES on page 26 for important information about how to get the most benefit from your exercise program. Also, refer to the accompanying
exercise guide to see the correct form for each exercise.
Make sure all parts are properly tightened each time the weight system is used. Replace any worn parts immediately. The weight system can be cleaned with a damp cloth and a mild, non-abrasive detergent. Do not use solvents.
ATTACHING THE ACCESSORIES
STATION

TO A PULLEY

Attach the Lat Bar (42) to the High Cable (45) with a
Cable Clip (52). For some exercises, the Chain (not
shown) should be attached between the Lat Bar and
the High Cable with two Cable Clips. Adjust the
length of the Chain between the Lat Bar and the
High Cable so the Lat Bar is in the correct starting position for the exercise to be performed.

42

The Handle (not shown) and Ab Strap (not shown)
can be attached in the same manner. The accessories can be attached to the Low Cable (not shown)
in the same manner.
CHANGING THE WEIGHT SETTING
To change the weight setting of the weight stack,
insert the Weight Pin (86) under the desired Weight
(72). Be sure to insert the Weight Pin until the bent
end of the Weight Pin is touching the Weights, and
turn the bent end downward. The weight setting of the
weight stack can be changed from 6 pounds to 106
pounds, in increments of 12.5 pounds. Note: Due to
the cables and pulJeys, the actual amount of
resistance at each exercise station may vary from
the weight setting. Use the WEIGHT RESISTANCE
CHART on page 23 to find the actual amount of
resistance at each weight station.

@ : @
J
J
J

CONVERTING

THE BUTTERFLY ARMS

To use the Butterfly Arms (10, 11) as butterfly arms,
insert the Locking Pins (53) into the butterfly holes in
the Right Upright (6).

Butterfly
Holes

To use the Butterfly Arms (10, 11)as press arms,
insert the Locking Pins (53) into the press holes in the
Butterfly Frame (9).

9
11
\

Make sure that the Locking Pins (53) are fully
inserted into the same set of holes before performing any exercises.

Press
Holes

21

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.
See drawing A. Slack can be removed by moving the
90mm Pulley (38) and Cable Trap (91) to a higher set
of holes in a Double "U"-Bracket (56). Remove the
M10 Nylon Locknut (70) and the M10 x 50mm Bolt (62)
from the Cable Trap, the Pulley, and the Double "U"Bracket. Re-attach the Pulley and the Cable Trap to
the new set of holes in the Double "U"-Bracket with the
Bolt and Locknut. Make sure that the Cable Trap is
in the proper position and that the Cable and
Pulley move smoothly.
Move the 90ram Pulley (38) in the other Double
"U'=Bracket (56) in the same manner.
See drawing B. Slack can be removed by moving the
90mm Pulley (38) and the Cable Trap (91) to the higher set of holes in a "U"-Bracket (85). Remove the M10
Nylon Locknut (70) and the M10 x 50mm Bolt (62)
from the Cable Trap, the Pulley, and the "U"-Bracket.
Re-attach the Pulley and the Cable Trap to the higher
set of holes in the "U"-Bracket with the Bolt and

B

Locknut. Make sure that the Cable Trap is in the
proper position and that the Cable and Pulley
move smoothly.

70

Move the 90ram Pulley (38) in the other "U'=Bracket
(85) in the same manner.
See drawing B. Slack can also be removed from the
cables by tightening the M6 Nylon Locknuts (26)
attaching a cable to either "U"-Bracket (85), or the
Small "U"-Bracket (79). To do this, you may need to
remove the 90mm Pulley (38) from the "U"-Bracket, or
remove the Small "U"-Bracket from the Weight Tube
(not shown). Make sure that the cables are not too tight
or the Top Weight (74) will be lifted off the weight stack.

\

87
88

ADJUSTING THE LEG PRESS PLATE
To adjust the Leg Press Plate (31), remove the Leg
Press Pin (87) from the Leg Press Frame (30) and the
Adjustment Tube (88). Move the Tube to the desired
position and secure it in place with the Pin. Be sure
the Pin is turned to the locked position around the
Leg Press Frame.

31

22

WEIGHT RESISTANCE

CHART

The chart below shows the approximate weight resistance at each exercise station. "Top" refers to the 6 lb. top
weight. The other numbers refer to the 12.5 lb. weight plates. Weight resistance shown for the butterfly arm station is for each butterfly arm. Note: The actual resistance at each station may vary due to differences in
individual weight plates as well as friction between the cables, pulleys, and weight guides.

WEIGHT

HIGH
PULLEY
(Ibs.)

PRESS
ARM
(Ibs.)

LEG
PRESS
(Ibs.)

BUTTERFLY ARM
(Ibs.)

AB
PULLEY
(Ibs.)

LEG
LEVER
(Ibs.)

LOW
PULLEY
(Ibs.)

Top

13

20

27

16

27

22

16

1

27

40

68

28

42

48

32

2

46

59

98

41

56

74

49

3

59

79

128

53

70

94

64

4

74

103

156

68

82

121

79

5

87

117

176

77

95

134

93

6

102

136

202

87

110

155

108

7

115

161

237

97

125

173

122

8

129

180

265

108

139

193

137

23

CABLE DIAGRAMS
The cable diagrams below show the proper routing of the High Cable (45), the Butterfly Cable (46), the Low
Cable (47), the Leg Press Cable (95), and the Leg Lever Cable (96). Use the diagrams to make sure that the
cables and the cable traps have been assembled correctly. If the cables have not been correctly routed, the
weight system will not function properly and damage may occur. The numbers show the correct route for each
cable, Make sure that the cable traps do not touch or bind the cables.

4

2

5

3
Butterfly

Cable (46)

\,
High Cable (45)

6

11
Low Cable (47)

3

8
10

24

1

Leg Press Cable (95)
Leg Lever Cable (96)

3
3

2

CABLE ID CHART
__

....._+

_-

_

-- (46) 47 3/7"

__

- (gs)9s1/2-

_------__

-- (95) 148 1/4"

_

- (.7)27s3/4"

25

EXERCISE GUiDELiNES
THE FOUR BASIC TYPES OF WORKOUTS

PERSONALIZING

YOUR EXERCISE PROGRAM

Muscle Building
To increase the size and strength of your muscles,
push them close to their maximum capacity. Your muscles will continually adapt and grow as you progressively increase the intensity of your exercise. You can
adjust the intensity level of an individual exercise in
two ways:
- by changing the amount of weight used
- by changing the number of repetitions or sets performed. (A "repetition" is one complete cycle of an
exercise, such as one sit-up. A "set" is a series of
repetitions.)

Determining the exact length of time for each workout,
as well as the number of repetitions or sets completed,
is an individual matter. It is important to avoid overdoing it during the first few months of your exercise program. You should progress at your own pace and be
sensitive to your body's signals. If you experience pain
or dizziness at any time while exercising, stop immediately and begin cooling down. Find out what is wrong
before continuing. Remember that adequate rest and a
proper diet are important factors in any exercise program.
WARMING UP

The proper amount of weight for each exercise
depends upon the individual user. You must gauge
your limits and select the amount of weight that is right
for you. Begin with 3 sets of 8 repetitions for each
exercise you perform. Rest for 3 minutes after each
set. When you can complete 3 sets of 12 repetitions
without difficulty, increase the amount of weight.

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

Toning
You can tone your muscles by pushing them to a moderate percentage of their capacity. Select a moderate
amount of weight and increase the number of repetitions in each set. Complete as many sets of 15 to 20
repetitions as possible without discomfort. Rest for 1
minute after each set. Work your muscles by completing more sets rather than by using high amounts of
weight.

Each workout should include 6 to 10 different exercises. Select exercises for every major muscle group,
emphasizing areas that you want to develop most. To
give balance and variety to your workouts, vary the
exercises from session to session.
Schedule your workouts for the time of day when your
energy level is the highest. Each workout should be
followed by at least one day of rest. Once you find the
schedule that is right for you, stick with it.

Weight Loss
To lose weight, use a low amount of weight and
increase the number of repetitions in each set.
Exercise for 20 to 30 minutes, resting for a maximum
of 30 seconds between sets.

EXERCISE FORM
Maintaining proper form is an essential part of an
effective exercise program. This requires moving
through the full range of motion for each exercise, and
moving only the appropriate parts of the body.
Exercising in an uncontrolled manner will leave you
feeling exhausted. On the exercise guide accompanying this manual you will find photographs showing the
correct form for several exercises, and a list of the
muscles affected. Refer to the muscle chart on page
27 to find the names of the muscles.

Cross Training
Cross training is an efficient way to get a complete and
well-balanced fitness program. An example of a balanced program is:
- Plan weight training workouts on Monday,
Wednesday, and Friday.
- Plan 20 to 30 minutes of aerobic exercise, such as
running on a treadmill or riding on an elliptical or
exercise bike, on Tuesday and Thursday.
- Rest from both weight training and aerobic exercise
for at least one full day each week to give your body
time to regenerate.

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

The combination of weight training and aerobic exercise will reshape and strengthen your body, plus develop your heart and lungs.

26

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

slowly as you stretch and do not bounce. Ease into
each stretch gradually and go only as far as you can
without strain. Stretching at the end of each workout
is an effective way to increase flexibility.

building workout.
- Rest for one minute after each set for a toning workout.

STAYING MOTIVATED

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

For motivation, keep a record of each workout. List
the date, the exercises performed, the weight used,
and the numbers of sets and repetitions completed.
Record your weight and key body measurements at
the end of every month. Remember, the key to
achieving the greatest results is to make exercise a
regular and enjoyable part of your everyday life.

Plan to spend the first couple of weeks familiarizing
yourself with the equipment and learning the proper
form for each exercise,
COOLING DOWN
End each workout with 5 to 10 minutes of stretching.
Include stretches for both your arms and legs, Move

MUSCLE CHART
A.
B.
C.
D.
E.
R
G.
H.
I.
J.
K.
L.
M.
N.
O.
R
Q.
R.
S.
T.
U.
V.
W.

Sternomastoid (neck)
Pectoralis Major (chest)
Biceps (front of arm)
Obliques (waist)
Brachioradials (forearm)
Hip Flexors (upper thigh)
Abductor (outer thigh)
Quadriceps (front of thigh)
Sartodus (front of thigh)
Tibialis Anterior (front of calf)
Soleus (front of calf)
Rectus Abdominus (stomach)
Adductor (inner thigh)
Trapezius (upper back)
Rhomboideus (upper back)
Deltoid (shoulder)
Triceps (back of arm)
Latissimus Dorsi (mid back)
Spinae Erectors (lower back)
Gluteus Medius (hip)
Gluteus Maximus (buttocks)
Hamstring (back of leg)
Gastrocnemius (back of calf)

c\
R
S

27

PART iDENTiFiCATiON

CHART--Model

M6 Washer
M8 Washer

(35)

(75)

(50)

M10 Nylon Locknut

25mm Round

R010SA

H

I
M10 Washer

No. 831.159822

(70)

M8 Nylon Locknut

Inner Cap (24)

19mm Round

(71)

Inner Cap (27)

M6 Nylon Locknut

(26)

M4 x 10mm Selftapping Screw (68)

J

38mm x 50mm Inner Cap (23)

38mm Square

Inner Cap (41)

m

i

m

J

50mm x 63mm Inner Cap (22)

50mm Square Inner Cap (33)

t?\\\\\\\\\\\\\\_ I
M8 x 65mm Bolt (63)

MIO x 65ram

Bolt (99)

_\\\\\\\\\\\\\\\\ I

M6 x 65mm Screw (90)

M8 x 65ram

_\\\\\\\1

Carriage

Bolt (57) U

MIO x 60ram Bolt (65)
M8 x 70ram

Carriage

Bolt (1

_\\\\\\\!
MIO x 55ram Bolt (89)

M8 x 70ram

_\\\\\\\!

Bolt (81)

t\\\\\\\l
MIO x 70mm Bolt (100)

M10 x 50mm Bolt (62)

_\\\\\\\!
M10 x 45mm Bolt (66)

M8 x 80ram

Bolt (60)

MIO x 80ram

Bolt (61)

MIO x 80ram Button Head

Bolt (97)

t\\\\\\\l

M8 x 45mm Bolt (69)

M8 x 20mm Shoulder

Bolt (78)

M8 x 85mm Bolt (59)
M4 x 20mm Self-tapping

Screw (77)

_\\\\\\\1
MIO x 95mm Bolt (98)
M8 x 16mm Button Head Bolt (64)

_\\\\\\\1
M6 x 16mm Bolt (13)

MIO x lOOmm Bolt (84)

MIO x 135mm Bolt (58)

PART LiST--Model

No. 831.159822

R0103A

Key No.

Qty.

Description

Key No.

Qty.

1
2

1
1

Right Base
Left Base

54
55

4
4

3
4
5
6
7
8
9
10
11
12
13

1
1
1
1
1
1
1
1
1
2
12

Left Top Frame
Leg Lever
Right Seat Frame
Right Upright
Left Upright
Right Top Frame
Butterfly Frame
Left Butterfly Arm
Right Butterfly Arm
Press Handle
M6 x 16mm Bolt

56
57
58
59
60
61
62
63
64
65
66

2
4
1
4
6
2
4
3
4
2
9

14
15
16

1
2
2

Center Top Frame
Backrest
Seat

67
68
69

1
1
1

17
18

1
4

Long Pad Tube
Foam Pad

70
71

34
38

19
20
21
22
23
24
25
26
27
28
29

2
2
4
7
4
2
1
3
4
1
1

Large Foam Pad
Weight Guide
Support Plate
50mm x 63mm Inner Cap
38ram x 50ram Inner Cap
25mm Round Inner Cap
Bumper
M6 Nylon Locknut
19mm Round Inner Cap
Base Cap
Left Seat Frame

72
73
74
75
76
77
78
79
80
81
82

8
1
1
33
2
3
3
1
2
13
1

30
31
32
33
34
35

1
1
1
3
16
14

Leg Press Frame
Leg Press Plate
Weight Tube Bumper
50mm Square Inner Cap
13mm Spacer
M6 Washer

83
84
85
86
87
88

2
1
2
1
1
1

36
37

1
1

Left Leg
Left Base Plate

89
90

2
2

38
39
40
41
42

23
2
2
1
1

90mm Pulley
"V"-Pulley
Long Cable Trap
38mm Square Inner Cap
Lat Bar

91
92
93
94
95

6
2
1
1
1

43
44
45
46
47
48
49
50
51

2
2
1
1
1
2
1
21
1

Handgrip
Weight Guide Bushing
High Cable
Butterfly Cable
Low Cable
Pivot Bracket
Chain
M10 Washer
Handle

96
97
98
99
100
101
102
#
#

1
2
1
1
9
2
4
1
1

52
53

3
2

Cable Clip
Locking Pin

#
#

1
1

Note: "#" indicates a non-illustrated part. Specifications

Description
Butterfly Cap
Plastic Washer
Double "U"-Bracket
M8 x 65ram Carriage Bolt
M10 x 135mm Bolt
M8 x 85mm Bolt
M8 x 80mm Bolt
M10 x 80mm Bolt
M10 x 50mm Bolt
M8 x 65ram Bolt
M8 x 16mm Button Head Bolt
M10 x 60ram Bolt
M10 x 45mm Bolt
Center Base
M4 x 10mm Self-tapping Screw
M8 x 45mm Bolt
M10 Nylon Locknut
M8 Nylon Locknut
Weight
Right Leg
Top Weight
M8 Washer
Foam Grip
M4 x 20mm Self-tapping Screw
M8 x 20mm Shoulder Bolt
Small "U"-Bracket
Long Spacer
M8 x 70mm Bolt
Weight Tube
Weight Bumper
M10 x 100ram Bolt
"U"-Bracket
Weight Pin
Leg Press Pin
Adjustment Tube
M10 x 55mm Bolt
M6 x 65mm Screw
Cable Trap
Pulley Cover
Ab Strap
Short Pad Tube
Leg Press Cable
Leg Lever Cable
M10 x 80ram Button Head Bolt
M10 x 95mm Bolt
M10 x 65mm Bolt
M10 x 70mm Bolt
Large Support Plate
M8 x 70mm Carriage Bolt
User's Manual
Exercise Guide
Allen Wrench
Grease Packet

are subject to change without notice.

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'_
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® Registered Trademark / TM Trademark / SM Service Mark of Sears, Roebuck and Co.
® Marca Registrada
/ TMMarca de F&brica / aM Marca de Servicio de Sears, Roebuck and Co.

f

FULL 90 DAY WARRANTY
For 90 days from the date of purchase, if failure occurs due to defect in material or workmanship in this
Sears Weight System Exerciser, contact the nearest Sears Service Center throughout the United States
and Sears will repair or replace the Weight System Exerciser, free of charge.
This warranty does not apply when the Weight System Exerciser 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

Part No. 190803 R0103A

and Co., Dept. 817WA, Hoffman

Estates, IL 60179

Printed in China © 2002 Sears, Roebuck and Co.



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