Weider 831159823 User Manual PRO 4100 Manuals And Guides L0310486

WEIDER Weight System Manual L0310486 WEIDER Weight System Owner's Manual, WEIDER Weight System installation guides

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WELDER
Model No. 831.159823
Serial No.
Write the serial number in the
space above for reference.

USER'S MANUAL

Serial Number Decal (under seat)

F-------XERCISE_
EOU

I

PM

ENT
•

b.E

HELPLINEI

1-800-736-6879

SEARS, ROEBUCK AND CO.
HOFFMAN ESTATES, IL 60179

www.weiderfitness.com
new products, prizes,
fitness tips, and much morel

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

WARNING:

TO reduce the risk of serious injury, read the following important precau-

tions before using the weight system.
1.

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 acommeritial, 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

14. If you feel pain or dizziness at any time while
exercising, stopimmediately
and begin cool-

-

weight.s_-to
5.

protect the _

.

:_ :

Make._ure all parts are properly_.tightened
•_ac_fi_lme_the weight system mused: _
Reip(;lce any worn parts mined ately.

15. The waroing.decals,.
shown herb_h_v_-I_serl

6.

Ke_:p childrenunder the age of 12 and.pets
sway from the weight system at all times.

7.

Keep,hands and feet away from moving parts.

8.

AIwayswear athletic shoes for foot protection when using, the weight system.
."

9.

The .w_e/ghtsystem is designed to support a
i_i_.m'us_r
Weight of 300 poundsL,_
'

placed on th_'_eigh_t :_'
system in the.locations
shown oh page 4.ff a
decal is missing or
illegible, please call
our ton-free HELPLINE
at 1-800-736-6879,
Monday through
Saturday, 7 a.m. until
7 p.m. Central Time, to
order a free replacemerit decal. Place the
decal on the weight
system in the-location shown.

-.

10. Nevl_r release the press arm, butterfl_annns,
°|_g-_eve;l',-leg press base, lat bar,-=_b_p,
or
harldle While weights are raised; the weights
will fal! with great force.

• Misuse of this product

mayresultin senous
injury.
• Readuser'smanual
and followall warmngs
and operat,_g
_nstructlonspriorto use
• Donotallowchildren
onor aroundmachine
• Replacelabelif
damaged,_lleg_ble,
or
removed,
Decal 1
>.'_: - _- -

Decal 2

WARNING:

Before beginning this or any exercise program, consult your physician. This

is -ei_p_d=iJly iml_ortant for persons _ver 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 df 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.

1-800-736-6879, Monday through Saturday, 7 a.m.
until 7 p.m. Central Time (excluding holidays). To help
us assist you, please note the product model number
and serial number before calling. The model number is
831.159823. 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 additional
questions, please call our toll-free HELPLINE at

ASSEMBLED
DIMENSIONS:
Height: 77 in.
Width:
81 in.
Ler_:
_ in.

Warning Decal 2
(One on each side
of the dght upright.)
Lat Bar
High Pulley Station

Butterfl_
/Press Arm

Left Side

Ab Pulley
Station

Decal 1
Backrest

Backrest
Right.Side
Leg Press
Plate
Seat
Weight
Leg

Low Pulley
Station

Note: The terms "right side" and "left side" are determined relative 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 onented as shown in the drawings.

Make::Thingb.
.
kEasierfor You_elf..
Every. hmg.m thlsmanual Is designed,to;ensure
• at the_we=ght_sy_em c_n.be,a_ed:successfuUy-by anyone.;How(tv_,_t_'s_Jr_l_il_int:to ' _
•_real_e2_at-_e
_e_ti
e w_giifks_em_as
_mapy__atts and,that :_:a ssemb_Nss_w=ll
_take:ti_e_!Iost'people_,flnd_th_'_t_g
as,de
_ plenty'_{,t,me, assembly w, II g_._;"-'._"
-

• For help identifying small parts, use the PART
IDENTIFICATION CHART.
An Allen wrench _)

and the following

tools (not included) are required for assembly:
• two adjustable wrenches
• one rubber mallet

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

• one standard screwdriver

• Assembly requires two people•

• one Phillips screwdriver

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

• lubricant, such as grease or petroleum jelly,
and soapy water.
Assembly will be more convement 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.

60
1.

26

Before beginning assembly, be sure that you
have read and understand the information in
the box above•
Attach the Base Cap (28) to the Right Base (1)
with two #8 x 3/4" Screws (68).

28
57

Attach the Center Base (67) to the Right Base (1)
with two 5/16" x 2 314"Bolts (60), two 5/16"
Washers (26), and two 5/16" Nylon Locknuts (71).

57
68

Insert four 5/16" x 2 112"Carriage Bolts (57) up
into the Right Base (1).
•

2
33
_.

Press two 2" Square Inner Caps (33) into the
ends of the Left Base (2). Attach the Rubber
Bumper (98) to the Left Base with a #8 x 3/4"
Screw (68).

26 60
60

2

Insert four 5/16" x 2 1/2" Carriage Bolts (57) up
into the Left Base (2).

71

67
57

Attach the Left Base (2) to the Right Base (1) and
Center Base (67) with three 5116" x 2 3/4" Bolts
(60), three 5/16" Washers (26), and three 5116"
Nylon Locknuts (71).

5

Attach the Base Plate (37) to the Left Base (2)
with a 3/8" x 5 1/2" Bolt (58) and a 3/8" Nylon
Locknut (70).
Attach the Left Upright (7) to the Left Base (2)
with the two indicated 5/16" x 2 1/2" Carriage
Bolts (57) and two 5/16" Nylon Locknuts (71).
Attach the Left Leg (36) to the Left Base (2) with
the two indicated 5/16" x 2 1/2" Carriage Bolts
(57) and two 5/16" Nylon Locknuts (71). Be sure
the large upper hole in the Left Leg is on the
side shown.
Do not tighten the 5116" Nylon Locknuts (7t)
yet.

7_

36
71
71

Hole
_/71

57
70

4.

Press a 2" x 2 1/2" Inner Cap (22) into the top of
the Right Leg (73).

4

Attach the Right Upright (6) to the Right Base (1)
with the two indicated 5/16" x 2 1/2" Carriage
Bolts (57) and two 5/16" Nylon Locknuts (71).
Attach the Right Leg (73) to the Right Base (1)
with the two indicated 5/16" x 2 112" Carriage
Bolts (57) and two 5/16" Nylon Locknuts (71).
Do not tighten the 5116" Nylon Locknuts (71)
yet.

22

71
71
71...

57
57

6

5.

Attach the Right Seat Frame (5) to the Right Leg
(73) with two 5/16" x 3 1/4" Bolts (59), two 5/16"
Washers (26), and two 5/16" Nylon Locknuts (71).

59

26

5

Attach the Right Seat Frame (5) to the Right
Upright (6) with two 5/16" x 3 1/4" Bolts (59), two
5/16" Washers (26), and two 5/16" Nylon
Locknuts (71).

26

I'foP _

Do not tighten the 5/16" Nylon Locknuts (71)
yet.
J

71 2_-'_" _'_!

Press a 2" Square Inner Cap (33) into the end of
the Left Seat Frame (29).

6.

71 "

Attach the Left Seat Frame (29) to the Left Leg
(36) with two 5116"x 2 112" Carriage Bolts (57)
and two 5/16" Nylon Locknuts (71).

57

Attach the Left Seat Frame (29) to the Left
Upright (7) with two 5/16" x 3 1/4" Bolts (59), two
5/16" Washers (26), and two 5/16" Nylon
Locknuts (71).
Do not tighten the 5116" Nylon Locknuts (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 5/16"
x 2 3/4" Bolts (60), four 5/16" Washers (26), and
two 5/16" Nylon Locknuts (71).

7

6O

7

8.

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

t

Lubdcate

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.

g.

Press two 2" x 2 1/2" Inner Caps (22) into the
ends of the Left Top Frame (3).

9

Attach the Left Top Fran_ (3) to the Left Up_ight
(7) with two 5/16" x 3 1/4" Bolts (59), a Support
Plate (21), and two 5/16" Nylon Locknuts (71). Do
not tighten the Locknuts yet.

22

10. Press a 2" x 2 1/2" Inner Cap (22) into the end of
the Right Top Frame (8).

10

Attach the Right Top Frame (8) to the Right
Upright (6) with two 5/16" x 3 1/4" Bolts (59), a
Support Plate (21), and two 5/16" Nylon Locknuts
(71).
Attach the Right Top Frame (8) to the Left Top
Frame (3) with two 5/16" x 2 3/4" Bolts (60), two
5/16" Washers (26), and two 5/16" Nylon
Locknuts (71).
Do not tighten the 5116" Nylon Locknuts (71)
yet.

8

59

59

11. Press the two Weight Guide Bushings (44) into
the Center Top Frame (14). Slide the Center Top
Frame onto the Weight Guides (20).
71

Attach the Center Top Frame (14) to the Right
Top Frame (8) with two 5/16" x 2 314"Bolts (60),
two 5/16" Washers (26), and two 5/16" Nylon
Locknuts (71).

71
44

_:

6O

60

Attach the Center Top Frame (14) to the Left Top
Frame (3) with two 5/16" x 2 314"Bolts (60), two
5116" Washers (26), and two 5/16" Nylon
Locknuts (71).
Tighten all of the 5116" Nylon Locknuts (71)
used in steps 3-11.
Note: The remaining hardware from the
"Frame Assembly" bag will be used later.
12

8

12. Press a 1 t/2" Square Inner Cap (41) into the
Right Upright (6). Press a 2" x 2 1/2" Inner Cap
(22) into the Butterfly Frame (9).
22

Lubricate a 3/8" x 3" Bolt (61) with grease. Attach
the Butterfly Frame (9) to the Right Top Frame (8)
with the Bolt and a 3/8" Nylon Locknut (70). Do
not overtighten the Locknut; the Butterfly
Frame must be able to pivot easily.

~6

70__icate
13. Lubricate a 3/8" x 2" Bolt (62) with grease. Attach
the Pivot Bracket (48) to the Right Butterfly Arm
(11) with the Bolt and a 3/8" Nylon Jamnut (50).
Do not overtighten the Locknut; the Pivot
Bracket must be able to pivot easily.

13

Press a 1 112"x 2" Inner Cap (23) into the indicated end of the Right Butterfly Arm (11). Wet the
bottom end of the Arm with soapy water. Slide a
Large Foam Pad (19) onto the Ann.
Slide a Foam Grip (76) onto a Press Handle (12).
Press a 1" Round Inner Cap (24) into the end of
the Handle. Attach the Handle to the Right
Butterfly Arm (11) with two 5/16" x 314"Button
Head Screws (64) and two Nut Clips (99).
Slide the Large Foam Pad (19) down so that the
bottom of the Foam Pad is even with the bottom
of the Right Butterfly Arm (11).
12
Repeat this step with the Left Butterfly Arm
(10).

9

14. Lubricate a 3/8" x 3" 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), two 3/8"
Washers (75), and a 318" Nylon Jamnut (50). Do
not overtighten the Jamnut; the Butterfly Arm
must be able to pivot easily. Be sure the
indented sides of the Plastic Washers fit over

97

14
Welded
Bushing

the welded bushing in the Butterfly Arm.
50
Repeat this step with the Left Butterfly Arm
(10).

15. Attach the Bumper (25) to the Right Leg (73) with
the #10 x 1" Screw (77).

15
73

Press two 1 1/2" x 2" Inner Caps (23) into the
ends of the Leg Lever (4).

23

Lubricate a 318"x 2 1/2" Bolt (63) with grease.
Attach the Leg Lever (4) to the Right Leg (73)
with the Bolt and a 318"Nylo n Jamnut (50). Do
not overtighten the Jamnut; the Leg Lever
must be able to pivot easily.

Lubricate

4"

23
16. Press a 2" x 2 1/2" Inner Cap (22) into the top of
the Leg Press Frame (30).

16

Lubricate a 3/8" x 3" Bolt (61) with grease. Attach
the Leg Press Frame (30) to the Left Base (2)
with the Bolt and a 3/8" Nylon Locknut (70). Do
not overtighten the Locknut; the Leg Press
Frame must be able to pivot easily.

7O

Lubricate

10

17

GoABI:EA;SSEMBLY
17. IMPORTANT: Whilb.bs'seinbling the cables¢,do
n0t-6_ier,tJg_,,en_the Ibi_kouts _at_ing_the
pult_s;_e
Rullpj_m USt'_ _ .ble_t6tum_ly.
-

_'ng

and _elp _de__les.-,:,

_,_

l/iv _40

Locate the High Cable (45). Route the Cable up
through the Left Top Frame (3) and around a
3 1/2" Pulley (38) Attach the Pulley inside the Top
Frame with a 3/8" x 2 3/4" Bolt (81), two 3/8"
Washers (75), two 1/2" Spacers (34), and a 3/8"
Nylon Locknut (70).
18. Route the High Cable (45) around a 3 1/2" Pulley
(38) and down through the Left Top Frame (3).
Attach the Pulley and a Cable Trap (91) inside
the Top Frame wetha 3/8" x 2 3/4" Bolt (81), two
318" Washers (75), two 112"Spacers (34), and a
318" 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 necessary to loosen the four indicated 5116" Nylon
Locknuts (71). Retighten the Locknuts when
this step is completed.
19. Remove the preassembled
from a Double "U"-Bracket

3 112" Pulleys (38)
(56).

Wrap the High Cable (45) around a 3 1/2" Pulley
(38). Attach the Pulley to the single hole side of a
Double "U"-Bracket (56) with a 3/8" x 2" Bolt (62)
and a 3/8" Nylon Locknut (70).

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

Wrap the High Cable (45) around a 3 1/2" Pulley
(38). Attach the Pulley at the rear hole, inside of
the bracket on the Center Top Frame (14) with a
3/8" x 1 3/4" Bolt (66) and a 3/8" Nylon Locknut
(70).

11

21. Wrap the High Cable (45) around a 3 1/2" Pulley
(38). Attach the Pulley at the forward hole, inside
of the bracket on the Center Top Frame (14) with
a 3/8" x 1 3/4" Bolt (66) and a 3/8" Nylon Locknut
(70).

22. Attach the end of the High Cable (45) to the
Small "U"-Bracket (79) with a 1/4" Washer (35)
and a 1/4" Nylon Locknut (65). Note: Do not
completely tighten the Nylon Locknut; it
should be threaded only two turns onto the
end of the Cable, as shown in the inset drawing.
Attach the Small °U"-Bracket (79) to the Weight
Tube (82) with a 5/16" x 1 314" Bolt (69) and a
5116" Nylon Locknut (71). Do not overtighten
the Locknut; the Weight Tube should be able
to pivot in the "U'-Bracket.

45-!I,
65

23. Locate the Leg Press Cable (95). Attach the
Cable inside the Left Leg (36) with a 318"x 2 3/4"
Bolt (81), two 3/8" Washers (75), two Long
Spacers (80), and a 318" Nylon Locknut (70).

23

_

_

iS

24. Wrap the Leg Press Cable (95) around a 3 1/2"
Pulley (38). Attach the Pulley inside the Leg
Press Frame (30) with a 3/8" x 2 3/4" Bolt (81),
two 318"Washers (75), two 1/2" Spacers (34),
and a 318"Nylon Locknut (70).

24

_.L_

12

7570

_

75_

,_.o , L

95

25. Route the Leg Press Cable (95) through the Left
Leg (36) and the Left Upright (7) as shown. Wrap
the Cable around a 3 1/2" Pulley (38). Attach the
Pulley inside the Upright with a 318" x 2 3/4" Bolt
(81), two 3/8" Washers (75), two 1/2" Spacers
(34), and a 3/8" Nylon Locknut (70).

95
81

26. Wrap the Leg Press Cable (95) around a 3 112"
Pulley (38). Attach the Pulley inside the bracket
on the Left Top Frame (3) with a 318"x 2" Bolt
(62) and a 3/8" Nylon Locknut (70).

26
3

27. Remove the preattached 3 1/2" Pulley (not
shown) from the "U"-Brecket
(85).
Attach the end of the Leg Press Cable (95) to the
=U"-Bracket (85) with a 1/4" Washer (35) and a
114"Nylon Locknut (65). 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.

28. Locate the Butterfly Cable (46). Attach the
Cable to the Pivot Bracket (48) on the Left
Butterfly Arm (10) with an 5116" x 1" Shoulder Bolt
(78) and a 5/16" Nylon Locknut (71).

28

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 a
3/8" x 2 1/2" Bolt (63) and a 3/8" Nylon Locknut
(70). Be sure the Cable Trap is turned to hold
the Cable in the groove of the Pulley.

29

_

/I

I"_

/
30. Remove the preattached 3 1/2" Pulleys (38)
from the Double "U"-Bracket
(56).

3O

Wrap the Butterfly Cable (46) around a 3 112"
Pulley (38). Attach the Pulley to the single hole
side of the other Double "U"-Bracket (56) with a
3/8" x 2" Bolt (62) and a 3/8" Nylon Locknut (70).

56
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 a
318" x 2 112"Bolt'(63) and a 3/8" Nylon Locknut
(70). Be sure the Cable Trap is turned to hold
the Cable in the groove of the Pulley.

31

63

39

32. Attach the Butterfly Cable (46) to the Pivot
Bracket (48) on the Right Butterfly Arm (11) with a
5116" x 1" Shoulder Bolt (78) and an 5/16" Nylon
Locknut (71).

32

11

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 a 5/16"
x 1" Shoulder Bolt (78) and a 5/16" Nylon Locknut
(71).

i

o

2'I

96_
78
34. Attach a 3 1/2" Pulley (38) inside the Right Leg
(73) with a 3/8" x 2 3/4" Bolt (81), two 3/8"
Washers (75), two 1/2" Spacers (34), and a 3/8"
Nylon Locknut (70).

34

7338
75 7
34

34

35. Route the Leg Lever Cable (96) through the Right
Upright (6) and around a 3 1/2" Pulley (38).
Attach the Pulley inside the Upright with a 3/8" x
2 314"Bolt (81), two 3/8" Washers (75), two 112"
Spacers (34), and a 3/8" Nylon Locknut (70).

35

36. Wrap the Leg Lever Cable (96) around a 3 112"
Pulley (38). Attach the Pulley and a Cable Trap
(91) to the bottom set of holes in the indicated
Double "U"-Bracket (56) with a 3/8" x 2" Bolt (62)
and a 318" Nylon Locknut (70). Be sure the
Cable Trap Is turned to hold the Cable in the
groove of the Pulley.

15

<

_"
81

11 11

37. Remove the preattached 3 1/2" Pulley (not
shown) from the "U"-Bracket
(85).

37

Attach the end of the Leg Lever Cable (96) to the
other "U"-Bracket (85) with a 1/4" Washer (35)
and a 114"Nylon Lecknut (65). Note: Do not
completely tighten the Nylon 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).
Attach a 3 1/2" Pulley (38) inside the Leg Press
Frame (30) with a 318" x 2 3/4" Bolt (81), two 318"
Washers (75), two 1/2" Spacers (34), and a 3/8"
Nylon Locknut (70).

39. Route the Low Cable (47) through the Left Leg
(36) and the Left Upright (7). Attach a 3 1/2"
Pulley (38) inside the Upright with a 3/8" x 2 3/4"
Bolt (81), two 3/8" Washers (75), two 1/2"
Spacers (34), and a 318" Nylon Locknut (70).

34

75
81

40. Wrap the Low Cable (47) around a 3 1/2" Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the lower set of holes in the indicated "U"-Bracket
(85) with a 3/8" x 2" Bolt (62) and a 318" Nylon
Locknut (70). Be sure the Cable Trap is turned
to hold the Cable in the groove of the Pulley.

16

7

75

41. Wrap the Low Cable (47) around a 3 1/2" Pulley
(38). Attach the Pulley to the indicated bracket on
the Left Base (2) with a 3/8" x 2" Bolt (62) and a
3/8" Nylon Locknut (70).

2

42. Wrap the Low Cable (47) around a 3 1/2" Pulley
(38). Attach the Pulley to the indicated bracket on
the Left Base (2) with a 3/8" x 2" Bolt (62) and a
318"Nylon Locknut (70).

43. Wrap the Low Cable (47) around a 3 112"Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the bottom set of holes in the indicated Double
"U"-Bracket (56) with a 318"x 2" Bolt (62) and a
3/8" Nylon Locknut (70). Be sure the Cable Trap
is turned to hold the Cable in the groove of
the Pulley.

43

38
44. Wrap the Low Cable (47) around a 3 1/2" Pulley
(38). Attach the Pulley to the indicated bracket on
the Right Base (1) v_th a 318"x 2" Bolt (62) and a
3/8" Nylon Locknut (70).

62

17

45. Wrap the Low Cable (47) around a 3 112" Pulley
(38). Attach the Pulley to the indicated bracket on
the Right Base (1) with a 3/8" x 2" Bolt (62) and a
3/8" Nylon Locknut (70).

46. Wrap the Low Cable (47) around a 3 112" Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the lower set of holes in the indicated "U"-Bracket

46

(85) with a 3/8" x 2" Bolt (62) and a 3/6" Nylon
Locknut (70). Be sure the Cable Trap is turned
to hold the Cable in the groove of the Pulley.

IJlJ

,,

47. Wrap the Low Cable (47) around a 3 112"Pulley
(38). Attach the Pulley and a Cable Trap (91) to
the side of the Right Upright (6) with a 3/8" x
3 3/4" Bolt (84), a 318"Washer (75), and a 3/8"
Nylon Locknut (70). Be sure the Cable Trap is
turned to hold the Cable in the groove of the
Pulley.

i ii

48. Wrap the Low Cable (47) around a 3 1/2" Pulley
(38). Attach the Pulley and a pair of Pulley
Covers (92) to the Right Upright (6) with a 318"x
3 3/4" Bolt (84), two 3/8" Washers (75), and a 3/8"
Nylon Jamnut (50). 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.

4792

18

49

SEAT ASSEMBLY

t6

49. Attach a Seat (16) to the Right Seat Frame (5)
with a 1/4" x 2 1/2" Bolt (90), a 1/4" Washer (35),
and two 1/4" x 3/4" Bolts (13).
5 :
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 1/4" x 314" Bolts (13).

5O

Repeat this step with the other Backrest (15)
and the Left Upright (not shown),

15_

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 314"
Round Inner Caps (27) into the ends of the Pad
Tube.

51

13

18

17 Ld'i

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

52. Press a 2" x 2 1/2" Inner Cap (22) into the indicated end of the Adjustment Tube (88).

52

87

Attach the Leg Press Plate (31) to the Adjustment
Tube (88) with a 5/16" x 2 1/2" Bolt (89), two
5/16" Washers (26), and a 5/16" Nylon Locknut
(71).

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,

26

71

26
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 a #8 x 3/4" Screw (68). Do
not fully tighten the Screw.

53
53

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
_dde_, yea will ,treed to remove it by tightening the cables; see _TENING
THE C_IISI.ES o_tpage
22.

20

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 propedy 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 [.at Bar and
the High Cable with two Cable Clips. Adjust the
length of the Chain between the Lat Bar and the
High Cable so the Lat Bar is in the correct starting position for the exercise to be performed.
The Handle (not shown) and Ab Strap (not shown)
can be attached in the same rammer. 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 pulleys, 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.

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.

Holes

21

\

ADJUSTING THE CABLE TENSION
Woven cable, the type of cable used on the weight
system, can stretch slightlywhen 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
3 1/2" Pulley (38) and Cable Trap (91) to a higher set
of holes in a Double "U"-Bracket (56). Remove the 318"
Nylon Locknut (70) and the 3/8" x 2" 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"-Brecket 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 3 112" Pulley (38) in the other Double "U"Bracket (56) in the same manner.
See drawing B. Slack can be removed by moving the
3 112"Pulley (38) and the Cable Trap (91) to the higher
set of holes in a "U"-Bracket (85). Remove the 3/8"
Nylon Locknut (70) and the 3/8" x 2" Bo|t (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 Locknut. Make
sure that the Cable Trap is in the proper position
and that the Cable and Pulley move smoothly.
Move the 3 112" Pulley (38) in the other "U"-Brecket
(85) in the same manner.
See drawing B. Slack can also be removed from the
cables by tightening the 1/4" Nylon Locknuts (65)
attaching a cable to either "U"-Brecket (85), or the
Small =U"-Bracket (79). To do this, you may need to
remove the 3 1/2" 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.

74

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

PRESS
ARM

LEG
PRESS

BUTTERFLY ARM

AB
PULLEY

LEG
LEVER

(Ibs.)

(Ibs.)

(Ibs.)

(Ibs.)

(Ibs.)

(Ibs.)

LOW
PULLEY
(Ibs.)

Left 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

_2

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 muting 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 muted, 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

4

3

1

Butterfly Cable (46)

\
CaUe p_,_

6

11
Low Cable (47)

3

7

8
lO

24

4_

Leg Press Cable (95)
Leg Lever Cable (96)
.5
3

1

2

2

CABLE ID CHART
_

-- (46) 47 3/7"

_

_

-- (96) 95 112"

_

_

-- (95) 148 1/4"

,,- _

_

-- (47) 276 3/4"

_'
"r'r_

_

-- (45) 116 314"

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 eac,_
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 delive,ring more oxygefl 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.
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.
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
cycling or swimming, 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 combination of weight training and aerobic exercise will reshape and strengthen your body, plus develop your heart and lungs.

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 vadety 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 dght for you, stick with it.
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 apprcpriate 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.
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
dudng the exertion stage of each repetition and inhale
dudng the return stroke. Never hold your breath.

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
building workout.
• Rest for one minute after each set for a toning workout.
• Rest for 30 seconds after each set for a weight loss
workout.
Plan to spend the first couple of weeks familiarizing
yourself with the equipment and learning the proper
form for each exercise.

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.
STAYING MOTIVATED
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.

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.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Q.
R.
S.
T.
U.
V.
W.

Stemomastoid (neck)
Pectoralis Major (chest)
Biceps (6"o_ of arm)
Obliques (waist)
Brachioradials(forearm)
Hip Flexors (upper thigh)
Abductor (outer thigh)
Quadricaps (frontof thigh)
Sartodus (front of thigh)
Tibialis Antedor (front of calf)
Soleus (front of calf)
Rectus Abdominus (stomach)
Adductor (inner thigh)
Trapezius (upper back)
Rhombo'_leus(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)

R
S

27

PART IDENTIFICATION

CHART--Model

1/4" Nylon Locknut (65)

3/8" Nylon Jamnut

No. 831.159823

R0103A

(50)
3/8" Washer

5/16" Nylon Locknut

(71)

(75)

3/8" Nylon Locknut (70)
5/16" Washer

(56)

3/4" Round Inner Cap (27)
1" Round Inner Cap (24)

1/4" Washer

I
1 1/2" Square Inner Cap (41)

1 1/2" x 2" Inner Cap (23)

F
I

m

m
i

I

I

2" x 2 1/2" Inner Cap (22)

2" Square Inner Cap (33)

(35)

3/8" x

1/4" x 2 1/2" Bolt (90)
2" Bolt (62)

5/16" x 2 1/2" Bolt (89)

5/16" x 1 3/4" Bolt (69)

3/8" x 2 1/2" Bolt (63)

3/8" x 1 3/4" Bolt (66)

5/16" x 2 3/4" Bolt (60)
5/16" x 1" Shoulder

Bolt (78)

_\\\\\\\\\_

3/8" x 2 3/4" Bolt (81)

1/4" x 1" Screw (77)

5/16

x 2 1/2" Carriage

Bolt (57) Lj

1/4" x 3/4" Bolt (13)

#8 x 3/4" Screw (68)

5/16" x 3/4" Button Head Bolt (64)

3/8" x 3" Bolt (61)

3/8" × 3" Button

Head

Bolt (97)

5/16" x 3 1/4" Bolt (59)

3/8" x 3 3/4" Bolt (84)

3/8" x 5 112" Bolt (58)

PART LISTmModel

No. 831.159823

RO203A

Key No.

Qty.

Description

Key No.

Qty.

Description

1
2

1
1

Right Base
Left Base

53
54

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
1/4" x 3/4" Bolt

55
56
57
58
59
60
61
62
63
64
65

2
4
4
2

Locking Pin
Butterfly Cap
Plastic Washer
Double "U"-Bracket

14
15
16

1
2
2

Center Top Frame
Backrest
Seat

66
67
68

17
18

1
4

Long Pad Tube
Foam Pad

69
70

19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

2
2
2
7
4
2
1
23
4
1
1
1
1
1
3
16
5
1
1
23
2
2
1
1

Large Foam Pad
Weight Guide
Support Plate
2" x 2 1/2" Inner Cap
1 1/2" x 2" Inner Cap
1° Round inner Cap
Bumper
5116" Washer
3/4" Round Inner Cap
Base Cap
Left Seat Frame
Leg Press Frame
Leg Press Plate
Weight Tube Bumper
2" Square Inner Cap
1/2" Spacer
1/4" Washer
Left Leg
Left Base Plate
3 112"Pulley
"V"-Pulley
Long Cable Trap
1 1/2" Square Inner Cap
Lat Bar

71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94

10
1
10
13
2
13
3
4
3
2
1
4
1
28
38
8
1
1
25

5/16" x 2 1/2" Carriage Bolt
318"x 5 1/2" Bolt
5/16" x 3 114"Bolt
5116" x 2 3/4" Bolt
318"x 3" Bolt
3/8" x 2" Bolt
318"x 2 112"Bolt
5/16" x 3/4" Button Head Bolt
1/4" Nylon Locknut
3/8" x 1 3/4" Bolt
Center Base
#8 x 3/4" Screw
5/16" x I 3/4" Bolt
3/8" Nylon Locknut
5/16" Nylon Locknut
Weight
Right Leg
Top Weight
318" Washer

43
44
45
46
47
48
49
50
51
52

2
2
1
1
1
2
1
6
1
3

Handgrip
Weight Guide Bushing
High Cable
Butterfly Cable
Low Cable
Pivot Bracket
Chain
3/8" Nylon Jamnut
Handle
Cable Clip

95
96
97
98
99
#
#
#
#

2
1
3
1

Foam Grip
#10 x 1" Screw
5/16" x 1" Shoulder Bolt
Small "U"-Bracket

2
9

Long Spacer
318" x 2 3/4" Bolt

1
2
2
2

Weight Tube
Weight Bumper
3/8" x 3 314"Bolt
"U"-Bracket

1
1
1
1
2

Weight Pin
Leg Press Pin
Adjustment Tube
5/16" x 2 1/2" Bolt
1/4" x 2 1/2" Bolt

6
2
1
1
1
1
2

Cable Trap
Pulley Cover
Ab Strap
Short Pad Tube
Leg Press Cable
Leg Lever Cable
318" x 3" Button Head Bolt

1
4
1
1
1
1

Rubber Bumper
Nut Clips
User's Manual
Exercise Guide
Allen Wrench
Grease Packet

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

71
i

68:

38 71
70!

14

59

38

"i _-,_
71
71.

70
39

22

38

2O
92

/6
13

16

16

38
32,

72

170
89

.X

57

t_

Your Home
For repair - in your home - of all major brand appliances, lawn and garden equipment,
or heating and cooling systems, no matter who made it, no matter who sold it!
For the replacement parts, accessories, and user's manuals that you need to do-it-yourself.
For Sears professional installation of home appliances
and items like garage door openers and water heaters.
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®

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www.sears.com

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For repair of carry-in products like vacuums, lawn equipment,
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call or go on-line for the location of your nearest
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® Marca Reglsb'ada I TM Mama de Fdbnca / sM Mama de Seeacto de Sears, Roebuck and Co

FULL 90 DAY WARRANTY
For 90 days from the date of purchase, tf failure occurs due to defect in material or workmanship in this
Sears Wetght System Exerciser, contact the nearest Sears Ser_ce Center throughout the United States
and Sears wtll repair or replace the Weight System Exerciser, free of charge.

|

Thin 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.

1

Sears, Roebuck and Co., Dept. 817WA, Hoffman Estates, IL 60179

Part No. 194159 R0203A

Printed in Canada © 2003 Seam, Roebuck and Co.



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