Weider WESY86303 User manual

USER'S MANUAL
QUESTIONS?
As a manufacturer, we are
committed to providing complete
customer satisfaction. If you
have questions, or if there are
missing or damaged parts, we
will guarantee complete satisfac-
tion through direct assistance
from our factory.
TO AVOID UNNECESSARY
DELAYS, PLEASE CALL DIRECT
TO OUR TOLL-FREE CUSTOMER
HOT LINE. The trained techni-
cians on our customer hot line
will provide immediate assis-
tance, free of charge to you.
CUSTOMER HOT LINE:
1-800-999-3756
Mon.–Fri., 6 a.m.–6 p.m. MST
Model No. WESY86303
Serial No.
Write the serial number in the space
above for future reference.
Patent Pending
CAUTION
Read all precautions and instruc-
tions in this manual before using
this equipment. Save this manual
for future reference.
Serial Number Decal (Under Seat)
Visit our website at
www.proform.com
new products, prizes,
fitness tips, and much more!
Visit our website at
www.healthrider.com
new products, prizes,
fitness tips, and much more!
Visit our website at
www.nordictrack.com
new products, prizes,
fitness tips, and much more!
Visit our website at
www.weiderfitness.com
new products, prizes,
fitness tips, and much more!

2
TABLE OF CONTENTS
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HOW TO USE THE TRAINING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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.
WEIDER is a registered trademark of ICON Health & Fitness, Inc.
LIMITED WARRANTY
ICON Health & Fitness, Inc. (ICON), warrants this product to be free from defects in workmanship and
material, under normal use and service conditions, for a period of ninety (90) days from the date of pur-
chase. This warranty extends only to the original purchaser. ICON's obligation under this warranty is lim-
ited to replacing or repairing, at ICON's option, the product at one of its authorized service centers. All
products for which warranty claim is made must be received by ICON at one of its authorized service cen-
ters with all freight and other transportation charges prepaid, accompanied by sufficient proof of purchase.
All returns must be pre-authorized by ICON. This warranty does not extend to any product or damage to
aproduct caused by or attributable to freight damage, abuse, misuse, improper or abnormal usage or
repairs not provided by an ICON authorized service center,products used for commercial or rental pur-
poses, or products used as store display models. No other warranty beyond that specifically set forth
above is authorized by ICON.
ICON is not responsible or liable for indirect, special or consequential damages arising out of or in con-
nection with the use or performance of the product or damages with respect to any economic loss, loss
of property, loss of revenues or profits, loss of enjoyment or use, costs of removal, installation or other
consequential damages of whatsoever nature. Some states do not allow the exclusion or limitation of inci-
dental or consequential damages. Accordingly, the above limitation may not apply to you.
The warranty extended hereunder is in lieu of any and all other warranties and any implied warranties of
merchantability or fitness for a particular purpose is limited in its scope and duration to the terms set forth
herein. Some states do not allow limitations on how long an implied warranty lasts. Accordingly,the above
limitation may not apply to you.
This warranty gives you specific legal rights. You may also have other rights which vary from state to state.
ICON HEALTH & FITNESS, INC., 1500 S. 1000 W., LOGAN, UT 84321-9813

3
IMPORTANT PRECAUTIONS
WARNING: To reduce the risk of serious injury, read the following important precautions before
using the training system.
1. It is the responsibility of the owner to ensure
that all users of the training system are ade-
quately informed of all precautions.
2. Read all instructions in this manual and in
the accompanying literature before using the
training system.
3. Use the training system only on a level sur-
face. Place a mat beneath the training sys-
tem to protect the floor or carpet.
4. Inspect and tighten all parts often. Replace
any worn parts immediately.
5. Keep children under the age of 12 and pets
away from the training system at all times.
6. Never release the press arm, butterfly arms,
leg lever, leg press plate, lat bar, ab strap, or
nylon strap while weights are raised. The
weights will fall with great force.
7. Keep hands and feet away from moving parts.
8. Always wear athletic shoes for foot protec-
tion.
9. Always stand on the foot plate when per-
forming an exercise that could cause the
training system to tip.
10. When using the leg press station, always be
sure that the lock pin is fully inserted and
that the lock pin is clipped in place on the
adjustment tube (see page 23).
11. Make sure that the cables remain on the pul-
leys at all times. If the cables bind while you
are exercising, stop immediately and make
sure that the cables are on all of the pulleys.
12. Always disconnect the lat bar from the train-
ing system when performing an exercise that
does not use the lat bar.
13. If you feel pain or dizziness at any time while
exercising, stop immediately and begin cool-
ing down.
14. The training system is intended for home use
only. Do not use the training system in any
commercial, rental, or institutional setting.
15. The decal shown
at the right has
been attached to
the training sys-
tem in the two
locations shown
on page 4. If a
decal is missing
or illegible,
please call toll-
free 1-800-999-
3756 to order a
free replacement
decal. Apply the
decal in the loca-
tion shown.
WARNING: Before beginning this or any exercise program, consult your physician. This is especially
important for persons over the age of 35 or persons with pre-existing health problems. Read all
instructions before using. ICON assumes no responsibility for personal injury or property damage
sustained by or through the use of this product.

4
BEFORE YOU BEGIN
ASSEMBLED
DIMENSIONS:
Height: 78 in.
Width: 64 in.
Length: 70 in.
Foot Plate
Low Pulley
Station
High Pulley Station
Lat Bar
Leg Lever
Butterfly Arms
Press Arm
Weight Stacks
Backrests
Leg Press
Plate
Ab Pulley Station
WARNING DECAL
WARNING
DECAL
Thank you for selecting the versatile WEIDER®8630
training system. The WEIDER®8630 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 WEIDER®
8630 will help you to achieve the specific results you
want.
For your benefit, read this manual carefully before
using the WEIDER®8630 training system. If you
have additional questions, please call our Customer
Service Department toll-free at 1-800-999-3756,
Monday through Friday, 6 a.m. until 6 p.m. Mountain
Time (excluding holidays). To help us assist you,
please note the product model number and serial
number before calling. The model number is
WESY86303. The serial number can be found on a
decal attached to the WEIDER®8630 (see the front
cover of this manual).
Before reading further, please review the drawing
below and familiarize yourself with the parts that are
labeled.

5
ASSEMBLY
Make sure you have the following tools:
•Two (2) adjustable wrenches
•One (1) standard screwdriver
•One (1) phillips screwdriver
•One (1) rubber mallet
• You will also need grease or petroleum jelly, a
small amount of soapy water, and clear tape or
masking tape.
Note: Assembly will be more convenient if you have
asocket set, a set of open-end or closed-end
wrenches, or a set of ratchet wrenches.
How to Identify Parts
To help you identify the small parts used in assembly,
we have included a PART IDENTIFICATION CHART
in the center of this manual. Place the chart on the
floor and use it to easily identify parts during each
assembly step. Note: Some small parts may have
been pre-attached. If a part is not in the parts
bag, check to see if it has been pre-attached.
How to Orient Parts
As you assemble the training system, make sure
that all parts are oriented exactly as shown in the
drawings.
Tightening Parts
Tighten all parts as you assemble them, unless
instructed to do otherwise.
Questions?
If you have questions after reading the assembly
instructions, please call our Customer Service
Department toll-free at 1-800-999-3756,Monday
through Friday, 6 a.m. until 6 p.m. Mountain Time.
Assembly Requires Two Persons
For your convenience and safety, assemble the
training system with the help of another person.
Set Aside Enough Time
Due to the many features of the training system,
the assembly process will require about six hours.
By setting aside plenty of time and by deciding to
make the task enjoyable, assembly will go smoothly.
You may want to assemble the training system over
acouple of evenings.
Select a Location for the Training
System
Because of its weight and size, the training system
should be assembled in the location where it will be
used. Make sure that there is enough room to walk
around the training system as you assemble it.
How to Unpack the Box
To make assembly as easy as possible, we have
divided the assembly process into four stages. The
parts needed for each stage are found in individual
bags. Important: Wait until you begin each stage
to open the parts bag for that stage. Place all
parts of the training system in a cleared area and
remove the packing materials. Do not dispose of
the packing materials until assembly is completed.
Make Assembly Easier for Yourself!
Everything in this manual is designed to
ensure that the training system can be
assembled successfully by anyone. Before
beginning assembly, make sure to read the
information on this page; this brief intro-
duction will save you much more time than
it takes to read it!
The Four Stages of the Assembly Process
Frame Assembly—You will begin by assembling
the base and the uprights that form the skeleton of
the training system.
Arm Assembly—During this stage you will
assemble the arms and the leg lever.
Cable Assembly—During this stage you will
attach the cables and pulleys that connect the
arms to the weights.
Seat Assembly—During the final stage you will
assemble the seats and the backrests.

1.
Locate and open the parts bags labeled
“FRAME ASSEMBLY BAG ONE” and
“FRAME ASSEMBLY BAG TWO.”
Press two 2” Square Outer Caps (58) onto the
Weight Base (14) in the indicated locations.
Press a 2” Square Inner Cap (56) into the end
of the Weight Base.
Insert four 5/16” x 2 1/2” Carriage Bolts (49)
up through the Press Base (13). Insert two
5/16” x 2 1/2” Carriage Bolts up through the
Weight Base (14).
Attach the Press Base (13) to the Weight
Base (14) with two 5/16” x 2 3/4” Bolts (55),
two 5/16” Washers (20), and two 5/16” Nylon
Locknuts (40). Do not tighten the Nylon
Locknuts yet.
2. Slide the Ab Upright (1) onto the indicated
5/16” x 2 1/2” Carriage Bolts (49) in the
Weight Base (14). Hand tighten two 5/16”
Nylon Locknuts (40) onto the Carriage Bolts.
Do not tighten the Nylon Locknuts yet.
Slide the Leg Press Upright (4) onto the indi-
cated 5/16” x 2 1/2” Carriage Bolts (49) in the
Weight Base (14). Hand tighten two 5/16”
Nylon Locknuts (40) onto the Carriage Bolts.
Do not tighten the Nylon Locknuts yet.
3. Press a 2” Square Inner Cap (56) into each
end of the Top Frame (2). Press a 2” Square
Inner Cap (56) into each side of the Butterfly
Frame (3). Press two 1” Inner Caps (98) into
the top of the Butterfly Frame.
Attach the Butterfly Frame (3) to the Top
Frame (2) with a 5/16” x 3” Bolt (92). Be sure
that the Bolt is on the side shown.
Finish attaching the Butterfly Frame (3) to the
Top Frame (2) with a 5/16” Nylon Jam Nut
(91), a 5/16” x 2 3/4” Bolt (55), a 5/16”
Washer (20), and a 5/16” Nylon Locknut (40).
2
3
FRAME ASSEMBLY
6
1
4
40 40
49 49
13
2
3
14
55
40
20
56 56
56
56
92 98
91
1
56
58
58
55
20
49
40
49
13
14
Before you begin this step, make sure
that you have read all of the information
on page 5. This brief introduction will
save you much more time than it takes
to read it!

4. Slide the Front Seat Frame (8) onto the indi-
cated 5/16” x 2 1/2” Carriage Bolts (49) in the
Press Base (13). Hand tighten two 5/16”
Nylon Locknuts (40) onto the Carriage Bolts.
Attach the other end of the Front Seat Frame
(8) to the Leg Press Upright (4) with two 5/16”
x23/4” Bolts (55), two 5/16” Washers (20),
and two 5/16” Nylon Locknuts (40).
Press a 2” Square Inner Cap (56) into the
Front Seat Frame (8).
5. Insert two Weight Guides (23) into one of the
brackets on the Weight Base (14). Attach the
lower ends of the Weight Guides with a 5/16”
x6” Bolt (67), two 1/2” x 3/4” Spacers (69),
and a 5/16” Nylon Locknut (40). Do not over-
tighten the Nylon Locknut.
Attach the other Weight Guides (23) in the
same manner.
6. Slide a Weight Bumper (27) onto each of the
Weight Guides (23).
Slide eight Weights (90) onto each set of
Weight Guides (23). Be sure that the pin
grooves are on the indicated side of each
stack of Weights.
7. Press a Weight Tube Bumper (26) into each
Weight Tube (25).
Insert a Weight Tube (25) into each stack of
Weights (90). Be sure that the pins on the
Weight Tubes are in the pin grooves in the
upper Weights.
7
6
7
FRAME ASSEMBLY
90
90
Pin
Grooves
27
27
23 23
26
25
Pin
Grooves
90 90
5
67
69
23
23
40
14
4
55
20
49
40
56
8
40
4
13

8. Lubricate the insides of the holes in the Top
Weights (24) as shown. Slide a Top Weight
onto each set of Weight Guides (23).
9. Attach the Top Frame (2) to the Ab Upright (1)
with two 5/16” x 2 3/4” Bolts (55), two 5/16”
Washers (20), and two 5/16” Nylon Locknuts
(40). Do not tighten the Nylon Locknuts
yet.
Attach the Butterfly Frame (3) to the Leg
Press Upright (4) with two 5/16” x 2 3/4” Bolts
(55), two 5/16” Washers (20), and two 5/16”
Nylon Locknuts (40). Do not tighten the
Nylon Locknuts yet.
10. Attach the upper ends of one set of Weight
Guides (23) to the Top Frame (2) with a 5/16”
x6” Bolt (67), two 1/2” x 3/4” Spacers (69),
and a 5/16” Nylon Locknut (40).
Attach the upper ends of the other set of
Weight Guides (23) in the same manner.
Before continuing, firmly tighten all nylon
locknuts used in steps 1 through 10.
8
10
8
FRAME ASSEMBLY
23
Lubricate
Lubricate
23
23
69
40
67
67
40
2
69
24
24
23
955
55 20
20
40 40 4
3
2
1

11. Attach the Leg Press Plate (11) to the
Adjustment Tube (10) with a 5/16” x 2 1/2”
Bolt (39), two 5/16” Washers (20), and a 5/16”
Nylon Locknut (40). Be sure that the Leg
Press Plate and Adjustment Tube are ori-
ented as shown.
Press a 1 3/4” Square Inner Cap (48) into the
Adjustment Tube (10).
12. Attach the Adjustment Tube (10) to the Leg
Press Arm (9) with the Lock Pin (73). Be sure
the Leg Press Plate (11) is oriented as
shown.
Press two 2” Square Inner Caps (56) into the
Leg Press Arm (9).
13. Locate and open the parts bag labeled
“ARM ASSEMBLY.”
Attach the Leg Press Bumper (53) to the
Front Seat Frame (8) with the 1” Tap Screw
(72).
Lubricate the 3/8” x 3 1/4” Bolt (71). Attach
the Leg Press Arm (9) to the Press Base (13)
with the Bolt and a 3/8” Nylon Locknut (42).
14. Press a 1” x 7/8” Plastic Bushing (54) onto
each welded spacer on the Press Frame (12).
Slide the Press Frame onto the Press Base
(13) so that the Plastic Bushings are aligned
with the indicated tube. Note: This will be a
tight fit. Make sure that the high pulley is
on the side shown.
Lubricate the 3/8” x 8” Bolt (52). Attach the
Press Frame (12) to the Press Base (13) with
the Bolt and a 3/8” Nylon Locknut (42).
14
11
12
13
9
ARM ASSEMBLY
20 40
39
Angle
10
48
11
56
42
71—Lubricate
53
72
13
54
42
12
13
11
9
9
8
10
73
52—Lubricate
Tube
Welded
Spacers
High
Pulley
FRAME ASSEMBLY

10
15. Attach a Press Arm (7) to one side of the
Press Frame (12) with two 5/16” x 2 1/2” Bolts
(39) and two 5/16” Nylon Locknuts (40).
Attach the other Press Arm (7) to the Press
Frame (12) in the same manner.
16. Press a 1” Round Inner Cap (70) into one of
the Press Arms (7). Press a 1 3/4” Square
Inner Cap (48) into the Press Arm.
Repeat this step for the other Press Arm (not
shown).
17. Lubricate both axles on the Butterfly Frame
(3).
Refer to the drawing and identify the Right Fly
Arm (5) and the Left Fly Arm (6).
Press a 1 3/4” Square Inner Cap (48) into the
upper end of the Left Arm (6). Slide the Left
Fly Arm onto the indicated axle. Note: Be
careful not to confuse the Left Arm with
the Right Arm (5). Be sure that the upper
end of the Left Arm is behind the indicated
bracket on the Butterfly Frame (3).
IMPORTANT NOTE: Before assembling the
1” Retainers (45) used in this step, be sure
that you thoroughly understand the step.
The Retainers can be assembled only once.
If they must be removed, you will need to
order new Retainers.
Tap two 1” Retainers (45) and a 1” Round
Outer Cap (46) onto the axle. Be sure that
the teeth on the Retainers bend toward the
Round Outer Cap, as shown in the inset
drawing.
Attach the Right Fly Arm (5) in the same man-
ner.
15
16
17
ARM ASSEMBLY
39 7
70
40
48
12
7
7
3
Lubricate Axle
Axle
6
5
45
48
46
Bracket
45
46

11
18. Press a 1 3/4” Square Inner Cap (48) into the
lower end of the Left Fly Arm (6). Wet the
lower end of the Left Fly Arm with soapy
water. Slide a 10” Pad (22) onto the Left Arm.
Repeat this step with the Right Fly Arm (5).
19. Locate and open the parts bags labeled
“CABLE ASSEMBLY” and “PULLEYS.”
During steps 19 through 50, refer to the
CABLE DIAGRAMS on pages 26 and 27 of
this manual to verify proper cable routing.
Before beginning this section, fully unwind the
five Cables and identify the Cables by com-
paring the lengths and the ends. The approxi-
mate length of each Cable, in inches, is listed
after the key number in the drawing.
IMPORTANT:While assembling the cables,
do not overtighten the bolts and nuts
attaching the pulleys. The pulleys must be
able to turn freely.
20. Insert a 5/16” x 1” Bolt (51) through the brack-
et on the Right Fly Arm (5). Tighten a 5/16”
Nylon Jam Nut (91) onto the Bolt.
Identify the Butterfly Cable (89)—this is the
second shortest Cable. Slide one end of the
Butterfly Cable onto the 5/16” x 1” Bolt (51).
Thread another 5/16” Nylon Jam Nut (91)
onto the Bolt, but do not fully tighten it.
Leave enough room between the two Jam
Nuts for the Cable to pivot.
20
18
19
CABLE ASSEMBLYARM ASSEMBLY
5
6
48
22
88—239”
51
5
91
89
22
86—110”
85—101”
89—82”
87—72”

12
21. Wrap the Butterfly Cable (89) around a 3 1/2”
Pulley (82) as shown. Attach the Pulley and a
Cable Trap (80) to the bracket on the Leg
Press Upright (4) with a 3/8” x 2” Bolt (50)
and a 3/8” Nylon Locknut (42). The Cable
Trap must be oriented as shown and be
positioned to hold the Cable in the groove
of the Pulley.
22. Locate one of the preassembled pairs of
Pulley Plates (31) and 3 1/2” Pulleys (82).
Route the Butterfly Cable (89) under the indi-
cated 3 1/2” Pulley (82). The end of the Pulley
Plates (31) with two holes should be down-
ward. Refer to the inset drawing. Be sure
that the Cable is between the Cable Trap
(80) and the Pulley, and that the Cable Trap
is positioned to hold the Cable in place.
Tighten the 3/8” x 2” Bolt (50) and the 3/8”
Nylon Locknut (not shown).
23. Wrap the Butterfly Cable (89) around a 3 1/2”
Pulley (82) as shown. Attach the Pulley and a
Cable Trap (80) to the other side of the bracket
on the Leg Press Upright (4) with a 3/8” x 2”
Bolt (50) and a 3/8” Nylon Locknut (42). The
Cable Trap must be oriented as shown and
be positioned to hold the Cable in the
groove of the Pulley.
24. Note: The Left Fly Arm (6) is shown
removed for easier part identification.
Insert a 5/16” x 1” Bolt (51) through the brack-
et on the Left Fly Arm. Fully tighten a 5/16”
Nylon Jam Nut (91) onto the Bolt.
Slide the free end of the Butterfly Cable (89)
onto the 5/16” x 1” Bolt (51). Thread another
5/16” Nylon Jam Nut (91) onto the Bolt, but
do not fully tighten it. Leave enough room
between the two Jam Nuts for the Cable to
pivot.
24
21
22
23
CABLE ASSEMBLY
6
End with
two holes
should be
down
82
31
4
89
82
50 80
4
42
89
82
50
80
89 89
50 80
51
91
89
42

13
25. Identify the Rear Cable (87)—this is the
shortest Cable. Slide one end of the Rear
Cable onto the 5/16” x 3” Bolt (92). Thread
another 5/16” Nylon Jam Nut (91) onto the
Bolt, but do not fully tighten it. Leave
enough room between the two Jam Nuts
for the Cable to pivot.
26. See the inset drawing. Attach a 3 1/2” Pulley
(82) and a Cable Trap (80) to the upper hole
in a Large “U” Bracket (84) with a 3/8” x 2”
Bolt (50) and a 3/8” Nylon Locknut (42). Be
sure that the Cable Trap is inside the
Large “U” Bracket. Note: This may come
pre-assembled.
Route the Rear Cable (87) through the Large
“U” Bracket (84) and the 3 1/2” Pulley (82).
Be sure that the Cable is in the groove of
the Pulley and that the Cable and Pulley
move smoothly.
27. Wrap the Rear Cable (87) around a 3 1/2”
Pulley (82). Attach the Pulley to the Top
Frame (2) with a 3/8” x 2” Bolt (50) and a 3/8”
Nylon Locknut (42). The Cable must be
routed from the direction shown.
28. Attach the Rear Cable (87) to a Small “U”
Bracket (32) with a 1/4” Nylon Locknut (44)
and a 1/4” Washer (37). Do not completely
tighten the Nylon Locknut. It should be
threaded onto the end of the Cable only a
couple of turns, as shown in the inset
drawing.
Attach the Small “U” Bracket (32) to the indi-
cated Weight Tube (25) with a 5/16” x 1 3/4”
Bolt (68) and a 5/16” Nylon Locknut (40).
28
25
26
27
CABLE ASSEMBLY
92
91
87
87
80
42
84
50
82
82
82
50
42
37
44
25
32
68
2
87
84
87
87
40
87
44
32
37

14
29. Identify the Press Cable (88)—this is the
longest Cable. Attach the end of the Press
Cable (88) to the Large “U” Bracket (84) with
a1/4” Nylon Locknut (44) and a 1/4” Washer
(37). Donot completely tighten the Nylon
Locknut. It should be threaded onto the
end of the Cable so only a couple of
threads are showing above the Nylon
Locknut, as shown in the inset drawing.
30. Wrap the Press Cable (88) around a 3 1/2”
Pulley (82). Attach the Pulley and a Cable
Trap (80) to the indicated bracket on the
Press Base (13) with a 3/8” x 2” Bolt (50) and
a3/8” Nylon Locknut (42). Be sure that the
Cable Trap is turned to hold the Cable in
place.
31. Wrap the Press Cable (88) around a 3 1/2”
Pulley (82). Attach the Pulley and a Cable
Trap (80) to the other bracket on the Press
Base (13) with a 3/8” x 2” Bolt (50) and a 3/8”
Nylon Locknut (42). Be sure that the Cable
Trap is turned to hold the Cable in place.
29
30
31
CABLE ASSEMBLY
88
37 84
44
88
50 13
82
80 42
50
88
82
80
42
13
44
37
84
88

15
32. Route the Press Cable (88) over the indicated
31/2” Pulley (82) attached to the Pulley
Plates (31). The Cable must be routed from
the direction shown. Refer to the inset draw-
ing. Besure that the Cable is between the
Cable Trap (80) and the Pulley, and that the
Cable Trap is positioned to hold the Cable
in place.
Tighten the 3/8” x 2” Bolt (50) and the 3/8”
Nylon Locknut (not shown).
33. Route the Press Cable (88) around a 3 1/2”
Pulley (82). Attach the Pulley and a Cable
Trap (80) to the Leg Press Upright (4) with a
3/8” x 3 3/4” Bolt (76), a 3/8” Washer (38) and
a3/8” Nylon Jam Nut (43). Be sure that the
Cable Trap is turned to hold the Cable in
place.
34. Route the Press Cable (88) over the indicated
31/2” Pulley (82) attached to the Press
Frame (12). Tighten the 3/8” x 3 1/2” Bolt (66)
and the 3/8” Nylon Locknut (not shown).
35. Wrap the Press Cable (88) around a “V”
Pulley (81). Attach the “V” Pulley to the upper
bracket on the Leg Press Upright (4) with a
3/8” x 2 1/4” Bolt (97) and a 3/8” Nylon Jam
Nut (43).
33
34
35
CABLE ASSEMBLY
32 31
82
50
88
80
88
82
88
88
66
12
82
88
81
4
97
43
38 43
4
80
76

16
36. Route the Press Cable (88) over the indicated
31/2” Pulley (82) attached to the Press
Frame (12). Besure that the Cable Trap
(80) is turned to hold the Cable in place
and that the Cable is between the Pulley
and the crossbar on the Press Frame.
Tighten the 3/8” Nylon Locknut (42) and the
3/8” x 3 1/2” Bolt (not shown).
37. Wrap the Press Cable (88) around a “V”
Pulley (81). Attach the “V” Pulley to the lower
bracket on the Leg Press Upright (4) with a
3/8” x 2 1/4” Bolt (97) and a 3/8” Nylon Jam
Nut (43).
38. Wrap the Press Cable (88) around a 3 1/2”
Pulley (82). Attach the Pulley and a Cable
Trap (80) to the Leg Press Arm (9) with the
3/8” x 5” Bolt (74).
Slide another 3 1/2” Pulley (82) with a Cable
Trap (80) onto the 3/8” x 5” Bolt (74). Hand
tighten a 3/8” Nylon Locknut (42) onto the
Bolt. Do not tighten the Nylon Locknut
until step 40.
39. Wrap the Press Cable (88) around a “V”
Pulley (81). Attach the “V” Pulley and a Large
Cable Trap (83) to the bracket on the Front
Seat Frame (8) with a 3/8” x 2 1/2” Bolt (65)
and a 3/8” Nylon Locknut (42). Be sure that
the Large Cable Trap is turned to hold the
Cable in place and that the Cable and
Pulley move smoothly.
39
36
37
38
CABLE ASSEMBLY
83
65
81
88
42
8
88
42
12
Crossbar
82
80
42
82
82
9
80
80
74
88
88
81
4
97
43

17
40. Note: The 3 1/2” Pulley (82) used in this
step was attached in step 38. It is shown
removed for easier part identification.
Route the Press Cable (88) around the 3 1/2”
Pulley (82). Be sure that the Cable Trap (80)
is turned to hold the Cable in place and
that the Cable is routed as shown. Tighten
the 3/8” x 5” Bolt (74) and the 3/8” Nylon
Locknut (42).
41. Slide a 5/16” Washer (20) onto a 5/16” x 2 3/4”
Bolt (55). Insert the Bolt into the Front Seat
Frame (8). Fully tighten a 5/16” Nylon Jam
Nut (91) onto the Bolt. Slide the end of the
Press Cable (88) onto the Bolt. Thread anoth-
er 5/16” Nylon Jam Nut onto the Bolt, but do
not fully tighten it. Leave enough room
between the two Jam Nuts for the Cable to
pivot.
42. Identify the High Cable (85)—this is the
shortest remaining cable. Wrap the High
Cable around a 3 1/2” Pulley (82). Attach the
Pulley to the Top Frame (2) with a 3/8” x 3 3/4”
Bolt (76), a 3/8” Washer (38), and a 3/8”
Nylon Locknut (42). Be sure that the end of
the Cable with the ball is on the indicated
side of the Pulley and that the Cable is
between the Pulley and the post.
43. Wrap the High Cable (85) around a 3 1/2”
Pulley (82). Attach the Pulley and a Cable
Trap (80) to the Top Frame (2) with a 3/8” x
33/4” Bolt (76), a 3/8” Washer (38), and a
3/8” Nylon Jam Nut (43). Be sure that the
Cable Trap is positioned to hold the Cable
in place.
43
41
42
CABLE ASSEMBLY
42
38 2
76
82
85
Post
85
80
38
76
2
82 43
40
9
82
42
80
88
91
8
88
20
55
74

18
44. Locate the remaining preassembled pair of
Pulley Plates (31) and 3 1/2” Pulleys (82).
Route the High Cable (85) under the indicated
31/2” Pulley (82). The end of the Pulley
Plates (31) with two holes should be down-
ward. Refer to the inset drawing. Be sure
that the Cable is between the Cable Trap
(80) and the Pulley, and that the Cable Trap
is positioned to hold the Cable in place.
Tighten the 3/8” x 2” Bolt (50) and the 3/8”
Nylon Locknut (not shown).
45. Wrap the High Cable (85) around a 3 1/2”
Pulley (82). Attach the Pulley to the Top
Frame (2) with a 3/8” x 2” Bolt (50) and a 3/8”
Nylon Locknut (42). The Cable must be
routed from the direction shown.
46. Attach the High Cable (85) to a Small “U”
Bracket (32) with a 1/4” Nylon Locknut (44)
and a 1/4” Washer (37). Do not completely
tighten the Nylon Locknut. It should be
threaded onto the end of the Cable only a
couple of turns, as shown in the inset
drawing.
Attach the Small “U” Bracket (32) to the indi-
cated Weight Tube (25) with a 5/16” x 1 3/4”
Bolt (68) and a 5/16” Nylon Locknut (40).
47. Lay the Low Cable (86) over a 3 1/2” Pulley
(82). Attach the Pulley and both Pulley Covers
(94) to the Ab Upright (1) with the 3/8” x 4”
Bolt (95), two 3/8” Washers (38), and a 3/8”
Nylon Locknut (42). Do not overtighten the
Nylon Locknut; the Pulley should turn eas-
ily.Make sure that the Cable is between
the Pulley and the post, and that the Pulley
Covers are turned so the wide tabs are on
the indicated side.
47
44
45
46
CABLE ASSEMBLY
8585
80
50
31
42 Post
1
86
Wide tabs
must be on
this side
38
38
95
94
82
End with two
holes should
be down
50
82
2
42
32
68
85
40
37
44
25
85
44
32
37
82
85

19
48. Wrap the Low Cable (86) around a 3 1/2”
Pulley (82). Attach the Pulley and a Cable
Trap (80) to the Ab Upright (1) with the 3/8” x
33/4” Bolt (76) and a 3/8” Nylon Locknut (42).
Besure that the Cable Trap is in the indi-
cated position.
49. Remove the indicated 3/8” x 2” Bolt (50), the
3/8” Nylon Locknut (42), the 3 1/2” Pulley
(82), and the Cable Trap (80) from the indicat-
ed Pulley Plates (31). Lay the Low Cable (86)
over the Pulley. Reattach the Pulley and the
Cable Trap to the lowest hole in the Pulley
Plates with the Bolt and the Nylon Locknut.
Make sure that the Cable Trap is turned to
hold the Cable in place.
50. Wrap the Low Cable (86) around a 3 1/2”
Pulley (82). Attach the Pulley to the Ab
Upright (1) with the 3/8” x 3 3/4” Bolt (76), a
3/8” Washer (38), and a 3/8” Nylon Locknut
(42). The ball on the Cable must be on the
indicated side of the Pulley.Be sure that
the Cable and Pulley move smoothly and
that the Cable is between the Pulley and
the post.
48
49
50
CABLE ASSEMBLY
42
31
42
82
80
50
80
82
86
76
1
42
38 82
76
Post
86
1
86

51. Locate and open the parts bag labeled
“SEAT ASSEMBLY.”
Attach the Small Backrest (18) to the Ab
Upright (1) with two 1/4” x 2 1/2” Machine
Screws (64) and two 1/4” Washers (37).
52. Press a 1 1/2” Square Inner Cap (57) into the
Rear Seat Frame (16).
Insert a 1/4” x 2” Carriage Bolt (61) through
the center hole in a Seat Plate (41). Attach
the Seat Plate to the Seat (17) with two 1/4” x
3/4” Screws (59).
Insert the 1/4” x 2” Carriage Bolt (61) through
the indicated hole in the Rear Seat Frame
(16). Tighten a 1/4” Nylon Locknut (44) with a
1/4” Washer (37) onto the Carriage Bolt.
Attach the other end of the Seat (17) to the
Rear Seat Frame (16) with a 1/4” Washer (37)
and a 1/4” x 2” Machine Screw (63).
53. Press a 1 1/2” Square Inner Cap (57) into the
Leg Lever (15).
Lubricate the 5/16” x 2 1/4” Bolt (62). Attach
the Leg Lever (15) to the Rear Seat Frame
(16) with the Bolt and a 5/16” Nylon Locknut
(40). Do not overtighten the Nylon
Locknut; the Leg Lever must pivot freely.
Insert the 5/16” x 2” Eyebolt (79) into the Leg
Lever (15) from the direction shown. Tighten a
5/16” Nylon Locknut (40) with a 5/16” Washer
(20) onto the Eyebolt.
54. Rest the slot in the Rear Seat Frame (16) on
the indicated post in the Ab Upright (1). Attach
the Rear Seat Frame to the Ab Upright with a
5/16” x 2 3/4” Carriage Bolt (77) and the Seat
Knob (30).
54
51
52
53
20
SEATASSEMBLY
Slot
44
63
17
16
57 41
61
59
1
18
Post
1
77
16
30
16
62—Lubricate
57
40
20
40
15
79
37
64
37