Sears Home Gym 831159370 User Guide

®
Model No. 831.159370  
Serial No.  
The serial number is found in the  
location shown below. Write the  
serial number in the space above.  
Patent Pending  
Serial  
Number  
Decal  
SEARS, ROEBUCK AND CO.  
HOFFMAN ESTATES, IL 60179  
CAUTION  
Read all precautions and instruc-  
tions in this manual before using  
this equipment. Save this manu-  
al for future reference.  
USER’S MANUAL  
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Before You Begin  
Thank you for selecting the versatile WEIDER® PRO  
9628 Home Gym System. The PRO 9628 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  
HELPLINE at 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 prod-  
uct model number and serial number before calling.  
The model number is 831.159370. The serial number  
can be found on a decal attached to the WEIDER®  
PRO 9628 will help you to achieve the results you want. PRO 9628 Home Gym System (see the front cover of  
this manual).  
For your benefit, read this manual carefully before  
using the WEIDER® PRO 9628 Home Gym System.  
Please use the drawing below to familiarize your-  
If you have additional questions, please call our toll-free self with the major parts and how they fit together.  
High Pulley Station  
Press Arm  
Leg Press  
Backrest  
Butterfly Arms  
Backrest  
Seat  
Seat  
Weight Stack  
Leg Lever  
ASSEMBLED  
DIMENSIONS:  
Low Pulley Station  
Height: 79 in.  
Width: 38 in.  
Length: 91 in.  
Foot Plate  
3
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Assembly  
Note: This introduction will save you more  
time than it takes to read it!  
Identifying Parts  
To help you identify the small parts used in assem-  
bly, we have included a PART IDENTIFICATION  
CHART located in the center of this manual. Place  
the chart on the floor or work table and use it to  
quickly identify different parts as you open the pack-  
ages for each step.  
Note: Some small parts may have been pre-attached  
for shipping. If a part is not in the parts bag, check to  
see if it has been pre-attached.  
Making Things Easier for Yourself  
Everything in this manual is designed to ensure  
that the assembly of our products can be complet-  
ed successfully by anyone. However, it is impor-  
tant to recognize that your new equipment is a  
sophisticated product with many small parts. The  
assembly process will take time—possibly several  
hours. Most people find that by setting aside plen-  
ty of time, and by deciding to make the task  
enjoyable, they can avoid feeling rushed or over-  
whelmed. You may want to complete the process  
over a couple of evenings.  
Orienting Parts  
As you assemble this product, be sure that all parts  
are oriented as shown in the drawings.  
Tightening of Parts  
Tighten all parts as you assemble them, unless  
instructed to do otherwise.  
Giving Yourself a Good Start  
Before you begin the assembly process itself, take  
the time to complete the steps outlined here.  
Lining Up the Tools  
Assembly requires the following tools (not included):  
Clearing the Workspace  
Clear a workspace that is large enough to hold all  
parts and allow you to walk all the way around the  
assembled equipment.  
• Two (2) adjustable wrenches  
• One (1) standard screwdriver  
• One (1) phillips screwdriver  
• One (1) rubber mallet  
Unpacking the Box  
To make the assembly process as smooth as possi-  
ble, we have broken it into separate stages. All parts  
used in each stage are found in individual packages  
in the shipping box. Place all parts in a cleared area  
and remove the packing materials. Do not dispose of  
the packing materials until assembly is completed.  
• Lubricant, such as grease or petroleum jelly,  
and soapy water  
Tape, such as clear tape or masking tape  
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.  
Important: Wait until you begin each assembly  
stage to open the parts bag labeled for that  
assembly stage.  
The Four Stages of the Assembly Process  
Frame Assembly  
Cable Assembly  
You will begin by assembling the base and the  
upright frames that serve as the skeleton of the  
equipment. The seats and all moving parts will be  
attached to the frame.  
Completes the cables and pulleys that connect the  
moving arms with each other and with the weights.  
This ties the different parts together and makes the  
equipment function as a unit  
Seat Assembly  
Arm Assembly  
Completes the seats and backrests that support  
your body while you are exercising.  
Completes the press and butterfly arms that you  
operate while you are exercising.  
4
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1
2
3
4
Frame Assembly  
1. Before beginning, be sure that you have read and  
understood the information on page 4.  
5
Locate and open the parts bag labeled “FRAME  
ASSEMBLY.”  
78  
Press a 2” Square Cover Cap (78) onto each end of  
the Stabilizer (5).  
94  
Insert two 3/8” x 2 3/4” Carriage Bolts (94) up through  
the Stabilizer (5) and place it flat on the floor.  
78  
2. Press a 2” Square Inner Cap (27) into the end of the  
Butterfly Base (4).  
Insert two 5/16” x 2 1/2” Carriage Bolts (1) up through  
the Butterfly Base. Secure the Carriage Bolts with  
pieces of tape (A) to prevent them from falling out.  
5
4
Place the Butterfly Base (4) on the floor with the  
holes in the mounting bracket over the Carriage Bolts  
in the Stabilizer (5).  
1
27  
A
3. Insert four 5/16” x 2 1/2” Carriage Bolts (1) up  
through the Press Base (51) and secure them with  
tape.  
51  
1
Place the Press Base (51) on the floor with the holes  
in the mounting bracket over the Carriage Bolts in the  
Stabilizer (5).  
1
Note: The mounting bracket on the Press Base (51)  
should be on top of the mounting bracket on the  
Butterfly Base (4).  
4
5
4. Insert two 3/8” x 2 3/4” Bolts (93) through the holes in  
the two mounting brackets and the Stabilizer (5).  
93  
21  
Hand tighten four 3/8” Nylon Locknuts (21) onto the  
four Bolts in the mounting brackets and Stabilizer.  
Do not tighten the Nylon Locknuts yet.  
21  
5
5
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5. Press a 1” Square Inner Cap (65) into the side arm  
(A) on the Press Upright (56).  
5
Slide the Press Upright (56) onto the 5/16” x 2 1/2”  
Carriage Bolts (1) in the Press Base (51). Hand tight-  
en a 5/16” Nylon Locknut (3) onto each Carriage Bolt.  
65  
A
Do not tighten the Nylon Locknuts yet.  
Note: The Press Upright (56) must be leaning  
towards the center of the unit with the side arm facing  
outward.  
56  
3
3
51  
1
6. Slide the Butterfly Upright (42) onto the 5/16” x 2 1/2”  
Carriage Bolts (1) in the Butterfly Base (4). Hand  
tighten a 5/16” Nylon Locknut (3) onto each Carriage  
Bolt.  
6
Do not tighten the Nylon Locknuts yet.  
Note: The Butterfly Upright must be leaning towards  
the center of the unit.  
42  
3
3
4
1
6
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7. Set two Weight Bumpers (19) onto the bracket on the  
Stabilizer (5).  
7
Insert both Weight Guides (62) through the Weight  
Bumpers and the bracket on the Stabilizer (5).  
62  
Attach the lower ends of the Weight Guides (62) to  
the Stabilizer (5) with a 3/8” x 6” Bolt (60), two 1/2” x  
3/4” Spacers (61) and a 3/8” Nylon Locknut (21).  
Tighten the Nylon Locknut fully.  
Pin  
Grooves  
Slide eight Weights (25) onto the Weight Guides.  
Make sure all of the Weights are turned so the pin  
grooves are on the same side and are facing  
away from the center of the unit.  
25  
19  
61  
61  
21  
60  
5
8. Press the Weight Tube Bumper (64) into the end of  
the Weight Tube (63).  
8
76  
Insert the Weight Tube into the stack of Weights (25).  
Make sure the pin on the Weight Tube is resting  
in the pin groove in the upper Weight.  
Pin  
63  
64  
B
Lubricate the insides of the holes in the Top Weight  
(76).  
25  
With the slot (B) facing down, slide the Top Weight  
onto the Weight Guides and set it on the stack of  
Weights (25).  
Pin  
Groove  
9. Press a 2” Square Inner Cap (27) into each end of  
the Top Frame (55) and the weight support arm (A).  
9
27  
27  
49  
Press a 1 3/4” Square Inner Cap (44) into each end of  
the crossbar (B) on the Top Frame.  
A
Press two 1” Round Inner Caps (49) into the top of the  
crossbar (B).  
44  
55  
B
27  
44  
7
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10. Place the Top Frame (55) on top of the two Uprights  
(56) and (42) in the direction shown. Align the holes in  
the Top Frame with the holes in the brackets on the  
Uprights.  
10  
11  
8
55  
8
Insert four 5/16” x 2 3/4” Bolts (11) with four 5/16” Flat  
Washers (8) through the holes in the Top Frame (55)  
and the brackets on the Uprights. Hand tighten a  
5/16” Nylon Locknut (3) unto each Bolt.  
56  
42  
Do not tighten the Nylon Locknuts yet.  
3
3
11. Attach the upper ends of the Weight Guides (62) to  
the Top Frame (55) with a 3/8” x 6” Bolt (60), two 1/2”  
x 3/4” Spacers (61) and a 3/8” Nylon Locknut (21).  
Tighten the Nylon Locknut fully.  
11  
12  
13  
61  
21  
60  
62  
55  
12. Press a 2” Square Inner Cap (27) into the Press Seat  
Frame (77). Slide the Press Seat Frame onto the  
5/16” x 2 1/2” Carriage Bolts (1) in the Press Base  
(51).  
27  
77  
42  
3
Insert two 5/16” x 2 3/4” Bolts (11) through the brack-  
et on the Seat Frame and through the holes in the  
Press Upright (42). Hand tighten a 5/16” Nylon  
Locknut (3) and a 5/16” Flat Washer (8) onto each  
Carriage Bolt.  
8
3
11  
3
1
Tighten all Nylon Locknuts used in steps 4  
through 12.  
51  
Arm Assembly  
75  
13. Press Arm Assembly—Locate and open the parts  
59 Lubricate  
55  
bag labeled “ARM ASSEMBLY.”  
A
Press a 1” x 7/8” Plastic Bushing (75) onto each  
welded spacer on the Press Frame (17). Align the  
welded spacers on the Press Frame with the tube (A)  
on the Top Frame (55). Note: This will be a tight fit.  
The Plastic Bushings should fit onto the ends of  
the tube on the Top Frame. Lubricate the 3/8” x 7 1/2”  
Bolt (59). Attach the Press Frame to the Top Frame  
with the Bolt and a 3/8” Nylon Jam Nut (83).  
83  
17  
8
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14. Press a 1 3/4” Square Inner Cap (44) into the lower  
end of each Press Arm (46).  
14  
Press a 1” Round Inner Cap (49) into the side of each  
Press Arm.  
17  
22  
Attach each Press Arm to the Press Frame (17) with  
two 5/16” x 2 1/2” Bolts (22) and two 5/16” Nylon  
Locknuts (3).  
3
46  
49  
44  
15. Butterfly Arm Assembly  
15  
Attach a “V”-Pulley (6) and a Long Cable Trap (50) to  
each Butterfly Arm (47) and (48) with a 3/8” x 2 1/2”  
Bolt (7) and a 3/8” Nylon Locknut (21).  
7
50  
Make sure the Long Cable Traps (50) are posi-  
tioned as shown.  
6
50  
Identify the Right Arm (48) and the Left Arm (47) by  
imagining yourself sitting on the seat. Note the posi-  
tion of the welded bracket (A) on each Arm. Arm  
identification is very important for the next step.  
6
A
A
47  
21  
48  
9
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16. Lubricate both axles (A) on the Top Frame (55).  
16  
55  
B
Slide the Right Arm (48) onto the right axle. Note: Be  
careful not to confuse the Right and Left Arm.  
47  
Make sure the upper end of the Right Arm is  
behind the indicated bracket (B) on the Top  
Frame.  
A
Tap two 1” Retainers (69) and a 1” Round Cover Cap  
(70) onto the right axle.  
69  
70  
Make sure the teeth on the Retainers (69) bend  
toward the Cover Cap (70), as shown in the inset  
drawing.  
48  
44  
Attach the Left Arm (47) in the same manner.  
Press a 1 3/4” Square Inner Cap (44) into the lower  
end of each Arm (47) and (48).  
45  
Wet the lower end of each Arm with soapy water.  
Slide a 10” Pad (45) onto the lower end of each Arm.  
Axle  
70  
69  
17. Refer to the inset drawing. Attach the Bumper (82) to  
the Press Seat Frame (77) with the 1” Tap Screw (92).  
17  
89  
27  
Press a 2” Square Inner Cap (27) into each end of  
the Leg Press Arm (89).  
92  
21  
82  
Lubricate the 3/8” x 3 1/4” Bolt (85). Attach the Leg  
Press Arm (89) to the Press Base (51) with the Bolt  
and a 3/8” Nylon Locknut (21).  
77  
85 Lubricate  
77  
27  
51  
Cable Assembly  
18. Locate and open the parts bag labeled “Cable  
Assembly and Pulleys.” For Cable identification  
and routing during steps 18-35, refer to the Cable  
Diagram and Cable ID Chart on page 19.  
18  
7
50  
6
55  
Tighten the Bolt and Locknut on the pre-assembled  
Pulley (15) on the Top Frame (55)  
A
21  
Attach a “V”-Pulley (6) and a Long Cable Trap (50) to  
the indicated bracket (A) on the Butterfly Upright (42)  
with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut  
(21). Make sure the Long Cable Trap is positioned  
as shown, so it will hold the Cable in place.  
15  
42  
10  
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19. Attach two 3 1/2” Pulleys (15) to the weight support  
arm (A) on the Top Frame (55) with two 3/8” x 2”  
Bolts (12) and two 3/8” Nylon Locknuts (21).  
19  
A
55  
12  
21  
15  
20. Locate the Short Cable (23). It has a ball on one end  
and a threaded tip on the other.  
20  
6
55  
Feed the threaded end of the Short Cable (23)  
between the pre-assembled 3 1/2” Pulley (15) and the  
hook (C) on the Top Frame (55). Next, route the Short  
Cable around the angled “V”-Pulley (6) on the  
Butterfly Upright (42) and then around the “V”-Pulley  
(6) on the Left Butterfly Arm (47).  
C
50  
23  
15  
Make sure the Long Cable Trap (50) is positioned  
to hold the Cable in place. If necessary, adjust the  
position of the Long Cable Trap.  
42  
47  
21. Move to the other side of the unit. Route the Short  
Cable (23) around the “V”-Pulley (6) on the Right  
Butterfly Arm (48). Make sure the Long Cable Trap  
(50) is positioned as shown.  
21  
Tighten the Bolt and Locknut on the pulley bracket  
(D).  
D
6
Tighten the Bolt and Locknut on the pre-assembled  
Pulley (15) attached to the pulley bracket (D). Route  
the Short Cable (23) around the Pulley in the direc-  
tion shown. Make sure the Long Cable Trap (50) is  
positioned to hold the Cable in place.  
50  
15  
48  
23  
22. Attach the 3 1/2” Pulley (15) and a Cable Trap (66) to  
the two “I”-plates (81) with a 3/8” x 2“ Bolt (12) and a  
3/8” Nylon Locknut (21).  
22  
23  
A
Make sure the Cable Trap (66) is positioned as  
shown.  
15  
Route the Short Cable (23) around the Pulley (15)  
attached to the “I”-plates in the direction shown.  
21  
81  
12  
81  
66  
15  
Route the Short Cable (23) through the first 3 1/2”  
Pulley (15) on the weight support arm (A).  
11  
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23. Move to the other side of the unit. Route the Short  
Cable (23) through the second 3 1/2” Pulley (15) on  
the weight support arm.  
23  
15  
Make sure the Short Cable (23) is in the groove of  
all Pulleys and that the Cable and the Pulleys  
move smoothly.  
Attach the Short Cable (23) to the Small “U”-Bracket  
(67) with a 1/4” Nylon Locknut (2) and a 1/4” Flat  
Washer (10).  
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.  
23  
Attach the small “U”-Bracket (67) to the Weight Tube  
(63) with the 5/16” x 1 3/4” Bolt (72) and a 5/16”  
Nylon Locknut (3).  
67  
72  
3
10  
2
23  
10  
67  
24  
63  
2
24. Attach a “V”-Pulley (6) and a Long Cable Trap (50) to  
the lower hole on the Press Upright (56) with a 3/8” x  
4 1/4” Bolt (80), a 3/8” Flat Washer (9) and a 3/8”  
Nylon Locknut (21).  
17  
6
Make sure the “V”-Pulley is on the indicated side  
of the Press Upright and that the Long Cable Trap  
is positioned as shown.  
Tighten the Bolt and Locknut on the pre-assembled  
“V”-pulley (6) on the Press Frame (17).  
80  
9
50  
56  
6
21  
25. Attach a 3 1/2” Pulley (15) and a Cable Trap (66) to  
the lower end of the Press Upright (56) with a 3/8” x  
3 3/4” Bolt (71), a 3/8” Flat Washer (9) and a 3/8”  
Nylon Jam Nut (83).  
25  
71  
66  
56  
Make sure the Pulley is on the right side of the  
Upright and that the Cable Trap is positioned as  
shown.  
9
15  
Tighten the Bolt and Locknut on the pre-assembled  
Pulley (15) on the Butterfly Base (4).  
83  
15  
Make sure the Cable Trap is positioned as shown.  
4
12  
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26. Attach a “V”-Pulley (6) and a Long Cable Trap (50) to  
the bracket on the Press Seat Frame (77) with a 3/8”  
x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21). It may  
be necessary to place the Long Cable Trap on top of  
the bracket.  
26  
83  
66  
89  
15  
21  
Make sure the Long Cable Trap is positioned as  
shown.  
66  
77  
Attach two 3 1/2” Pulleys (15) and two Cable Traps  
(66) to the Leg Press Arm (89) with a 3/8” x 4 1/2”  
Bolt (79) and a 3/8” Nylon Jam Nut (83). Make sure  
the Cable Traps are positioned as shown.  
50  
79  
6
7
27. Locate the Long Cable (58). It has a closed loop on  
one end and a threaded tip on the other.  
27  
6
17  
Attach the closed loop to the Press Upright (56) with  
a 5/16” x 2 3/4” Bolt (11), a 5/16” Flat Washer (8) and  
a 5/16” Nylon Locknut (3).  
Make sure the flat side of the closed loop is  
turned towards the Upright.  
3
Make sure the Long Cable is attached on the indi-  
cated side of the Press Upright.  
58  
8
6
Route the threaded end of the Long Cable around the  
“V”-Pulley (6) on the Press Frame (17) in the direction  
shown.  
22  
Route the Long Cable around the “V”-Pulley (6) on  
the Press Upright (56) in the direction shown.  
56  
Route the Long Cable around the 3 1/3” Pulley (15)  
on the Press Upright in the direction shown.  
15  
28. Route the Long Cable (58) around the indicated 3 1/2”  
Pulley (15) on the Leg Press Arm (89) in the direction  
shown.  
28  
15  
77  
Route the Long Cable around the “V”-Pulley (6) on  
the Press Seat Frame (77) in the direction shown.  
6
89  
13  
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29. Move to the other side of the unit. Route the Long  
Cable (58) around the second 3 1/2” Pulley (15) on  
the Leg Press Arm (89) in the direction shown.  
29  
30  
31  
32  
89  
15  
58  
30. Route the Long Cable (58) around the 3 1/2” Pulley  
(15) on the Butterfly Base (4).  
57  
2
Attach the Long Cable to the Long “U”-Bracket (57)  
with a 1/4” Nylon Locknut (2) and a 1/4” Flat Washer  
(10).  
10  
58  
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.  
57  
2
10  
15  
4
31. Locate the Medium Cable (86). It has a closed loop  
on one end and a ball on the other.  
42  
Wrap the end of the Medium Cable with the ball  
around a 3 1/2” Pulley (15) in the direction shown.  
Attach the Pulley to the Butterfly Upright (42) with a  
3/8” x 3 3/4” Bolt (71), a 3/8” Flat Washer (9) and a  
3/8” Nylon Jam Nut (83).  
83  
9
86  
15  
71  
32. Wrap the Medium Cable (86) around a 3 1/2” Pulley  
(15) in the direction shown.  
81  
66  
Attach the 3 1/2” Pulley (15) and a Cable Trap (66) to  
the two “I”-plates (81) with a 3/8” x 2“ Bolt (12) and a  
3/8” Nylon Locknut (21).  
15  
21  
Make sure the Cable Trap (66) is positioned as  
shown.  
12  
86  
14  
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33. Remove the 3 1/2” Pulley (15) from the Long “U”-  
Bracket (57).  
33  
86  
15  
21  
Route the Medium Cable (86) around the Pulley in  
the direction shown.  
66  
Re-attach the Pulley to the Long “U”-Bracket (57) with  
the 3/8” x 2” Bolt (12) and the 3/8” Nylon Locknut  
(21). Make sure the Cable Trap (66) is positioned  
as shown.  
57  
12  
34. Attach the closed loop on the end of the Medium  
Cable (86) to the Top Frame (55) with a 5/16” x 2 3/4”  
Bolt (11), a 5/16” Flat Washer (8) and a 5/16” Nylon  
Locknut (3).  
34  
55  
86  
8
11  
3
Make sure the flat side of the closed loop is  
turned towards the Top Frame.  
35  
Seat Assembly  
41  
10  
35. Locate and open the parts bag labeled “Seat  
Assembly.”  
43  
Attach the Backrest (41) with the name decal to the  
Press Upright (56) with two 1/4” x 2 1/2” Screws (43)  
and two 1/4” Flat Washers (10).  
56  
10  
43  
36. Insert the 1/4” x 2 1/2” Carriage Bolt (91) into the cen-  
ter hole in a Seat Plate (37). Attach the Seat Plate to  
a Seat (13) with two 1/4” x 3/4” Screws (18).  
36  
91  
13  
Insert the 1/4” x 2 1/2” Carriage Bolt (91) into the indi-  
cated hole in the Press Seat Frame (77). Tighten a  
1/4” Nylon Locknut (2) with a 1/4” Flat Washer (10)  
onto the Carriage Bolt.  
37  
18  
10  
77  
2
15  
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37. Attach the other end of the Seat (13) to the Press  
Seat Frame (77) with a 1/4” Flat Washer (10) and a  
1/4” x 2 1/2” Screw (43).  
37  
77  
13  
10  
43  
38. Move to the other end of the unit. Attach the remain-  
ing Backrest (41) to the Butterfly Upright (42) with two  
1/4” x 2 1/2” Screws (43) and two 1/4” Flat Washers  
(10).  
38  
42  
41  
10  
43  
39. Press a 1 1/2” Square Inner Cap (32) into the  
Butterfly Seat Frame (36).  
Insert the 1/4” x 2” Carriage Bolt (38) into the center  
hole in a Seat Plate (37).  
39  
13  
Attach the Seat Plate to the Seat (13) with two 1/4” x  
3/4” Screws (18).  
36  
38  
37  
Insert the 1/4” x 2” Carriage Bolt (38) into the indicat-  
ed hole in the Butterfly Seat Frame. Tighten a 1/4”  
Nylon Locknut (2) with a 1/4” Flat Washer (10) onto  
the Carriage Bolt.  
18  
2
32  
10  
Attach the other end of the Seat to the Butterfly Seat  
Frame with a 1/4” Flat Washer (10) and the 1/4” x  
2 1/4” Screw (24).  
24  
10  
16  
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40. Press a 1 1/2” Square Inner Cap (32) into the Leg  
Lever (29).  
40  
41  
42  
36  
3
Lubricate the 5/16” x 2 1/4” Bolt (33). Attach the Leg  
Lever (29) to the Seat Frame (36) with the Bolt and  
a 5/16” Nylon Locknut (3).  
29  
33 Lubricate  
Do not overtighten the Nylon Locknut. The Leg  
Lever must be able to pivot freely.  
8
3
Insert the 5/16” x 2” Eyebolt (35) into the Leg Lever  
(29) from the direction shown. Tighten a 5/16” Nylon  
Locknut (3) with a 5/16” Flat Washer (8) onto the  
Eyebolt.  
35  
32  
41. Rest the Butterfly Seat Frame (36) on the indicated  
pin (A) in the Butterfly Upright (42). Attach the  
Butterfly Seat Frame to the Butterfly Upright with a  
5/16” x 2 3/4” Carriage Bolt (14) and the Seat Knob  
(40).  
42  
40  
36  
14  
A
42. Press two 3/4” Round Inner Caps (34) into each Pad  
Tube (28).  
36  
Insert one Pad Tube into the Butterfly Seat Frame  
(36). Slide a Foam Pad (30) onto each end of the  
Pad Tube.  
30  
34  
28  
Insert the other Pad Tube into the Leg Lever (29).  
Slide a Foam Pad (30) onto each end of the Pad  
Tube.  
30  
34  
29  
43  
Miscellaneous Assembly  
43. Leg Press Assembly  
88  
3
Attach the Leg Press Plate (87) to the Adjustment  
Tube (88) with a 5/16” x 2 1/2” Bolt (22), two 5/16”  
Flat Washers (8) and a 5/16” Nylon Locknut (3).  
Make sure the Leg Press Plate and the  
Adjustment Tube are oriented as shown.  
44  
87  
8
22  
Press a 1 3/4” Square Inner Cap (44) into the  
Adjustment Tube (88).  
17  
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44. Attach the Adjustment Tube (88) to the Leg Press  
Arm (89) with the Small Lock Pin (90).  
44  
87  
Make sure the Leg Press Plate (87) is oriented as  
shown.  
88  
90  
89  
45. Remove the decals from the decal sheets (not shown) and apply them to the home gym system in the loca-  
tions shown in the illustration below.  
45  
HIGH PULLEY  
BUTTERFLY  
LEG  
PRESS  
ARM  
PRESS  
LEG EXTEN-  
SION/CURL  
SERIAL NUMBER  
DECAL  
LOW PULLEY  
18  
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46. Make sure that all parts have been properly tightened. The use of the remaining parts will be explained in  
ADJUSTMENT, beginning on page 20 of this manual.  
Before using the home gym system, pull each cable a few times to be sure that the cables move smoothly  
over the pulleys. If one of the cables does not move smoothly, find and correct the problem. IMPORTANT: If  
the cables are not properly installed, they may be damaged when heavy weight is used. If there is  
any slack in the cables, you will need to remove the slack by tightening the cables. See TROUBLE-  
SHOOTING AND MAINTENANCE on page 22.  
Cable Diagram  
The Cable Diagram below shows the proper routing of the Short Cable (23), the Medium Cable (86) and the  
Long Cable (58). The numbers show the correct route for each cable. Make sure the Cables are routed cor-  
rectly, that the Pulleys move smoothly and that the Cable Traps do not touch or bind the Cables.  
Incorrect cable routing can damage the weight system.  
4
2
8
3
7
1
2
4
1
5
3
6
2
3
Short Cable (23)  
5
6
9
4
Medium Cable (86)  
7
9
Long Cable (58)  
Cable ID Chart  
1
8
19  
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Adjustment  
The instructions below describe how each part of the home gym system can be adjusted. Refer to the exercise  
poster accompanying this manual to see how the home gym system should be set up for each exercise.  
IMPORTANT: When attaching the lat bar or nylon strap, make sure that the attachments are in the cor-  
rect starting position for the exercise to be performed. If there is any slack in the cables or chain as an  
exercise is performed, the effectiveness of the exercise will be reduced.  
Changing the Weight Setting  
To change the weight setting of the weight stack, insert a  
Weight Pin (26) under the desired Weight (25). 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 6.5 pounds to 106.5 pounds, in increments of 12.5  
pounds. Note: Due to the cables and pulleys, the  
amount of resistance at each exercise station may  
25  
vary from the weight setting. Use the WEIGHT  
RESISTANCE CHART on page 23 to find the approxi-  
mate amount of resistance at each weight station.  
26  
Attaching and Removing the Butterfly Seat  
Set the bracket on the Butterfly Seat Frame (36) onto the  
indicated pins on the Butterfly Upright (42). Attach the  
Butterfly Seat Frame to the Butterfly Upright with the  
5/16” x 2 3/4” Carriage Bolt (14) and the Seat Knob (40).  
42  
40  
For some exercises, the Butterfly Seat Frame (36) must  
be removed. First, be sure that the chain is not attached  
to the leg lever. Next, remove the Seat Knob (40) and the  
5/16” x 2 3/4” Carriage Bolt (14) from the Seat Frame. Lift  
the Seat Frame off the Butterfly Upright (42).  
A
14  
36  
Attaching the Lat Bar or Nylon Strap to the  
High Pulley Station  
39  
Attach the Lat Bar (54) to the Short Cable (23) with a  
Cable Clip (53). For some exercises, the Chain (52)  
should be attached between the Lat Bar and the Medium  
Cable with two Cable Clips. Adjust the length of the  
Chain between the Lat Bar and the Medium Cable so  
the Lat Bar is in the correct starting position for the  
exercise to be performed.  
53  
23  
52  
54  
The Nylon Strap (39) can be attached in the same man-  
ner.  
20  
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Attaching the Lat Bar or Nylon Strap to the  
Low Pulley Station  
Attach the Lat Bar (54) to the Medium Cable (86) with a  
Cable Clip (53). For some exercises, the Chain (52)  
should be attached between the Lat Bar and the Long  
Cable with two Cable Clips. Adjust the length of the  
Chain between the Lat Bar and the Long Cable so the  
Lat Bar is in the correct starting position for the exer-  
cise to be performed.  
39  
52  
86  
53  
54  
The Nylon Strap (39) can be attached in the same  
manner.  
Attaching the Leg Lever to the Low Pulley  
Station  
To use the Leg Lever (29), the seat must be attached to  
the Butterfly upright (see ATTACHING AND REMOVING  
THE BUTTERFLY SEAT on page 20).  
Attach one end of the Chain (52) to the Medium Cable  
(86) with a Cable Clip (53). Attach the other end of the  
Chain to the Eyebolt (35) with a Cable Clip. Always  
remove the Chain (52) from the Eyebolt (35) before  
removing the seat.  
52  
53  
29  
35  
86  
Adjusting the Position of the Foot Plate  
To adjust the position of the foot plate, pull out the Small  
Lock Pin (90). Move the Adjustment Tube (88) to the  
desired position and re-insert the Lock Pin.  
88  
90  
21  
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Weight Resistance Chart  
This chart shows the approximate weight resistance at each station. “Top” refers to the 6.5 lbs. top  
weight. The other numbers refer to the 12.5 lbs. weight plates. Note: The actual resistance at each  
weight station may vary due to differences in individual weight plates, as well as friction between  
the cables, pulleys, and weight guides.  
Press  
Arm  
(lbs.)  
Butterfly  
Arm  
High  
Pulley  
(lbs.)  
Leg  
Lever  
(lbs.)  
Leg  
Press  
(lbs.)  
Low  
Pulley  
(lbs.)  
Weight  
Plates  
(lbs.)  
Top  
1
19  
41  
5
7
7
17  
30  
43  
58  
68  
83  
95  
107  
31  
7
17  
30  
43  
58  
68  
83  
95  
107  
10  
23  
32  
38  
43  
48  
51  
60  
20  
30  
40  
53  
65  
76  
87  
98  
74  
2
62  
115  
146  
183  
220  
283  
334  
395  
3
84  
4
108  
131  
168  
195  
225  
5
6
7
8
22  
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Trouble-shooting and Maintenance  
Inspect and tighten all parts each time you use the home gym system. Replace any worn parts  
immediately. The home gym system can be cleaned using a damp cloth and mild non-abrasive  
detergent. Do not use solvents.  
Tightening the Cables  
1
Woven cable, the type of cable used on the home gym  
system, can stretch slightly when it is first used. If there is  
23  
slack in the Cables before resistance is felt, the Cables  
should be tightened. Insert the Weight Pin (26) under one  
of the indicated Weights (25). Slack can be removed from  
the Cables by tightening the 1/4” Nylon Locknuts (2) at  
the end of the Short Cable (23) (see drawing 1) and at  
the end of the Long Cable (58) (see drawing 2). To do this  
you may need to remove the Small “U”-Bracket (67) from  
the Weight Tube (not shown) or remove the 3 1/2” Pulley  
(15) from the Long “U”-Bracket (57). Make sure that the  
Cables are not too tight or the Top Weight (76) will be lift-  
ed off the weight stack.  
67  
76  
2
25  
26  
Additional slack can be removed by moving the 3 1/2”  
Pulley (15) to the other hole in the “I”-Brackets (81) as  
shown in the upper inset drawing. Remove the 3/8” Nylon  
Locknut (21) and the 3/8” x 2” Bolt (12) from the Cable  
Trap (66), Pulley and “U”-Bracket. Re-attach the Pulley  
and Cable Trap. Be sure that the Cable trap is in the  
proper position and that the Cable and Pulley move  
smoothly.  
2
81  
21  
12  
Slack can also be removed by moving the 3 1/2” Pulley  
(15) to the other hole in the Long “U”-Bracket (57) as  
shown in the lower inset drawing. Remove the 3/8” Nylon  
Locknut (21) and the 3/8” x 2” Bolt (12) from the Cable  
Trap (66), Pulley and “U”-Bracket. Re-attach the Pulley  
and Cable Trap. Be sure that the Cable trap is in the  
proper position and that the Cable and Pulley move  
smoothly.  
66  
15  
15  
21  
66  
Note: If a Cable tends to slip off the Pulleys often, the  
Cable may have become twisted. Remove the Cable  
and re-install it.  
12  
57  
2
If the Cables need to be replaced, see ORDERING  
REPLACEMENT PARTS on the back cover of this manual.  
58  
23  
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3/4" Round Inner Cap (34)  
1" Round Inner Cap (49)  
1" Round Cover Cap (70)  
5/16" x 2" Eyebolt (35)  
1" Square Inner Cap (65)  
1 3/4" Square Inner Cap (44)  
2" Square Cover Cap (78)  
2" Square Inner Cap (27)  
1 1/2" Square Inner Cap (32)  
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3 / 8 " x 7 1 / 2 " B o l t ( 5 9 )  
l e C l C i p a ( b 5 3 )  
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R0998A  
Part List—Model No. 831.159370  
Key No. Qty.  
Description  
Key No. Qty.  
Description  
1
2
3
4
5
6
7
8
6
4
23  
1
1
6
4
11  
3
10  
7
7
2
4
12  
1
1
4
2
1
19  
5
1
1
8
1
7
2
1
4
4
2
1
4
1
1
2
1
5/16” x 2 1/2” Carriage Bolt  
1/4” Nylon Locknut  
5/16” Nylon Locknut  
Butterfly Base  
Stabilizer  
“V”-Pulley  
3/8” x 2 1/2” Bolt  
5/16” Flat Washer  
3/8” Flat Washer  
1/4” Flat Washer  
5/16” x 2 3/4” Bolt  
3/8” x 2” Bolt  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
#
4
5
1
1
3
1
1
1
1
1
2
2
4
2
1
1
1
8
1
1
4
2
2
1
2
2
2
1
1
2
1
1
2
1
5
2
1
1
1
1
1
1
1
1
2
2
1
1
1” Round Inner Cap  
Long Cable Trap  
Press Base  
Chain  
Cable Clip  
Lat Bar  
Top Frame  
Press Upright  
Long “U”-Bracket  
Long Cable  
3/8” x 7 1/2” Bolt  
3/8” x 6” Bolt  
1/2” x 3/4” Spacer  
Weight Guide  
Weight Tube  
Weight Tube Bumper  
1” Square Inner Cap  
Cable Trap  
Small “U”-Bracket  
5/16” x 5” Bolt  
1” Retainer  
1” Round Cover Cap  
3/8” x 3 3/4” Bolt  
5/16” x 1 3/4” Bolt  
1/2” x 1 1/4” Spacer  
Plastic Bushing  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
Seat  
5/16” x 2 3/4” Carriage Bolt  
3 1/2” Pulley  
3/8” x 3 1/2” Bolt  
Press Frame  
1/4” x 3/4” Screw  
Weight Bumper  
Pulley Bracket  
3/8” Nylon Locknut  
5/16” x 2 1/2” Bolt  
Short Cable  
1/4” x 2 1/4” Screw  
Weight  
Weight Pin  
2” Square Inner Cap  
Pad Tube  
Leg Lever  
1” x 7/8” Plastic Bushing  
Top Weight  
Press Seat Frame  
2” Square Cover Cap  
3/8” x 4 1/2” Bolt  
3/8” x 4 1/4” Bolt  
“I”-Plate  
Foam Pad  
Hand Grip  
1 1/2” Square Inner Cap  
5/16” x 2 1/4” Bolt  
3/4” Round Inner Cap  
5/16” x 2” Eyebolt  
Butterfly Seat Frame  
Seat Plate  
1/4” x 2” Carriage Bolt  
Nylon Strap  
Seat Knob  
Bumper  
3/8” Nylon Jam Nut  
Leg Press Bushing  
3/8” x 3 1/4” Bolt  
Medium Cable  
Leg Press Plate  
Adjustment Tube  
Leg Press Arm  
Lock Pin  
1/4” x 2 1/2” Carriage Bolt  
1” Tap Screw  
1
1
2
1
5
7
2
2
Backrest  
Butterfly Upright  
1/4” x 2 1/2” Screw  
1 3/4” Square Inner Cap  
10” Pad  
Press Arm  
Left Butterfly Arm  
Right Butterfly Arm  
3/8” x 2 3/4” Bolt  
3/8” x 2 3/4” Carriage Bolt  
User’s Manual  
1
1
#
Exercise Poster  
Note: “#” indicates a non-illustrated part. Specifications are subject to change without notice.  
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Ordering Replacement Parts  
The model number and serial number of your WEIDER® PRO  
9628 Home Gym System are listed on a decal attached to the  
frame. See the front cover of this manual to find the location of  
the decal.  
All replacement parts are available for immediate purchase or  
special order when you visit your nearest SEARS Service Center.  
To request service or to order parts by telephone, call the toll-free  
numbers listed at the left.  
QUESTIONS?  
If you find that:  
When requesting help or service, or ordering parts, please be pre-  
pared to provide the following information:  
• you need help assembling or  
operating the WEIDER® PRO  
9628 Home Gym System  
• The MODEL NUMBER of the product (831.159370).  
• a part is missing  
• The NAME of the product (WEIDER® PRO 9628 Home Gym  
System).  
• or you need to schedule repair  
service  
• The KEY NUMBER and DESCRIPTION of the PART (see the  
PART LIST/EXPLODED DRAWING at the center of this manual).  
call our toll-free HELPLINE  
1-800-736-6879  
Monday–Saturday, 7 am–7 pm  
Central Time (excluding holidays)  
REPLACEMENT  
PARTS  
If parts become worn and need to  
be replaced, call the following toll-  
free number  
1-800-FON-PART  
(1-800-366-7278)  
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 AND CO., DEPT. 817WA, HOFFMAN ESTATES, IL 60179  
Part No. 147567 H01572-A R0998A  
Printed in USA © 1998 Sears, Roebuck and Co.  
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