Weider D621 User's Manual
Contents
1. D19 BB 0216 C6308 D35 C0442 D35 C6302 D19 C0426 A14 DE 4151 DE 4149 HH 5301 HH 5323 HH 5053 HH 5321 HH 5058 PART NAME DIAGRAM NO QTY ORDERING NO 46 5 16 18 EYELET BOLT HH 5325 47 5 16 FLAT WASHER 23 HH 5127 5 16 LOCK NUT 27 HH 5012 1 4 20 X 3 4 SLOT HEAD SCREW HH 5022 1 4 20 X 2 3 4 SLOT HEAD SCREW HH 5326 1 4 LOCK NUT HH 5011 5 32 10 SELF TAPPING SCREW HH 5290 5 32 FLAT WASHER HH 5048 3 8 16 X 1 1 2 HEX HEAD BOLT HH 5068 3 8 16 X 2 1 2 HEX HEAD BOLT 3 8 FLAT WASHER HH 5265 3 8 LOCK NUT HH 5088 AA 8002 AA 8001 1 ROUND PLASTIC CAP 7 AA 8005 7 8 ROUND PLASTIC CAP AA 8088 3 4 ROUND PLASTIC CAP HARDWARE BAG NUTS amp BOLTS HARDWARE BAG PLASTICS C5863 D35 WW 7038 HARDWARE BAG PINS amp FOAM PADS C5864 D35 CNN 1113 TRAINING MANUAL CNN 1094 4 PULLEY 17 70 Arr he 47 48 49 HARDWARE BAG NUTS amp BOLTS Gw D 621 HARDWARE ILLUSTRATION SHEET 7 2 3 8 HEAD BOLT lt 54 55 3 8 NUT 3 8 FLAT WASHER 56 5 16 HEX HEAD BOLT HO 41 42 43 45 5 16 TE NUT 5 16 FLAT WASHER B o V 1 4 SLOT HEAD SCREW 1 4 NUT 5 16 CARRIAGE BOLT 49 50 55 5 32 10 SELF so ee SCREW 5 32 ic WASHER EYELET BOLT 46 2 SQUARE EM CAP 58 1 1 2 SQUARE P2. 1D621 POWER FLEX TRAINER ASSEMBLY INSTRUCTIONS MODEL NO 354 156350 REPLACEMENT PARTS WEIDER HEALTH AND FITNESS 21100 ERWIN STREET WOODLAND HILLS CA USA 91367 m PARTS LIST me DIAGRAM NO PART NAME QTY ORDERING NO BASE FRAME BASE CROSSMEMBER C2123 D35 UPRIGHT UPRIGHT CROSSBRACE C0277 D21 C0293 D35 FRONT FRAME LEG TOP MAIN FRAME 7 LEG CURL BRACKET LEG CURL TUBE ADJUSTABLE EXTENSION TUBE BACKREST ADJUSTER BAR LONG ANGLE IRON 12 BACKREST SEAT PLASTIC FRAME SHROUD RIGHT PLASTIC FRAME SHROUD LEFT LARGE CONNECTOR PLATE MEDIUM CONNECTOR PLATE 18 SMALL CONNECTOR PLATE C0618 D21 C0619 D21 C6706 D35 C6707 D35 gt C6708 D35 BUTTERFLY ARM C0280 D20 PIVOT TUBE C0281 D20 8 BUTTERFLY WEIGHT PIN 1 DIA 1 LAT BAR 27 LAT ROPE 72 LONG C6603 D 16 CURL ROPE 66 LONG C6606 D35 C6241 D20 DUMBBELL ROPE 28 LONG DUMBBELL HANDLE AA 8119 BAR HOLDER BRACKET C0278 D21 CHROME WEIGHT PIN 1 X 10 LONG EZ ON CLIP COLLAR ANKLE PAD BAR 3 4 X 18 LONG 3 X 6 FOAM ROLLER PAD KNEE PAD BAR 3 4 X 16 LONG 2 1 2 X 7 FOAM ROLLER PAD SMALL SHROUD DECAL 7 8 X 13 LARGE SHROUD DECAL LEG CURL DECAL 5 16 18 X 1 3 4 HEX BOLT 5 16 18 X 2 1 4 HEX BOLT 5 16 18 X 2 1 2 HEX BOLT 5 16 18 X 2 1 2 CARRIAGE BOLT 5 16 18 X 2 3 4 HEX BOLT C6300
3. CTOR PLATE 17 to front of shroud and SMALL CONNECTOR PLATES 18 to rear of shroud using 5 32 SELF TAPPING SCREWS 52 and 5 32 FLATWASHERS 53 Position assembled shroud against frame so that the notch in the front of the shroud is forward against Base Frame Cross Brace and back lower connector plate is sitting on top of Base Frame L Using a 1 4 X 2 3 4 ROUND HEAD SCREW 50 fasten the front of the shroud in position by trapping shroud between frame and 5 16 FLATWASHER 47 with 1 4 NUT 51 D Position the other plastic shroud so that the connector plates align with holes in shroud and attach with other 5 32 SELF TAPPING SCREWS 52 and 5 32 FLATWASHERS 53 L Using another 1 4 X 2 3 4 ROUND HEAD SCREW 50 5 16 FLATWASHERS 47 and 1 4 NUT 51 fasten down the front of the other plastic shroud STEP 5 BUTTERFLY ARM ASSEMBLY HARDWARE D Insert PIVOT TUBE 20 into UPRIGHTS 3 so that tube 66 passes thru upright and bolt holes align Bolt in place using 5 16 X 2 1 2 HEX BOLT 43 5 16 FLATWASHER 47 and 5 16 HEX NUT 48 D Press 7 8 ROUND PLASTIC CAP 62 into front end of 30 Pivot Tube Press 2 PLASTIC BUSHING 64 into round tube at end of FLY ARM 19 Slide Fly Arm over Pivot Tube and secure in place by inserting STOPPER PIN 67 into Pivot Tube so that tab on Stopper Pin snaps into locating hole in Pivot Tube DJ Press 1 ROUND PLASTIC CAP 61 into end of 8 WEIGHT PIN 21 and fasten t
4. EMBLY METHOD BY CHECKING THE BOXES AS YOU GO IT IS VERY EASY TO FOLLOW ALONG THE ASSEMBLY WITHOUT REREADING TO FIND YOUR PLACE IN THE ASSEMBLY YOU WILL ALSO NOTICE THAT AT THE BEGINNING OF EACH ASSEMBLY STEP THERE IS A HARDWARE LIST SHOWING THE QUANTITY AND DESCRIPTION OF THE HARDWARE REQUIRED TO DO ALL ASSEMBLIES IN THAT STEP BY PRE SELECTING THE HARDWARE FOR EACH STEP YOU WILL SAVE TIME AND CONFUSION TAKE NOTE OF ANY SPECIAL WARNINGS CAUTIONS NOTES OR NOTICES LAY OUT UNASSEMBLED PARTS FAMILIARIZE YOURSELF WITH THE DRAWINGS THEN READ AND UNDERSTAND THE INSTRUCTIONS THOROUGHLY THIS PRODUCT MUST BE ASSEMBLED BY AN ADULT PRIOR TO USE DO NOT DESTROY THE PACKING AND CARTON UNTIL THE UNIT IS COMPLETELY ASSEMBLED DO NOT DESTROY THE INSTRUCTION MANUAL USE IT FOR ORDERING REPLACEMENT PARTS TO HELP SECURE PLASTIC CAPS IN TUBING IT IS ADVISABLE TO GLUE ON ALL PLASTIC CAPS DURING ASSEMBLY USING ANY HOUSEHOLD TYPE GLUE PERIODICALLY CHECK THE UNIT FOR BOLT TIGHTNESS AND PARTS WEAR TO INSURE THAT YOUR EQUIPMENT IS KEPT IN TOP CONDITION THE PLASTIC SHROUDS PROTECTING YOUR MACHINE SHOULD BE CLEANED PERIODICALLY WITH MILD SOAP AND WATER STEP 1 BENCH FRAME ASSEMBLY Assemble BASE FRAME 1 to BASE CROSSMEMBER 2 using 5 16 X 2 1 2 HEX BOLTS 43 5 16 FLATWASHERS 47 and 5 16 HEX LOCKNUTS 48 HARDWARE PART NAME 5 16 X 2 1 4 HEX HEAD BOLT 5 18 X 2 1 2 HEX HEAD BOLT UPRIGHTS 3 to BASE C
5. ER IN ORDER TO RECEIVE SERVICE ON THIS PRODUCT YOU WILL HAVE TO FIRST SEND IN YOUR WARRANTY CARD CUSTOMER SERVICE 1 800 225 0653 ALL OF THE PARTS FOR THE WEIGHTBENCH CAN BE ORDERED FROM WEIDER HEALTH AND FITNESS PARTS SERVICE DEPT 900 WEST ST JOHN ST OLNEY IL 62450 WHEN ORDERING PARTS WILL BE SENT AND BILLED AT THE CURRENT PRICES PRICES MAY BE SUBJECT TO CHANGE WITHOUT NOTICE STANDARD HARDWARE ITEMS ARE AVAILABLE AT LOCAL HARDWARE STORES TO OBTAIN PARTS DO NOT GO BACK TO THE STORE WHERE YOU PURCHASED THIS UNIT ALWAYS INCLUDE THE FOLLOWING INFORMATION WHEN ORDERING PARTS MODEL NO NAME OF PART ORDERING NUMBER WARNING CONSULT YOUR PHYSICIAN _ CONSUL YOUR PHYSICIAN BEFORE STARTING YOUR EXERCISE PROGRAM IT IS ADVISABLE TO HAVE A PHYSICAL EXAMINATION BY YOUR PHYSICIAN BEFORE YOU ENTER ANY EXERCISE PROGRAM 2 FOR YOUR OWN SAFETY DO NOT BEGIN ANY EXERCISE WITHOUT PROPER INSTRUCTION CHILDREN AND HANDICAPPED PERSONS SHOULD NOT USE ANY ut EXERCISE EQUIPMENT WITHOUT A QUALIFIED PERSON IN ATTENDANCE TRAIN WITH A PARTNER et IS RECOMMENDED THAT AN INDIVIDUAL SHOULD NOT WORK OUT WITHOUT A TRAINING PARTNER IN ATTENDANCE SET UP YOUR PROGRAM TO ACCOMMODATE TWO PEOPLE AND YOU WILL BE HIGHLY MOTIVATED
6. LASTIC CAP 3 4 on 7 8 aor 1 er 60 1 6 BOLT LENGTH SCALE BEFORE BEGINNING ASSEMBLY READ THE FOLLOWING THIS PRODUCT REPRESENTS THE STATE OF THE ART IN TECHNOLOGY IN HOME FITNESS EQUIPMENT EVERY EFFORT HAS BEEN MADE TO BRING TO YOU A PRODUCT OF THE HIGHEST QUALITY AND WORKMANSHIP WE HOPE YOU WILL FIND THIS PRODUCT BENEFICIAL TO YOUR PHYSICAL CONDITIONING AND WELL BEING 7 DO NOT LET THE QUANTITY OF PARTS DISCOURAGE YOU BY READING AND FOLLOWING THE ASSEMBLY INSTRUCTIONS YOU WILL FIND IT GOES TOGETHER EASILY THIS UNIT TAKES TOOLS REQUIRED FOR ASSEMBLY INCLUDE A HAMMER PLIERS MEDIUM SIZE FLAT HEAD SCREWDRIVER AND TWO 6 ADJUSTABLE WRENCHES 2 PRIOR TO BEGINNING THE ASSEMBLY OF THIS PRODUCT WE RECOMMEND THAT YOU TAKE FEW MINUTES TO UNPACK AND LAY OUT ALL THE PARTS SO THEY CAN BE EASILY IDENTIFIED INCLUDED WITH THE LITERATURE OF THE UNIT IS AN ILLUSTRATED PARTS LIST TO HELP IN IDENTIFYING AND SIZING PARTS IS EXTREMELY HELPFUL IF THE CONTENTS OF THE HARDWARE BAG ARE EMPTIED OUT AND LIKE PARTS GROUPED TOGETHER 5 16 X 3 HEX HEAD BOLTS TOGETHER HANDY PLACE TO HOLD THE HARDWARE MIGHT BE TO USE THE INSIDE OF THE CARTON TOP AFTER GROUPING PARTS AGAINST THE HARDWARE ILLUSTRATIONS AND PARTS LIST TO IDENTIFY PARTS AND SIZES WRITE THE SIZE AND PART NAME BESIDE EACH PART SO YOU KNOW EXACTLY WHICH PART TO GO TO FOR A PARTICULAR ITEM THE ASSEMBLY INSTRUCTIONS HAVE BEEN WRITTEN USING CHECK AS YOU GO ASS
7. LAT MAST TUBE 22 and 4 PULLEY 71 Slide another 5 8 PULLEY SPACER BUSHING 69 and 3 8 FLAT WASHER 56 over Bolt and secure with a 3 8 LOCK NUT 57 Cli LOWER PULLEY BRACKET 23 to bottom of MAST TUBE 22 using a 5 16 X 2 1 2 HEX BOLT 43 5 16 FLAT WASHER 47 and 5 16 LOCK NUT 48 C insert a 3 4 METAL FERRULE 68 into 3 PULLEY 24 and bolt it into LOWER PULLEY BRACKET 23 with a 3 8 X 1 1 2 HEX BOLT 54 and 3 8 LOCK NUT 57 D Insert 72 long LAT ROPE 27 thru upper slot in LAT MAST TUBE 22 and over PULLEY 24 Prepare a loop in each end of rope by doubling rope over and inserting thru 3 4 LONG METAL FERRULES 68 Hook 5 HOOKS 66 into each looped end and draw Lat Rope tightly around hooks D For lower 66 CURL ROPE 28 assembly insert rope between PULLEY 24 and PULLEY BRACKET 23 and prepare looped ends in rope as previously done for Lat Rope Draw rope around another S HOOK 66 at the lower end of rope D Press 1 ROUND PLASTIC CAPS 61 into each end of LAT BAR 25 and slide on FOAM GRIPS 26 using small amount of liquid detergent to aid as a lubricant assemble LAT MAST 22 assembly to bench position Lat Mast so that the notch in the bottom end of the Mast Tube fits down over the Pad Bar and is positioned between the LEG CURL BRACKETS 7 The small tab that is welded in the top of the FRONT FRAME LEG 5 should be fitted inside the Lat Tube secure in position u
8. N 2 POSITION 3 LEG EXTENSION POSITIONS With the extension in Position 1 you can perform Seated Leg Extensions and Standing Leg Curls Position 2 is used for Lat Mast Exercises Position 3 with upper Knee Rollers and Bar removed is used for Prone Leg Curls With Knee Bar and Rollers assembled in the Mast Tube you can hook your feet under to perform Sit ups Crunches and Back Hyperextensions STEP 3 SEAT AND BACKREST ASSEMBLY HARDWARE PART NAME 4 4 X 3 4 ROUND HEAD SCREW 1 4 X 2 3 4 ROUND HEAD SCREW 4 ROUND PLASTIC CAP D Press 1 ROUND PLASTIC CAP 61 into each end of the BACKREST ADJUST BAR 10 and insert backrest tube into any set of positioning holes in UPRIGHTS 3 C turn BACKREST 12 over and bolt the LONG ANGLE IRONS 11 to back of backrest using 1 4 X 3 4 ROUND HEAD SCREWS 49 On one angle iron fasten only at the top so bottom ends can be spread slightly Fit holes in angle iron over pivot pin on TOP MAIN FRAME 6 so that the pivot pin is securely inserted into angles Finish bolting loose end of angle iron onto backrest Position SEAT 13 over holes in top frame bracket and assemble seat using 1 4 X 3 4 ROUND HEAD SCREWS 49 thru flat bracket and 1 4 X 2 3 4 ROUND HEAD SCREW 50 up thru frame into rear of seat STEP 4 SIDE SHROUD ASSEMBLY HARDWARE one PLASTIC SHROUD either 14 or 15 assemble LARGE CONNECTOR PLATE 16 and MEDIUM CONNE
9. RL BRACKETS 7 using 5 16 x 2 3 4 HEX BOLT 45 and 5 16 LOCKNUT 48 DO NOT OVER TIGHTEN so Leg Curl Tube can pivot freely LI Insert 10 WEIGHT PIN 32 into bottom of LEG CURL TUBE 8 and secure with 5 16 x 2 1 2 HEX BOLT 43 FLATWASHERS 47 and 5 16 LOCKNUT 48 The EZ ON CLIP COLLAR 33 is used to secure weights in position while exercising Cap with 1 ROUND PLASTIC CAP 61 4 Cl insert 18 ANKLE PAD BAR 34 into ADJUSTABLE EXTENSION TUBE 9 and align bolt hole in pad bar with hole in extension tube Insert 5 16 EYELET BOLT 46 thru 3 4 METAL FERRULE 68 and into 45 EXTENSION TUBE 9 and secure with 5 16 FLATWASHER 47 and LOCKNUT 48 Cap 37 tube with 1 1 2 SQUARE PLASTIC CAP 60 Using a small amount of liquid detergent wiped 63 over the surface of the pad bar slide a 3 X 6 FOAM ROLLER 35 onto each side of bar Cap with 3 4 ROUND PLASTIC CAPS 63 the completed ADJUSTABLE EXTENSION ASSEMBLY can be bolted to the LEG CURL TUBE 8 in any of three positions using 5 16 X 2 1 2 CARRIAGE BOLT 44 and THREADED PLASTIC KNOB 65 See leg extension positions illustrations Again using a small amount of liquid detergent wiped over the surface of the KNEE PAD BAR 36 insert the bar thru the holes in the LEG CURL BRACKETS 7 and assemble 2 1 2 X 7 FOAM PADS 37 to each end of bar Cap with 3 4 ROUND PLASTIC CAPS 63 POSITION 1 POSITIO
10. ROSSMEMBER 2 with 5 16 X 2 1 4 HEX BOLTS 42 and 5 16 LOCKNUTS 48 5 16 FLAT WASHER 5 16 LOCKNUT 2 0 Position UPRIGHT CROSSBRACE 4 between UPRIGHTS 3 2 SQUARE PLASTIC CAPS bolt together in bottom hole using 5 16 X 2 1 2 HEX BOLT 43 5 16 FLATWASHER 47 and 5 16 LOCKNUT 48 using 5 16 X 2 1 4 HEX BOLTS 42 and 5 16 LOCKNUTS 48 fasten FRONT FRAME LEG 5 to BASE FRAME 1 Position TOP MAIN FRAME 6 between UPRIGHT CROSS BRACE 4 and FRONT FRAME LEG 5 Bolt together using 5 16 X 2 1 2 HEX BOLTS 43 5 16 FLATWASHERS 47 and 5 16 LOCKNUTS 48 2 Boit BAR HOLDER BRACKETS 31 to UPRIGHTS 3 with 5 16 x 2 1 2 HEX BOLTS 43 5 16 FLATWASHERS 47 and 5 16 43 LOCKNUTS 48 74 oe cap open ends of base and uprights with 2 SQUARE PLASTIC CAPS 58 STEP 2 LEG EXTENSION ASSEMBLY se LEG CURL BRACKETS 7 to FRONT LEG 5 using 5 16 x 2 3 4 HEX BOLTS 45 and 5 16 LOCKNUTS 48 HARDWARE PART 546 X 2 1 2 HEX BOLT 5 16 X 2 3 4 HEX BOLT CHASE cap top of LEG CURL TUBE 8 with 2 SQUARE 5 16 EYELET BOLT 5 16 FLATWASHER 5 16 HEX LOCKNUT 73 4 LONG METAL FERRULE PLASTIC KNOB 3 4 ROUND PLASTIC CAP 1 ROUND PLASTIC CAP 2 SQUARE PLASTIC CAP 4 1 2 SQUARE PLASTIC 2 SQUARE COVER CAP PLASTIC CAP 58 and bottom with 2 SQUARE COVER CAP 59 Bolt Leg Curl Tube between LEG CU
11. o BUTTERFLY ARM 19 using 5 16 X 1 3 4 HEX BOLT 41 and 5 16 LOCK NUT 48 OG D Form loop in one end on 28 BUTTERFLY ROPE 29 by doubling over the rope and passing it thru a 3 4 METAL FERRULE 68 Tie a knot in the end of the rope and pull it tight against the ferrule Fasten the rope to the BUTTERFLY ARM 19 using a 5 16 X 2 1 2 HEX BOLT 43 5 16 FLATWASHERS 47 and 5 16 LOCKNUT 48 Fasten bolt so that the rope is trapped between the Flatwasher and Butterfly Arm Draw rope loop tightly around bolt and tighten bolt to hold rope in place insert other end of Butterfly Rope thru another metal ferrule and around midpoint of rope on DUMBBELL HANDLE 30 Pass rope back thru ferrule and secure end by knotting Draw rope tightly around Dumbbell Rope C insert 1 1 2 SQUARE PLASTIC CAP 60 into end of BUTTERFLY ARM 19 STEP 6 LAT MAST ASSEMBLY HARDWARE PART 5 16 X 2 1 2 HEX BOLT odd 5 16 LOCK LOCK I 85 16 X 2 1 2 CARRIAGE BOLT 5 8 PULLEY SPACER BUSHING 3 4 LONG METAL FERRUI _ 4 ROUND PLASTIC _ 2 SQUARE PLASTIC CAP 5 HOOK us PLASTIC KNOB C insert 3 4 METAL FERRULE 68 into 4 PULLEY 71 Position Pulley assembly in slot in the top of LAT MAST TUBE 22 aligning bolt holes Place a 3 8 FLAT WASHER 56 and a 5 8 PULLEY SPACER BUSHING 69 onto a 3 8 X 2 1 2 HEX HEAD BOLT 55 and insert Bolt and Spacer through
12. sing a 5 16 2 1 2 CARRIAGE BOLT 44 and THREADED PLASTIC KNOB 65 8 Connect LAT ROPE 27 to ADJUSTABLE LEG EXTENSION 9 with extension bar assembled in the proper location by hooking S HOOK 66 into EYE BOLT 46 located at end of leg extension For use of LAT BAR 25 in the upper position for lat pull down work connect Lat Bar to LAT ROPE 27 by use of 5 HOOK 66 use mast assembly for low or seated rowing exercises connect CURL ROPE 28 to LAT ROPE 27 and connect LAT BAR 25 to Curl Rope upper knee pad assembly can be assembled into the pad bar hole the lower part of the MAST TUBE 22 to accommodate foot restraint while doing sit ups and abdominal crunches NOTE The Carriage Bolt Knob Assembly has been provided for quick and easy mounting and removal of the Lat Assembly to facilitate a broader range of exercises STEP 7 DECAL INSTALLATION Cl apply SMALL SHROUD DECAL 38 to upper recessed area in shroud sides LARGE SHROUD DECALS 39 are in two sections Align the front decal section about 1 2 above and in line with the molded embossing Apply the back section by butting it up against the front section C Apply the LEG CURL DECAL 40 to upper portion of the Leg Curl Tube apply the LAT MAST DECAL 70 to the front of the Mast Tube In the approximate position shown in the illustration REPAIR PARTS AND SERVICE IMPORTANT BEFORE CALLING THE 800 NUMB
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