Model No. PFSY69520 Serial No. The serial number is found in the location shown below. Write the serial number in the space above. USER’S MANUAL Serial Number Decal QUESTIONS? As a manufacturer, we are committed to providing complete customer satisfaction. If you have questions, or if there are missing parts, we will guarantee complete satisfaction through direct assistance from our factory. TO AVOID DELAYS, PLEASE CALL DIRECT TO OUR TOLLFREE CUSTOMER HOT LINE.
TABLE OF CONTENTS IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CABLE DIAGRAM . . . . . . . . . .
IMPORTANT PRECAUTIONS WARNING: To reduce the risk of serious injury, read the following important precautions 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. 12. Never release the press arm, leg lever, lat bar, leg press, ab strap, or ankle strap while weights are raised. The weights will fall with great force. 2.
BEFORE YOU BEGIN Thank you for selecting the versatile PROFORM® 650 weight system. The 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. toll-free at 1-800-999-3756, Monday through Friday, 6 a.m. until 6 p.m. Mountain Time (excluding holidays).
ASSEMBLY Make sure you have the following tools: Make Assembly Easier for Yourself • Two adjustable wrenches Everything in this manual is designed to ensure that the weight system can be assembled successfully by anyone. Before beginning assembly, make sure to read the information on this page; this brief introduction will save you much more time than it takes to read it.
Frame Assembly 1. 1 24 Before beginning assembly, make sure you have read and understood the information on page 5. This brief introduction will save you much more time than it takes to read it. 33 3 Open the parts bag labeled “FRAME ASSEMBLY.” Press two 2” x 3” Inner Caps (24) into the ends of the Stabilizer (5). Press a 2” x 3” Inner Cap and a 2” Square Inner Cap (33) into the Main Upright (3) in the indicated locations.
3. Place two Weight Bumpers (19) over the indicated holes in the Stabilizer (5). Insert the two Weight Guides (23) into the Weight Bumpers and the Stabilizer. 3 Attach the indicated Weight Guide (23) to the Stabilizer (5) with a 3/8” x 2 1/2” Bolt (54), two 5/8” x 1/2” Bushings (42), two 3/8” Washers (55), and a 3/8” Nylon Jamnut (63). 23 63 55 42 19 5 55 42 4. Open the parts bag labeled “Weight Inserts.” 54 4 See the inset drawing.
5. Slide the welded tubes on the Top Frame (1) over the upper ends of the Weight Guides (23). Align the bracket on the Top Frame with the indicated holes in the Main Upright (3). Insert two 3/8” x 3” Bolts (45) into the holes. Thread a 3/8” Nylon Locknut (50) onto the lower Bolt. Do not thread a Locknut onto the upper Bolt yet. 5 Bracket 45 1 50 3 50 Attach the Weight Guides (23) to the Top Frame (1) with two 3/8” x 1 3/4” Bolts (60) and two 3/8” Nylon Locknuts (50). 60 Welded Tubes 23 6.
Arm Assembly 33 9. Open the parts bags labeled “ARM ASSEMBLY.” 97 Attach the Rear and Forward Leg Press Uprights (97, 98) to the Leg Press Base (84) with two 3/8” x 3 1/4” Bolts (87) and two 3/8” Nylon Locknuts (50). Note: The Rear Leg Press Upright (97) has an extra hole in it. 98 50 Press two 2” Square Inner Caps (33) into the Rear and Forward Leg Press Uprights (97, 98). 84 87 10.
13. Attach the Leg Lever Lock (11) to the front leg of the Base (8) with a 5/16” x 3” Bolt (78), three 5/16” Washers (80), and a 5/16” Nylon Locknut (81). Do not overtighten the Nylon Locknut; the Leg Lever Lock must pivot easily. 13 78 80 Front Leg 8 11 81 14. Press two 2” Square Inner Caps (33) into the top of the Press Frame (12). Press two 3/4” x 1/2” Flange Bushings (18) into the Main Upright (3).
16 Cable Assembly 63 16. Open the parts bags labeled “CABLE ASSEMBLY” and “4 PULLEYS.” Refer to the CABLE DIAGRAM on page 21 to identify the cables and for correct cable routing. 76 55 84 Locate the Leg Press Cable (76). Attach the Leg Press Cable to the indicated hole in the Leg Press Base (84) with a 3/8” x 3” Bolt (45), two 3/8” Washers (55), a 5/8” x 1/4” Bushing (90), and a 3/8” Nylon Jamnut (63). 90 45 55 17. Wrap the Leg Press Cable (76) up around a 4” Pulley (35).
20. Wrap the Leg Press Cable (76) around a 4” Pulley (35). Attach the Pulley and a Cable Trap (44) to the bracket on the Stabilizer (5) with a 3/8” x 2” Bolt (62) and a 3/8” Nylon Locknut (50). 20 35 62 Be sure that the Cable Trap (44) is positioned to hold the Cable in the pulley groove. 76 Bracket 44 5 50 21. Remove the pre-assembled 4” Pulley (not shown) from the Pulley Bracket (91).
23. Remove the upper 3/8” x 3” Bolt (45) from the Top Frame (1) and the Main Upright (3). 23 35 Route the High Cable (73) around a 4” Pulley (35) and down through the indicated slot in the Main Upright (3), as shown. Attach the Pulley inside the slot with a 3/8” x 2 1/2” Bolt (54), two 3/8” Washers (55), two 5/8” x 1/2” Bushings (42), and a 3/8” Nylon Jamnut (63). 45 Slot 55 54 42 50 73 1 Re-insert the 3/8” x 3” Bolt (45) and secure it with a 3/8” Nylon Locknut (50).
26. Wrap the High Cable (73) around a 4” Pulley (35). Attach the Pulley inside the slot in the Main Upright (3) with a 3/8” x 2 1/2” Bolt (54), two 3/8” Washers (55), two 5/8” x 1/2” Bushings (42), and a 3/8” Nylon Jamnut (63). 26 54 42 3 35 55 73 63 42 55 27. Disassemble the pre-assembled Pulley Plates (31). 27 Wrap the High Cable (73) around a 4” Pulley (35) in the direction shown.
29. Wrap the High Cable (73) around a 4” Pulley (35). Attach the Pulley and a Cable Trap (44) to the top hole in the Pulley Bracket (91) attached to the Leg Press Cable (76), with a 3/8” x 1 3/4” Bolt (60) and a 3/8” Nylon Jamnut (63). 29 35 44 73 91 63 60 76 30. Route the High Cable (73) up through the next slot in the Top Frame (1) and wrap the Cable around a 4” Pulley (35) in the direction shown.
33. Attach a 4” Pulley (35) over the Low Cable (72), inside the front leg of the Base (8) with a 3/8” x 2 1/2” Bolt (54), two 3/8” Washers (55), two 5/8” x 1/2” Bushings (42), and a 3/8” Nylon Jamnut (63). 33 8 72 55 35 54 42 63 42 55 34. Route the Low Cable (72) through the indicated slot in the Main Upright (3) and the Base (8). 34 35 62 Wrap the Low Cable (72) around a 4” Pulley (35) in the direction shown.
37. Route the end of the Low Cable (72) through the indicated slot in the Main Upright (3). 37 Wrap the Low Cable (72) around a 4” Pulley (35). Attach the Pulley inside the slot in the Main Upright (3) with a 3/8” x 2 1/2” Bolt (54), two 3/8” Washers (55), two 5/8” x 1/2” Bushings (42), and a 3/8” Nylon Jamnut (63). 54 55 42 35 72 63 55 42 Slot 3 38. IMPORTANT: Follow the cables from end to end; make sure that they are in the grooves of the pulleys and that the cables and pulleys move smoothly.
40. Insert a 1/4” x 3 3/4” Carriage Bolt (43) into each Backrest Plate (27). Attach the Backrest Plates to the Backrest (41) with four 1/4” x 3/4” Bolts (17). 40 71 17 27 25 43 41 Attach the Backrest (41) to the Main Upright (3) with the two 1/4” x 3 3/4” Carriage Bolts (43), two 1/4” Washers (71), and two 1/4” Nylon Locknuts (25). Be sure the Backrest is oriented as shown. 25 17 27 43 71 3 41. Attach the other Seat (13) to the Sliding Seat Frame (74) with four 1/4” x 3/4” Bolts (17).
44. Press two 3/4” Round Inner Caps (34) into the ends of the remaining Pad Tube (28). 44 Slide the Pad Tube (28) through the hole in the Main Upright (3). Slide two Foam Pads (30) onto the ends of the Pad Tube. 34 30 28 30 3 34 45. Slide the two Tinnerman Clips (38) down over the slots in the bracket on the Stabilizer (5). 45 Attach the lower end of the Shroud (56) to the bracket on the Stabilizer (5) with two #8 x 3/4” Screws (32).
46. Attach the upper end of the Shroud (56) to the two “L”-brackets on the Top Frame (1) with two 1/4” x 3/4” Bolts (17), two 1/4” Washers (71), and two 1/4” Nylon Locknuts (25). Make sure that the indicated corner of the Shroud is lined up with the indicated corner of the Top Frame. The Bolts must be inserted through the square holes in the Shroud. 46 17 71 1 “L”-Brackets 25 71 17 Align Corners 56 47. Attach the Curl Pad (21) to the Curl Post (83) with four 1/4” x 3/4” Bolts (17).
CABLE DIAGRAM The diagram below shows the proper routing of the Low Cable (72), the High Cable (73), and the Leg Press Cable (76). The numbers show the correct route for each cable. Make sure that the cables are routed correctly, 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.
ADJUSTMENTS The instructions below describe how each part of the weight system can be adjusted. Refer to the exercise guide accompanying this manual to see how the weight system should be set up for each exercise. IMPORTANT: When attaching the lat bar, ankle strap, or ab strap, make sure that the accessories are in the correct 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.
CONVERTING THE PRESS/FLY ARMS 20 To use the Press/Fly Arms (46, 49) as fly arms, insert the Adjustment Pins (20) into the inner holes in the Press Frame (12) (see inset drawing A). 12 To use the Press/Fly Arms (46, 49) as press arms, insert the Adjustment Pins (20) into the outer holes in the Press Frame (12) and the tabs on the Press/Fly Arms (see inset drawing B).
WEIGHT RESISTANCE CHART This chart shows the approximate weight resistance at each weight station. “Top” refers to the 10 lb. top weight. The other numbers refer to the 10 lb. weight plates. 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 Plates Press Arm (lbs.) Low Pulley (lbs.) High Pulley (lbs.) AB Pulley (lbs.) Leg Lever (lbs.) Leg Press (lbs.
TROUBLESHOOTING AND MAINTENANCE Make sure all parts are properly tightened each time you use the weight system. Replace any worn parts immediately. The weight system can be cleaned using a damp cloth and mild non-abrasive detergent. Do not use solvents. TIGHTENING THE CABLES 73 Woven cable, the type of cable used on the weight system, can stretch slightly when it is first used. If there is slack in the cables before resistance is felt, the cables should be tightened.
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.
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. COOLING DOWN slowly as you stretch and do not bounce.
PART IDENTIFICATION CHART—Model No.
3/8" x 2 1/2" Bolt (54) 5/16" x 3" Bolt (78) 3/8" x 3 1/4" Bolt (87) 3/8" x 3 1/2" Bolt (22) 3/8" x 3 3/4" Bolt (92) 1/4" x 3 3/4" Carriage Bolt (43) 3/8" x 3 3/4" Carriage Bolt (52) 3/8" x 4" Bolt (65) 3/8" x 5" Carriage Bolt (82) 3/8" x 9" Bolt (51) 3/8" x 3" Carriage Bolt (64) 3/8" x 8 1/2" Bolt (59) 3/8" x 3" Bolt (45)
1/2” x 1 3/4” Bushing (94) 1/2” x 3/4” Long Bushing (93) 5/8” x 1/2” Bushing (42) 3/4" Round Inner Cap (34) 5/8” x 1/4” Bushing (90) 1" Round Inner Cap (103) 2" Square Inner Cap (33) Cable Clip (69) 2" Round Inner Cap (57) 2" x 3” Inner Cap (24) 3/4” x 1/2” Flange Bushing (18)
PART LIST—Model No. PFSY69520 Key No. Qty.
53 63 9 95 101 17 17 66 42 55 33 73 101 74 47 36 68 40 86 25 17 23 17 16 93 2 95 70 32 25 17 53 71 17 25 86 71 13 77 35 44 55 50 26 33 52 50 24 32 56 102 17 55 35 50 64 45 84 82 38 19 62 35 44 44 88 50 92 55 38 50 39 42 77 50 42 42 55 87 90 76 4 63 54 64 52 50 50 5 24 55 35 50 55 63 99 31 33 50 92 54 35 44 97 44 31 55 1 42 24 87 35 35 44 60 63 55 63 63 55 42 35 42 35 50 63 98 50 50 30 33 34 60 42
ORDERING REPLACEMENT PARTS To order replacement parts, simply 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 be prepared to give the following information: 1. The MODEL NUMBER of the product (PFSY69520) 2. The NAME of the product (PROFORM® 650 weight system) 3. The SERIAL NUMBER of the product (see the front cover of this manual) 4.