Model No. PFSY59001 Serial No. Write the serial number in the space above for future reference. USER'S MANUAL Serial Number Decal (Under Seat) 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 assistance from our factory. TO AVOID DELAYS, PLEASE CALL DIRECT TO OUR TOLL-FREE CUSTOMER HOT LINE.
TABLE OF CONTENTS IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 ADJUSTMENTS . . . . . . . . . . . . .
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. 11. Never release the press arm, butterfly arms, leg lever, leg press, lat bar, ab strap, or nylon strap while weights are raised. The weights will fall with great force. 2.
BEFORE YOU BEGIN 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 PFSY59001. The serial number can be found on a decal attached to the weight system (see the front cover of this manual). Thank you for selecting the versatile PROFORM® 960 weight system.
ASSEMBLY Make sure you have the following tools: Make Assembly Easier! • Two (2) 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.
1 FRAME ASSEMBLY 83 48 62 50 1. 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. 48 4 6 92 92 Locate and open the parts bags labeled “FRAME ASSEMBLY.” See the inset drawing. Insert two 1 1/2” x 2 1/2” Inner Caps (83) and two 3/8” x 2” Carriage Bolts (92) into the Butterfly Base (4).
4. Attach the Butterfly Seat Frame (14) to the Butterfly Upright (1) with two 3/8” x 3 3/4” Bolts (102), two 3/8” Washers (48), and two 3/8” Nylon Locknuts (50). 4 50 1 102 50 Attach the Butterfly Seat Frame (14) to the Butterfly Front Leg (3) with two 3/8” x 3 3/4” Bolts (102), two 3/8” Washers (48) and two 3/8” Nylon Locknuts (50). 50 48 14 50 48 Do not tighten the Nylon Locknuts (50) yet. 3 102 5. Press a 3” Round Inner Cap (78) into the Press Front Leg (20).
. See the inset drawing. Insert two Weight Inserts (56) into each Weight (21). 8 56 15 Set the two Weight Bumpers (51) over the holes in the corner bar of the Press Base (6). 21 Slide the Weight Guides (15) through the Weight Bumpers (51) and into the holes in the Press Base (6). Secure the Weight Guides to the Press Base with two 3/8” x 2 3/4” Bolts (89), four 3/8” Washers (48), and two 3/8” Nylon Locknuts (50).
11. Secure the Press Top Frame (9) to the Butterfly Top Frame (33) with two 3/8” x 3 1/4” Bolts (62), two 3/8” Washers (48), and two 3/8” Nylon Locknuts (50). Do not tighten the Nylon Locknuts yet. 11 50 62 48 9 48 33 12. Secure the Weight Guides (15) to the Press Top Frame (9) with two 3/8” x 1 3/4” Bolts (57) and two 3/8” Nylon Locknuts (50). 12 Tighten the Nylon Locknuts (50) used in steps 2–12. 57 9 50 50 15 ARM ASSEMBLY 13 13. Locate and open the parts bag labeled “ARM ASSEMBLY.
14. Insert a 2” Round Inner Cap (101) into the end of a Butterfly Arm (10). 14 Attach a Butterfly Handle (53) to the Butterfly Arm (10) with two 3/8” x 1” Bolts (84) and two 3/8” Washers (48). 10 48 10 53 48 Repeat this step with the other Butterfly Arm (10). 84 53 101 48 48 101 15. Lubricate a 3/8” x 3 1/4” Bolt (62). Attach the left Butterfly Arm (10) to the Left Pivot Arm (71) with the Bolt and a 3/8” Nylon Locknut (50).
18. Attach a Bumper (40) to the Press Front Leg (20) with a 1” Tap Screw (80). 18 78 Press a 3” Round Inner Cap (78) into the top of the Press Leg Lever (90). 90 Lubricate a 1/2” x 4” Bolt (68). Attach the Press Leg Lever (90) to the Press Base (6) with the Bolt and a 1/2” Nylon Jamnut (36). Note: Do not over tighten the Nylon Jamnut; the Press Leg Lever must be able to pivot easily. 40 20 80 68 6 Lubricate 36 19. Insert two 2” Square Inner Caps (28) into the Leg Lever (41).
22. Remove the preassembled 3/8” x 2” Bolts (54) from one set of Adjustable Pulley Plates (23). 22 Wrap the Butterfly Cable (73) around a 3 1/2” Pulley (24). Attach the Pulley and a Cable Trap (25) between the top holes of the Adjustable Pulley Plates (23) with a 3/8” x 2” Bolt (54) and a 3/8” Nylon Locknut (50). Be sure that the Cable Trap is turned to hold the Cable in place. 54 25 24 73 50 23 23. Wrap the Butterfly Cable (73) around a “V”-Pulley (27).
26. Wrap the Ab Cable (47) around a 3 1/2” Pulley (24). Insert the Ab Cable down through the Press Top Frame (9). 26 66 24 62 48 Slide a 3/8” Washer (48) and a 5/8” x 3/4” Bushing (66) onto a 3/8” x 3 1/4” Bolt (62). Slide the Bolt through the Press Top Frame (9) and the 3 1/2” Pulley (24). Secure another 5/8” x 3/4” Bushing and 3/8” Washer to the Bolt with a 3/8” Nylon Locknut (50). 50 48 47 9 27. Remove the preassembled 3/8” x 2” Bolts (54) from the other Adjustable Pulley Plates (23).
30. Locate the Weight Cable (72). Note that one end of the Weight Cable has a bolt on it, and the other end has a ball on it. 30 Lay the Weight Cable (72) inside the bracket on the Butterfly Base (4) in the manner shown. Attach a 3 1/2” Pulley (24) to the bracket with a 3/8” x 2” Bolt (54) and a 3/8” Nylon Locknut (50). Be sure the Weight Cable is in the groove of the Pulley. 3 24 54 72 4 50 Bracket 31. Wrap the Weight Cable (72) around a 3 1/2” Pulley (24).
34. Wrap the Weight Cable (72) around a 3 1/2” Pulley (24). Attach the Pulley and a Cable Trap (25) to the Butterfly Upright (1) with a 3/8” x 4 3/4” Bolt (60), a 3/8” Washer (48), and a 3/8” Nylon Jamnut (63). Be sure that the Cable Trap is turned to hold the Cable in place. 34 1 60 24 25 72 48 63 35. Wrap the Weight Cable (72) around a 3 1/2” Pulley (24).
38. Wrap the Weight Cable (72) around a 3 1/2” Pulley (24). Attach the Pulley and a Cable Trap (25) between the lowest holes in the Adjustable Pulley Plates (23) hanging from the Ab Cable (47) with a 3/8” x 2” Bolt (54) and a 3/8” Nylon Locknut (50). Be sure that the Cable Trap is turned to hold the Cable in place. 38 47 23 54 25 50 24 72 39. Remove the preassembled 3/8” x 1 3/4” Bolts (57) from the Small Pulley Plates (22). 39 Wrap the Weight Cable (72) around a 3 1/2” Pulley (24).
42. Locate the Leg Press Cable (75). Attach the Leg Press Cable to the indicated side of the Press Upright (2) with a 3/8” x 3 3/4” Bolt (102) and a 3/8” Nylon Locknut (50). Do not tighten the Nylon Locknut yet. Wrap the Leg Press Cable (75) around a 3 1/2” Pulley (24) in the direction shown. Attach the Pulley and a Cable Trap (25) to the indicated side of the Press Frame (8) with a 3/8” x 4 3/4” Bolt (60) and a 3/8” Nylon Locknut (50). Do not tighten the Nylon Locknut yet.
46. Remove the 3/8” Nylon Locknut (50) from the indicated 3/8” x 5 1/2” Bolt (55). 46 76 Wrap the Leg Press Cable (75) around a 3 1/2” Pulley (24). Secure the Pulley and a Cable Trap (25) to the 3/8” x 5 1/2” Bolt (55) on the indicated side of the Press Base (6) with the 3/8” Nylon Locknut (50). Be sure the Cable Trap is oriented to hold the Cable in place. 24 Press a 2 1/2” Square Inner Cap (76) into the Press Base (6). 6 55 25 75 47.
50 SEAT ASSEMBLY 14 13 50. Locate and open the parts bag labeled “SEAT ASSEMBLY.” Attach a Seat (13) to the brackets on the Butterfly Seat Frame (14) using four 1/4” x 3/4” Bolts (49). Repeat this step with the other Seat (not shown) and the Press Seat Frame (not shown). 49 51. Press a 1 1/2” Square Inner Cap (35) into the end of the Press Backrest Frame (44). Press four 3/4” Round Inner Caps (43) into the welded tubes on the Press Backrest Frame.
54. Lubricate a 1/2” x 4” Bolt (68). Attach the Foot Press Plate (29) to the Press Leg Lever (90) with the Bolt and a 1/2” Nylon Jamnut (36). 54 Lubricate 90 68 36 29 55. Press two 3/4” Round Inner Caps (43) into each of the two Pad Tubes (42). 55 Welded Tube Slide a Foam Pad (30) onto one side of a Pad Tube (42). Slide the Pad Tube through the hole in the Leg Lever (41). Slide another Foam Pad onto the other side of the Pad Tube. 30 Slide a Foam Pad (30) onto one side of the other Pad Tube (42).
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, ab strap, or nylon strap, make sure that the attachments 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.
ATTACHING THE AB STRAP TO THE AB PULLEY STATION Attach the Ab Strap (81) to the Ab Cable (47) at the ab pulley station with a Cable Clip (69). 47 69 81 ADJUSTING THE BACKREST 2 To adjust a Backrest (12), loosen the Adjustment Knob (5) on the Press Upright (2) or the Butterfly Upright (not shown) by turning it counterclockwise and pulling it out as far as possible. Slide the Backrest forward or backward to the desired position, and snap the Adjustment Knob into a hole in the Backrest Frame (not shown).
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. The butterfly arm resistance listed is the resistance for each butterfly arm. 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.
TROUBLE-SHOOTING AND MAINTENANCE Inspect and tighten all parts 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 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.
CABLE DIAGRAMS The cable diagrams on this page and the next page show the proper routing of the Leg Press Cable (75), the Ab Cable (47), the Butterfly Cable (73), and the Weight Cable (72). Use the diagrams to be sure that the Cables have been assembled correctly. The starting and ending points of each Cable have been labeled. The numbers show the proper route for each Cable. IMPORTANT: If the Cables have not been correctly routed, the weight system will not function properly and damage may occur.
Weight Cable (72) Cable ID 11 9 10 6 12—Weight Stack 72 47 75 73 8 7 5 3 1—Low Pulley 4 2 26
PART IDENTIFICATION CHART—Model No.
3/8" x 2" Bolt (54) 3/8" x 1 3/4" Bolt (57) 3/8" x 4 3/4" Bolt (60) 3/8" x 2" Carriage Bolt (92) 5/16" x 2 1/4" Shoulder Bolt (79) 3/8" x 2 1/2" Bolt (87) 5/16" x 2 3/4" Bolt (96) 3/8" x 2 3/4" Bolt (89) 3/8" x 1 1/4" Button Head Bolt (98) 3/8" x 1" Bolt (84) 1" Tap Screw (80) 3/8" x 3" Bolt (88) 3/8" x 3 1/4" Bolt (62) 1/4" x 3/4" Bolt (49) 3/8" x 3 3/4" Bolt (102) #8 x 1/2" Screw (45) 1/2" x 4" Bolt (68) 3/8" x 5 1/2" Bolt (55) 3/8" x 6" Bolt (59)
1 1/2" x 2 1/2” Inner Cap (83) 2 1/2" Square Inner Cap (76) 2" Square Inner Cap (28) 2” Round Inner Cap (78) 1 1/2" Square Inner Cap (35) 3” Round Inner Cap (78)
PART LIST—Model No. PFSY59001 R0402A Key No. Qty. Description Key No. Qty.
86 29 68 68 39 96 24 60 49 49 25 77 101 68 59 25 58 25 24 77 43 54 78 36 50 58 65 64 24 36 12 65 36 8 49 91 25 24 44 48 24 83 80 50 86 50 49 25 47 83 62 50 13 50 40 35 24 23 101 50 49 49 24 60 43 25 102 90 23 25 92 6 25 50 50 20 78 7 102 48 24 24 50 102 47 48 48 50 50 50 50 75 2 66 87 62 76 89 50 48 92 48 25 22 24 24 48 50 45 22 69 89 24 25 34 65 82 50 45 24 9 54 93 50 50 24 50 102 75
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 (PFSY59001) 2. The NAME of the product (PROFORM® 960 weight system) 3. The SERIAL NUMBER of the product (see the front cover of this manual) 4.