Weider WESY49201 User Manual

QUESTIONS?

As a manufacturer, we are committed to providing complete customer satisfaction. If you have questions, or find that there are missing or damaged parts, we will guarantee you complete satisfaction through direct assistance from our factory.

TO AVOID UNNECESSARY DELAYS, PLEASE CALL DIRECT TO OUR TOLL-FREE CUSTOMER HOT LINE. The trained technicians on our customer hot line will provide immediate assistance, free of charge to you.

CUSTOMER HOT LINE:

1-800-999-3756

Mon.–Fri., 6 a.m.–6 p.m. MST

Model No. WESY49201 Serial No.

Write the serial number in the space above for reference.

CAUTION

Read all precautions and instructions in this manual before using this equipment. Save this manual for future reference.

USER'S MANUAL

Serial Number Decal (Under Seat)

TABLE OF CONTENTS

IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . .24

TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . .25

CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . .Back Cover

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

Note: A P AR T IDENTIFICATION CHART and a PART LIST/ EXPLODED DRAWING are attached in the center of this manual.

1. Read all instructions in this manual and in the accompanying literature before using the weight system.

2. It is the responsibility of the owner to ensure that all users of the weight system are adequately informed of all precautions.

3. The weight system is intended for home use only. Do not use the weight system in any commercial, rental, or institutional setting.

4. Use the weight system only on a level surface. Cover the floor beneath the weight system to protect the floor.

5. Make sure all parts are properly tightened each time you use the weight system. Replace any worn parts immediately.

6. Keep children under 12 and pets away from the weight system at all times.

7. Keep hands and feet away from moving parts.

8. Always wear athletic shoes for foot protection.

9. The weight system is designed to support a a maximum user weight of 250 pounds.

10. Always stand on the foot plate when performing an exercise that could cause the weight system to tip.

11. Always disconnect the lat bar from the

weight system when performing an exercise that does not use the lat bar.

12. Make sure that the cables remain on the pulleys 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.

13. Never release the press arm, butterfly arms, military press arm, leg lever, leg press plate, lat bar or nylon strap when weights are raised. The weights will fall with great force.

14. Keep your hands away from the assist upright when the assist arm is being used. Your hand could become pinched between the assist upright and the assist arm.

15. Keep your hands away from the leg press upright when the military press arm is being used. Your hand could become pinched between the leg press upright and the military press arm.

16. Always be sure that your body weight is fully supported by the dip arms or the pull-up arms before kneeling on the assist arm. The assist arm can drop quickly when your body weight is placed on it.

17. If you feel pain or dizziness at any time while exercising, stop immediately and begin cooling down.

18. The decals shown below have been placed

on the weight system in the locations shown on page 3. If a decal is missing or illegible, call our toll-free Customer Hot Line at

1-800-999-3756 and order a free replacement decal. Apply the decal in the location shown.

WARNING:To reduce the risk of serious injury, read the following important precau-

tions before using the weight system.

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.

Keep hands and fingers clear of this area.

• Keep clear of this area.

IMPORTANT PRECAUTIONS

Warning Decal 2

Warning Decal 1

Warning Decal 3

BEFORE YOU BEGIN

ASSEMBLED DIMENSIONS: Height: 78 in. Width: 86 in. Length: 66 in.

Foot Plate

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Assist Arm

Press Arm

Weight Stacks

Backrests

Dip Handles

Pull-up Handles

Warning Decal 1

Warning Decal 3

Warning Decal 2

Leg Press

Plate

Thank you for selecting the versatile CLUB WEIDER

16.6ST weight system. The CLUB WEIDER®16.6ST 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 CLUB WEIDER

16.6ST will help you to

achieve the specific results you want.

For your benefit, read this manual carefully before using the weight 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 WESY49201. The serial number can be found on a decal attached to the weight system (see the front cover of this manual).

Before reading further, please review the drawing below and familiarize yourself with the parts that are labeled.

Weight Pin

Low Pulley

Station

Military Press Arm

ASSEMBLY

1. Before beginning assembly, be sure that

you have read and understand the information in the box above.

Locate and open the parts bag labeled “FRAME ASSEMBLY.”

Press two 2” Square Outer Caps (51) onto the Stabilizer (5). Press a 2” Square Inner Cap (27) into the Base (4).

Insert six 5/16” x 2 1/2” Carriage Bolts (1) up through the Stabilizer (5). Insert two 5/16” x 2 1/2” Carriage Bolts up through the Base (4).

Attach the Base (4) to the Stabilizer (5) with two 5/16” x 2 3/4” Bolts (1 1), two 5/16” Washers (8), and two 5/16” Nylon Locknuts (3). Do not tighten the Nylon Locknuts yet.

FRAME ASSEMBLY

Before beginning assembly, carefully read the following information and instructions:

• Place all parts of the weight system in a cleared

area and remove the packing materials; do not dispose of the packing materials until assembly is completed.

• The assembly is broken into four stages: 1) frame assembly, 2) arm assembly, 3) cable assembly, and 4) seat and backrest assembly. The hardware for each stage is packaged separately.

• Wait until you begin each assembly stage to open the parts bag labeled for that assembly stage.

• For help identifying the small parts used in assembly, use the PART IDENTIFICATION

CHART located in the center of this manual.

Note: Some small parts may have been preattached for shipping. If a part is not in the parts bag, check to see if it has been pre-attached.

• As you assemble the weight system be sure that all parts are oriented as shown in the drawings.

• Tighten all parts as you assemble them, unless instructed to do otherwise.

THE FOLLOWING TOOLS (NOT INCLUDED) ARE REQUIRED FOR ASSEMBLY:

• Two (2) adjustable wrenches

• One (1) standard screwdriver

• One (1) phillips screwdriver

• One (1) rubber mallet

• Lubricant, such as grease or petroleum jelly, and soapy water will also be needed.

Assembly will be more convenient if you have the following tools: A socket set, a set of open-end or closed-end wrenches, or a set of ratchet wrenches.

2. Slide the Assist Upright (74) and the Leg Press Upright (56) onto the indicated 5/16” x 2 1/2” Carriage Bolts (1) in the Stabilizer (5).

The high side of the brackets on the Assist Upright and Leg Press Upright should be on the side shown. Hand-tighten four 5/16”

Nylon Locknuts (3) onto the Carriage Bolts.

Do not tighten the Nylon Locknuts yet.

Press a 2” Square Inner Cap (27) into the Leg Press Upright (56). Press a 2” Square Inner Cap into the Assist Upright (74).

Attach the Rubber Bumper (91) to the Leg Press Upright (56) with the #8 x 1/2” Self-tapping Screw (87).

3. Slide the Front Upright (42) onto the 5/16” x 2 1/2” Carriage Bolts (1) in the Base (4). Hand-tighten a 5/16” Nylon Locknut (3) onto each Carriage Bolt. Do not tighten the

Nylon Locknuts yet.

Press a 1” Square Inner Cap (6) into the Front Upright (42).

High Sides of Brackets

FRAME ASSEMBLY

4. Press a 2” Square Inner Cap (27) into the end of the Top Frame (55). Press a 1 3/4” Square Inner Cap (44) into each end of the crossbar on the Top Frame. Press two 1” Inner Caps (113) into the top of the crossbar.

Attach the Top Frame (55) to the Assist Upright (74) and the Leg Press Upright (56) with two 5/16” x 2 3/4” Bolts (11) and two 5/16” Nylon Locknuts (3).

Attach the Top Frame (55) to the Front Upright (42) with two 5/16” x 2 3/4” Bolts (11), two 5/16” Washers (8), and two 5/16” Nylon Locknuts (3).

5. Slide the Rear Seat Frame (100) onto the indicated 5/16” x 2 1/2” Carriage Bolts (1) in the Stabilizer (5). Hand-tighten two 5/16” Nylon Locknuts (3) onto the Carriage Bolts.

Do not tighten the Nylon Locknuts yet.

Attach the other end of the Rear Seat Frame (100) to the Leg Press Upright (56) with two 5/16” x 2 3/4” Bolts (11), two 5/16” Washers (8), and two 5/16” Nylon Locknuts (3).

Attach the Handle (82) to the Rear Seat Frame (100) with two 5/16” x 2 1/2” Carriage Bolts (1) and two 5/16” Nylon Locknuts (3).

Tighten all Nylon Locknuts used in steps 1–5.

6. Set two Weight Bumpers (19) on the bracket on the Base (4) as shown. Set two Weight Bumpers (19) on the bracket on the Stabilizer (5).

Stack ten Weights (25) onto the bracket on the Stabilizer (5). Stack eight Weights onto the bracket on the Base (4). Be sure that the

pin grooves are all on the same side of each stack of Weights.

Be careful not to tip either stack of Weights (25) until step 8 is complete.

113

Crossbar

100

Bracket

4—Bracket

FRAME ASSEMBLY

Grooves

7. Press a Weight Tube Bumper (64) into the end of the Short Weight Tube (108). Insert the Weight Tube into the front stack of Weights (25). Be sure that the pin on the Weight

Tube is sitting in the pin groove in the top Weight.

Lubricate the inside of the holes in a Top Weight (65). Set the Top Weight onto the front stack of Weights (25). Insert both Long Weight Guides (62) into the stack of Weights.

Be sure that the holes in the Weight Guides are at the top, as shown.

8. Press a Weight Tube Bumper (64) into the end of the Long Weight Tube (63). Insert the Weight Tube into the rear stack of Weights (25). Be sure that the pin on the Weight

Tube is sitting in the pin groove in the top Weight.

Lubricate the inside of the holes in the other Top Weight (65). Set the Top Weight onto the rear stack of Weights (25). Insert both Short Weight Guides (73) into the stack of Weights.

Be sure that the holes in the Weight Guides are at the top, as shown.

Holes

Lubricate

Pin 108

Pin Groove

Holes

Lubricate

Pin Groove

FRAME ASSEMBLY

9. Attach the upper ends of the Short Weight Guides (73) to the Top Frame (55) with a 5/16” x 6” Bolt (60), two 1/2” x 3/4” Spacers (61), and a 5/16” Nylon Locknut (3).

Attach the upper ends of the Long Weight Guides (62) to the Top Frame (55) in the same manner.

10. Locate and open the parts bag labeled

“ARM ASSEMBLY.”

Make sure there is a Bushing (98) in each side of the Stabilizer (5). Press a 2” Square Inner Cap (27) into each end of the Leg Press Arm (96).

Lubricate a 3/8” x 3 1/4” Bolt (67). Attach the Leg Press Arm (96) to the Stabilizer (5) with the Bolt and a 3/8” Nylon Locknut (21). Do not over-

tighten the Nylon Locknut; the Leg Press Arm must be able to pivot freely .

Align the welded tubes on the Leg Press Plate (95) with a set of holes in the Leg Press Arm (96). Attach the Leg Press Plate to the Leg Press Arm with the Press Pin (97).

11. Press a 1” x 7/8” Plastic Bushing (90) onto each welded spacer on the Press Frame (17). Slide the Press Frame into place onto the Base (4). Note: This will be a tight fit; the Plastic

Bushings should fit snuggley over the ends of the indicated tube in the Base. Make sure that the pulleys are on the side shown.

Lubricate the 3/8” x 8” Bolt (59). Attach the Press Frame (17) to the Base (4) with the Bolt and a 3/8” Nylon Locknut (21).

Pulleys

must be on

this side

Lubricate

Welded Spacers

Tube

FRAME ASSEMBLYARM ASSEMBLY

27 Welded

Tube

Lubricate

12. Press a 1” Round Inner Cap (49) into one of the Press Arms (46). Press a 1 3/4” Square Inner Cap (44) into the Press Arm.

Attach the Press Arm (46) to one side of the Press Frame (17) with two 5/16” x 2 1/2” Bolts (22) and two 5/16” Nylon Locknuts (3).

Assemble the other Press Arm (46) in the same manner.

13. Identify the Right Arm (48) and the Left Arm (47). Note the position of the welded bracket on each Arm. Arm identification is very

important for step 14.

Attach a “V”-Pulley (50) and a Long Cable Trap (31) to the Right Arm (48) with a 3/8” x 2 1/2” Bolt (86) and a 3/8” Nylon Locknut (21).

Do not tighten the Nylon Locknut yet.

Attach a “V”-Pulley (50) and a Long Cable Trap (31) to the Left Arm (47) in the same manner.

14. Lubricate both axles on the Top Frame (55). Slide the Right Arm (48) onto the right axle.

Note: Be careful not to confuse the Right Arm with the Left Arm (47); refer to step 13 to identify the Right Arm. Be sure that the upper end of the Right Arm is behind the indicated bracket on the Top Frame (55).

Tap two 1” Retainers (69) and a 1” Round Cover Cap (70) onto the axle. Be sure that

the teeth on the Retainers bend toward the Round Cover Cap, as shown in the inset drawing.

Attach the Left Arm (47) in the same manner. Press 1 3/4” Square Inner Caps (44) into the

lower ends of the Right and Left Arms (47,

48). Wet the lower end of each Arm with soapy water. Slide a 10” Pad (45) onto the lower end of each Arm.

Welded

Brackets

ARM ASSEMBLY

Bracket

Lubricate Axle

Axle

15. See the inset drawing. Attach the Military Press Arm (84) to the Pivot Arm (101) with two 5/16” x 2 1/4” Bolts (33) and two 5/16” Nylon Locknuts (3).

Press two 1 1/2” Square Inner Caps (32) into the Military Press Arm (84). Press two 1” Round Inner Caps (49) into the Military Press Arm.

Attach the Pivot Arm (101) to the Assist Upright (74) with a 3/8” x 3 1/4” Bolt (67) and a 3/8” Nylon Locknut (21).

16. Press two 1” x 2” Inner Caps (107) into the Assist Arm (105).

Attach the Assist Arm (105) to the Leg Press Upright (56) with a 3/8” x 6” Bolt (106), two 3/8” Washers (9), and a 3/8” Nylon Locknut (21). See the inset drawing. The Assist

Arm must be attached to the lowest hole in the Leg Press Upright (56). The Assist Arm must also be below the welded bracket on the Assist Upright (74).

101

5674

ARM ASSEMBLY

107

106

105

Bracket

17. Attach the Left Pull-up Arm (75) and the Right Pull-up Arm (77) to the Assist Upright (74) with two 5/16” x 2 3/4” Bolts (11) and two 5/16” Nylon Locknuts (3).

Attach the Left Dip Arm (78) and the Right Dip Arm (79) to the Assist Upright (74) with two 5/16” x 2 3/4” Bolts (11) and two 5/16” Nylon Locknuts (3).

Wet the end of the Left Pull-up Arm (75) with soapy water. Slide a Long Handgrip (80) onto the Left Pull-up Arm.

Slide a Long Handgrip (80) onto the Right Pull-up Arm (77), onto the Left Dip Arm (78), and onto the Right Dip Arm (79) in the same manner.

Press two 1 1/4” Round Inner Caps (109) into the Left Pull-up Arm (75) and into the Right Pull-up Arm (77).

Press a 1 1/4” Round Inner Cap (109) into the Left Dip Arm (78), and into the Right Dip Arm (79).

18. Locate and open the parts bags labeled

“CABLE ASSEMBLY” and “PULLEYS.”

During steps 19 through 39, refer to the CABLE DIAGRAMS on pages 26–27 of this manual to verify proper cable routing. Before beginning this section, fully unwind the four Cables. Identify the four Cables by comparing the lengths and ends of the Cables. The approximate length of each Cable 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.

19. Locate the High Cable (58). Wrap the High Cable around a 3 1/2” Pulley (15). Attach the Pulley to the Top Frame (55) with a 3/8” x 3 3/4” Bolt (88) and a 3/8” Nylon Locknut (21).

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 hook.

Ball

Hook

23—75.5”

58—148”

72—190”

99—64”

ARM ASSEMBLYCABLE ASSEMBLY

109

+ 24 hidden pages