Weslo gym4000 User Manual

Page 1

USER’S MANUAL

QUESTIONS?

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

Please CALL:

Or WRITE: ICON Fitness Lifestyle Ltd. Greenwich House 223 North Street Sheepscar West Yorkshire Leeds LS7 2AA

Model No. WLEMSY82000 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.

If you encounter any difficulties with this product or if you need to order replacement parts, please call or write the ICON Health & Fitness, Ltd. office.

ICON Health & Fitness, Ltd. Greenwich House 223 North Street Sheepscar Leeds LS7 2AA West Yorkshire

Tel: Country Code:

Fax: 0113-2411120 When calling or writing, please provide the following information:

1. The MODEL NUMBER of the product (WLEMSY82000)

2. The NAME of the product (WESLO

GYM 4000)

3. The SERIAL NUMBER of the product (see the front cover of this manual)

4. The KEY NUMBER and DESCRIPTION of the part(s) (see the PARTLIST and EXPLODED DRAWING attached in the centre of this manual).

Serial Number Decal

How To Order Replacement Parts

Visit our website at

www.weslo.com

new products, prizes,

fitness tips, and much more!

0345-089009

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192

IMPORTANTPRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

CABLE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

HOW TO ORDER REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

Note: An EXPLODED DRAWING/PART LIST and a PART IDENTIFICATION CHARTare attached in the centre of this manual. Remove the EXPLODED DRAWING/PART LIST and the PARTIDENTIFICATION CHART before beginning assembly.

WESLO is a registered trademark of ICON Health & Fitness, Inc.

The cable diagram below shows the proper routing of the Short Cable (58) and the Long Cable (23). Use the diagram to be sure that the two cables and the cable traps have been assembled correctly. If the cables have not been correctly routed, the home gym system will not function properly and damage may occur. The numbers show the correct route for each cable. The starting and ending points of each cable are labelled. Be sure that

the cable traps do not touch or bind the cables.

Weight Stack—8

1—Low Pulley

1—High Pulley

Long Cable (23)

7—Long “U”-Bracket

Short Cable (58)

Table of Contents Cable Diagram

Page 3

1. It is the responsibility of the owner to ensure that all users of the home gym system are adequately informed of all precautions.

2. Read all instructions in this manual and in the accompanying literature before using the home gym system.

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

4. Use the home gym system only on a level surface. Cover the floor or carpet beneath the home gym system for protection.

5. Inspect and tighten all parts often. Replace any worn parts immediately.

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

7. The home gym system is designed to be

used by only one person at a time.

8. Keep hands and feet away from moving parts.

9. Always wear athletic shoes for foot protection.

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

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

12. Make sure that the cables remain on the pulleys at all times. If the cables bind whilst you are exercising, stop immediately and make sure that the cables are on all of the pulleys.

13. Always disconnect the lat bar from the home gym system when performing an exercise that does not use the lat bar.

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

15. The decal shown below has been placed on the home gym system. If the decal is missing or illegible, please call our Customer Service Department at 0345-089009 to order a free replacement decal. Apply the decal in the location shown.

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

before using the home gym 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.

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

Woven cable, the type of cable used on the home gym 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. Slack can be removed from the cables by tightening the 1/4” Nylon Locknuts (2) at the end of the Long Cable (23) (see drawing 1) and at the end of the Short 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 lifted off the weight stack.

Additional slack can be removed by moving the 3 1/2” Pulley (15) to the other hole in the Long “U”-Bracket (57). 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.

Note: If a cable tends to slip off the pulleys often, the cable may have become twisted. Remove the cable and re-install it.

If the cables need to be replaced, see ORDERING REPLACEMENT PARTS on the back cover of this manual.

Important PrecautionsTrouble-shooting and Maintenance

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174

ASSEMBLED DIMENSIONS: Height: 193 cm Width: 97 cm Length: 150 cm

Leg Press Plate

Low Pulley Station

Foot Plate

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Press Arm

Weight Stack

Seat

Backrest

Weight Pin

Lat Bar Holder

Thank you for selecting the versatile WESLO®GYM 4000 home gym system. The WESLO®GYM 4000 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 WESLO

GYM 4000 will help you to achieve

the specific results you want.

For your benefit, read this manual carefully before using the home gym system. If you have additional

questions, please call our Customer Service Department at 0345-089009. To help us assist you, please note the product model number and serial number before calling. The model number is WLEMSY82000. The serial number can be found on a decal attached to the home gym system (see the front cover of this manual).

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

ADJUSTING AND REMOVING THE LEG PRESS PLATE AND ADJUSTMENT TUBE

To adjust the position of the Leg Press Plate (78), remove the “L”-Pin (40) from the Press Adjustment Tube (79) and the Rocker Arm (32). Align a different set of holes in the Press Adjustment Tube with the set of holes in the Rocker Arm. Re-insert the “L”-Pin.

For some exercises, the Press Adjustment Tube (79) must be removed. Remove the “L”-Pin (40). Lift the Press Adjustment Tube off the bracket on the Rocker Arm (32).

LOCKING THE LEG LEVER

When the low pulley station is in use, the Leg Lever (29) must be locked in place. Insert the “L”-Pin (40) through the hole in the Leg Lever and the hole in the Rocker Arm (32).

PRESS BUTTERFLY LEG HIGH LOW LEG WEIGHT ARM ARM LEVER PULLEY PULLEY PRESS PLATES (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.)

Top 13 9 27 14 32 30

136 2352 305265 257 3281 449397 3 73 46 115 58 121 130 4 99 58 142 69 144 170 5 118 74 171 88 178 215 6 132 88 201 101 217 247 7 151 112 217 114 230 319 8 165 131 264 131 262 347

This chart shows the approximate weight resistance at each station. “Top” refers to the 6.5 lb. top weight. The other numbers refer to the 12.5 lb. weight plates. Weight resistance shown for the butterfly arm station is 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.

Before You Begin

Weight Resistance Chart

Page 5

High Side of

Bracket

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

• Place all parts of the home gym system in a

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

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

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

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

CHART located in the centre 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 home gym 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 spanners

• 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: Asocket set, a set of open-end or closed-end wrenches, or a set of ratchet wrenches.

1. Before beginning assembly, be sure that

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

Press a 2” Square Outer Cap (51) onto each end of the Stabiliser (5). Press a 2” Square Inner Cap (27) into the end of the Base (4).

Insert two 5/16” x 2 3/4” Carriage Bolts (14) up through the Stabiliser (5). Insert four 5/16” x 2 1/2” Carriage Bolts (1) up through the Base (4).

Slide the indicated end of the Base (4) onto the 5/16” x 2 3/4” Carriage Bolts (14) in the Stabiliser (5). Slide the Rear Upright (56) onto the Carriage Bolts. Hand tighten a 5/16” Nylon Locknut (3) onto each Carriage Bolt.

The high side of the bracket on the Rear Upright must be on the side shown. Do not tighten the Nylon Locknuts yet.

FRAME ASSEMBLY

The instructions below describe how each part of the home gym system can be adjusted. IMPORTANT: When attaching the lat bar 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.

Lat Bar Holder

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 vary from the weight setting. Use the WEIGHT RESISTANCE CHART on page 17 to find the approximate amount of resistance at each weight station.

ATTACHING THE LAT BAR OR NYLON STRAP TO THE HIGH PULLEY STATION

Attach the Lat Bar (54) to the Long Cable (23) 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 exercise to be performed.

The Nylon Strap (39) can be attached in the same manner.

ATTACHING THE LAT BAR OR NYLON STRAP TO THE LOW PULLEY STATION

Attach the Lat Bar (54) to the Short Cable (58) with a Cable Clip (53). For some exercises, the Chain (52) should be attached between the Lat Bar and the Pulley Cable with two Cable Clips. Adjust the length

of the Chain between the Lat Bar and the Short Cable so the Lat Bar is in the correct starting position for the exercise to be performed.

The Nylon Strap (39) can be attached in the same manner.

Always remove the leg press plate and lock the leg lever before using the low pulley station (see ADJUSTING AND REMOVING THE LEG PRESS PLATE AND ADJUSTMENT TUBE and LOCKING THE LEG LEVER on page 17).

AssemblyAdjustment

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156

FRAME ASSEMBLY

2. 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.

3. Press a 2” Square Inner Cap (27) into the open 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 (81) into the top of the crossbar.

Attach the Top Frame (55) to the Front Upright (42) and the Rear Upright (56) with four 5/16” x 2 3/4” Bolts (11), four 5/16” Flat Washers (8), and four 5/16” Nylon Locknuts (3).

Tighten all Nylon Locknuts used in steps 1 through 3.

4. Set two Weight Bumpers (19) onto the bracket on the Base (4) as shown.

Stack eight Weights (25) on the Weight Bumpers (19). Be sure that all of the Weights are turned so the pin grooves are on the same side.

Crossbar

Pin Groove

4—Bracket

32. Press a 1 3/4” Square Inner Cap (44) into the Press Adjustment Tube (79).

Align one set of holes in the Press Adjustment Tube (79) with the holes in the Rocker Arm (32). Insert the “L”-Pin (40) through the holes.

Be sure that the Press Adjustment Tube is oriented as shown.

Attach the Press Plate (78) to the Press Adjustment Tube (79) with a 5/16” x 2 1/2” Bolt (22), two 5/16” Flat Washers (8), and a 5/16” Nylon Locknut (3).

33. Press a 3/4” Round Inner Cap (34) into each end of the Short Pad Tube (28). Press a 3/4” Round Inner Cap into each end of the Long Pad Tube (80).

Insert the Short Pad Tube (28) into the Seat Frame (36). Slide a 5 1/2” Pad (30) onto each end of the Short Pad Tube.

Insert the Long Pad Tube (80) into the Leg Lever (29). Slide a 5 1/2” Pad (30) onto each end of the Long Pad Tube.

SEAT ASSEMBLY

Slant must be

turned this way

34. Make sure that all parts have been properly tightened. The use of the remaining parts will be explained in ADJUSTMENT, beginning on page 16 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. See the CABLE DIAGRAM on page 19 of this manual for proper cable routing. If there is any slack in the cables, you will need to remove it by tightening the cables. See TROUBLESHOOTING AND MAINTENANCE on page 18.

Page 7

FRAME ASSEMBLY

ARM ASSEMBLY

5. Press the Weight Tube Bumper (64) into the end of the Weight Tube (63). Insert the Weight Tube into the stack of Weights (25). Be sure that the pins on the Weight Tube are resting in the pin grooves in the upper Weight.

Lubricate the insides of the holes in the Top Weight (76). Set the Top Weight onto the stack of Weights (25).

Insert both Weight Guides (62) into the stack of Weights (25). Be sure that the holes in

the Weight Guides are at the top, as shown.

6. Attach the upper ends of the Weight Guides (62) to the Top Frame (55) with the 5/16” x 6” Bolt (60), two 1/2” x 3/4” Spacers (61), and a 5/16” Nylon Locknut (3).

Be sure that the Pulley Bracket (20) is in front of the Weight Guide (62) as shown.

7. Press a 1” x 7/8” Plastic Bushing (75) onto each welded spacer on the Press Frame (17). Slide the Press Frame into place on the Base (4). Note: This will be a tight fit. The

Plastic Bushings should fit onto each end of the indicated tube in the Base. Be sure that the pulley is on the indicated side.

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

Lubricate

Pins

4—Tube

Welded

Spacers

Lubricate

Pulley

Holes

29. Attach the Long Cable (23) to the Small “U”Bracket (67) with a 1/4” Nylon Locknut (2) and a 1/4” Flat Washer (10). Do not com-

pletely 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.

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).

30. Attach the Backrest (41) to the Front Upright (42) with two 1/4” x 2 1/2” Screws (43) and two 1/4” Flat Washers (10).

31. Insert the 1/4” x 2 1/2” Carriage Bolt (38) into the centre hole in the Seat Plate (37). Attach the Seat Plate to the Seat (13) with two 1/4” x 3/4” Screws (18).

Insert the 1/4” x 2 1/2” Carriage Bolt (38) into the indicated hole in the Seat Frame (36). Tighten a 1/4” Nylon Locknut (2) with a 1/4” Flat Washer (10) onto the Carriage Bolt.

Attach the other end of the Seat (13) to the Seat Frame (36) with a 1/4” Flat Washer (10) and the 1/4” x 2 1/4” Screw (24).

CABLE ASSEMBLYSEAT ASSEMBLY

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138

ARM ASSEMBLY

8. Press a 1 3/4” Square Inner Cap (44) into the top of a Press Arm (46). Wet the handle on the Press Arm with soapy water. Slide a Handgrip (31) onto the handle. Press a 1” Round Inner Cap (49) into the other end of the handle. Attach the Press Arm 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.

9. 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 10.

Attach a “V”-Pulley (6) and a Long Cable Trap (50) to the Right Arm (48) with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21).

Attach a “V”-Pulley (6) and a Long Cable Trap (50) to the Left Arm (47) with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21).

10. 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 9 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 right axle. Be sure

that the teeth on the Retainers bend toward the 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.

Bracket Lubricate Axle

Welded Brackets

26. Note: The 3 1/2” Pulley (15) labelled in this

step is pre-attached. It is shown removed for easy part identification.

Route the Short Cable (58) around the 3 1/2” Pulley (15) attached to the upper hole in the Press Frame (17). Be sure that the Cable is

routed around the Pulley as shown.

Tighten the 3/8” Nylon Locknut (21) and the 3/8” x 3 1/2” Bolt (16).

27. Note: The 3 1/2” Pulley (15) labelled in this

step is pre-attached. It is shown removed for easy part identification.

Route the Short Cable (58) around the 3 1/2” Pulley (15) attached to the upper hole in the Front Upright (42). Be sure that the Cable

Trap (66) is turned to hold the Cable in place and that the Cable is routed around the Pulley as shown. Tighten the 3/8” Nylon

Locknut (21) and the 3/8” x 3 3/4” Bolt (71).

28. Attach the end of the Short Cable (58) to the Long “U”-Bracket (57) 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 so only a couple of threads are showing above the nut, as shown in the inset drawing.

CABLE ASSEMBLY

Page 9

11. Press a 1 3/4” Square Inner Cap (44) into the Seat Frame (36). Attach a Bumper (73) to the Seat Frame with a 1/2” Tap Screw (65).

Slide the Seat Frame (36) onto the 5/16” x 2 1/2” Carriage Bolts (1) in the Base (4). See

the inset drawing. The bracket on the Seat Frame must be behind the Press Frame (17). Hand-tighten a 5/16” Nylon Locknut (3) onto each Carriage Bolt. Do not tighten the Nylon Locknuts until the end of this assembly step.

Attach the Seat Frame (36) to the Front Upright (42) with two 5/16” x 2 3/4” Bolts (11), two 5/16” Flat Washers (8), and two 5/16” Nylon Locknuts (3).

Tighten all Nylon Locknuts used in this step now.

12. Attach a Bumper (73) to the Rocker Arm (32) with a 1/2” Tap Screw (65).

Lubricate a 3/8” x 3 1/4” Bolt (35). Attach the Rocker arm (32) to the Base (4) with the 3/8” x 3 1/4” Bolt and a 3/8” Nylon Locknut (21).

13. Lubricate a 3/8” x 2 1/2” Bolt (7). Attach the Leg Lever (29) to the Rocker Arm (32) with the 3/8” x 2 1/2” Bolt and a 3/8” Nylon Jam Nut (33).

Press a 1 3/4” Square Inner Cap (44) into each end of the Leg Lever (29).

ARM ASSEMBLY

Bracket

7—Lubricate

Lubricate—35

22. Locate the Short Cable (58). Route the Short Cable under the 3 1/2” Low Pulley (77).

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 welded spacer on the Leg Lever (29). Tighten the 3/8” x 3 1/2” Bolt (16) and

the 3/8” Nylon Locknut (not shown).

23. Wrap the Short Cable (58) around a “V”Pulley (6). Attach the Pulley and a Long Cable Trap (50) inside the bracket on the Seat Frame (36) with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21). Be sure that

the Cable Trap is turned to hold the Cable in place and that the Cable is routed around the Pulley as shown.

24. Wrap the Short Cable (58) around a 3 1/2” Pulley (15). Attach the Pulley to the Rocker Arm (32) with a 3/8” x 3 1/2” Bolt (16), a 3/8” Flat Washer (9), and a 3/8” Nylon Locknut (21). Be sure that the Cable Trap (66) is

turned to hold the Cable in place and that the Cable is routed around the Pulley as shown.

25. Note: The 3 1/2” Pulley (15) labelled in this step is pre-attached. It is shown removed for easy part identification.

Route the Short Cable (58) around the 3 1/2” Pulley (15) attached to the lower hole in the Front Upright (42). Be sure that the Cable

Trap (66) is turned to hold the Cable in place and that the Cable is routed around the Pulley as shown. Tighten the 3/8” Nylon

Locknut (21) and the 3/8” x 3 3/4” Bolt (71).

CABLE ASSEMBLY

Ball

Welded Spacer

Page 10

14. During steps 15 through 29, refer to the CABLE DIAGRAM on page 19 of this manual to verify proper cable routing. Before beginning this section, identify the Long Cable (23) and the Short Cable (58) by comparing the lengths of the cables.

IMPORTANT: Whilst assembling the cables, do not overtighten the bolts and nuts securing the pulleys. The pulleys must be able to turn freely.

15. Locate the Long Cable (23). Route the Long Cable around the indicated 3 1/2” Pulley (15) attached to the Top Frame (55). 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.

Tighten the 3/8” x 3 3/4” Bolt (71) and the 3/8” Nylon Locknut (not shown).

16. Wrap the Long Cable (23) around a “V”-Pulley (6). Attach the “V”-Pulley and a Long Cable Trap (50) to the indicated bracket on the Front Upright (42) with a 3/8” x 2 1/2” Bolt (7) and a 3/8” Nylon Locknut (21). Be sure that

the Long Cable Trap is positioned to hold the Cable in place.

17. Route the Long Cable (23) around the “V”Pulley (6) on the Left Arm (47). Be sure that

the Cable is in the groove of the Pulley and that the Long Cable Trap (50) is positioned to hold the Cable in place. Tighten

the 3/8” x 2 1/2” Bolt (7) and the 3/8” Nylon Locknut (not shown).

Hook

Ball

CABLE ASSEMBLY

18. Route the Long Cable (23) around the “V”Pulley (6) on the Right Arm (48). Be sure

that the Cable is in the groove of the “V”Pulley and that the Long Cable Trap (50) is turned to hold the Cable in place. Tighten

the 3/8” x 2 1/2” Bolt (7) and the 3/8” Nylon Locknut (not shown).

19. Route the Long Cable (23) around the 3 1/2” Pulley (15) attached to the Pulley Bracket (20). Be sure that the Cable is in the

groove of the Pulley and that the Cable Trap (66) is turned to hold the Cable in place. Tighten the 3/8” x 2” Bolt (12) and the

3/8” Nylon Locknut (not shown). Be sure that the 5/16” x 5” Bolt (68) is proper-

ly tightened and that the Pulley Bracket (20) can move freely.

20. See the inset drawing. Attach a 3 1/2” Pulley (15) and a Cable Trap (66) to the indicated hole in the Long “U”-Bracket (57) with a 3/8” x 2” Bolt (12) and a 3/8” Nylon Locknut (21). Be

sure that the Cable Trap is inside the “U”Bracket. Note: This may come pre-assembled.

Route the Long Cable (23) around the 3 1/2” Pulley (15) and through the Long “U”-Bracket (57). Be sure that the Cable is in the

groove of the Pulley and that the Cable and Pulley move smoothly.

21. Note: The 3 1/2” Pulley (15) labelled in this step is pre-attached. It is shown removed for easy part identification.

Route the Long Cable (23) around the 3 1/2” Pulley (15) attached to the bracket on the Top Frame (55). Tighten the 3/8” x 2” Bolt (12) and the 3/8” Nylon Locknut (21). Be sure that

the Cable is in the groove of the Pulley and that the Cable and Pulley move smoothly.

CABLE ASSEMBLY

Bracket

Page 11

Please Note: The assembly is divided into four stages: 1) frame assembly, 2) press and butterfly arm assembly, 3) cable and pulley assembly, and 4) seat and backrest assembly. The hardware for each stage is packaged separately. Wait until you begin each assembly stage to open that parts bag.

1" Round Inner Cap (49)

1" Round Cover Cap (70)

3/4" Round Inner Cap (34)

1/2" x 3/4" Spacer (61)

1" Inner Cap (81)

1 3/4" Square Inner Cap (44)

2" Square Inner Cap (27)

2" Square Outer Cap (51)

1" x 7/8" Plastic Bushing (75)

WLEMSY82000 R1000A

REMOVE THIS PART IDENTIFICATION

CHART FROM THE MANUAL

This chart is provided to help you identify the small parts used in assembly. Important: Some parts may have been pre-assembled for shipping purposes. If you cannot find a part in the parts bags, check to see if it has been pre-assembled. The number in parenthesis following each part description refers to the key number

of the part.

Page 12

1/4" Flat Washer (10)

5/16" Flat Washer (8)

1" Retainer (69)

3/8" Flat Washer (9)

1/4" x 2 1/2" Screw (43)

5/16" x 1 3/4" Bolt (72)

3/8" Nylon Locknut (21)

3/8" Nylon Jam Nut (33)

5/16" x 2 1/2" Carriage Bolt (1)

5/16" x 2 3/4" Carriage Bolt (14)

3/8" x 2" Bolt (12)

3/8" x 3 1/2" Bolt (16)

1/4" x 3/4" Screw (18)

5/16" x 2 1/2" Bolt (22)

3/8" x 2 1/2" Bolt (7)

5/16" x 5" Bolt (68)

3/8" x 3 3/4" Bolt (71)

3/8" x 8" Bolt (59)

Cable Clip (53)

5/16" x 6" Bolt (60)

5/16" x 2 3/4" Bolt (11)

1/4" x 2 1/2" Carriage Bolt (38)

1/4" x 2 1/4" Screw (24)

3/8" x 3 1/4" Bolt (35)

5/16" Nylon Locknut (3)

1/4" Nylon Locknut (2)

Page 13

Note: “#” indicates a non-illustrated part. Specifications are subject to change without notice.

Key No. Qty. Description

1 4 5/16” x 2 1/2” Carriage Bolt 2 3 1/4” Nylon Locknut 3 20 5/16” Nylon Locknut 4 1 Base 5 1 Stabiliser 6 4 “V”-Pulley 7 5 3/8” x 2 1/2” Bolt 8 8 5/16” Flat Washer

9 5 3/8” Flat Washer 10 6 1/4” Flat Washer 11 6 5/16” x 2 3/4” Bolt 12 3 3/8” x 2” Bolt 13 1 Seat 14 2 5/16” x 2 3/4” Carriage Bolt 15 8 3 1/2” Pulley 16 3 3/8” x 3 1/2” Bolt 17 1 Press Frame 18 2 1/4” x 3/4” Screw 19 2 Weight Bumper 20 1 Pulley Bracket 21 15 3/8” Nylon Locknut 22 5 5/16” x 2 1/2” Bolt 23 1 Long Cable 24 1 1/4” x 2 1/4” Screw 25 8 Weight 26 1 Weight Pin 27 2 2” Square Inner Cap 28 1 Small Pad Tube 29 1 Leg Lever 30 4 5 1/2” Pad 31 4 Hand Grip 32 1 Rocker Arm 33 1 3/8” Nylon Jam Nut 34 4 3/4” Round Inner Cap 35 1 3/8” x 3 1/4” Bolt 36 1 Seat Frame 37 1 Seat Plate 38 1 1/4” x 2 1/2” Carriage Bolt 39 1 Nylon Strap 40 1 “L”-Pin 41 1 Backrest 42 1 Front Upright

Key No. Qty. Description

43 2 1/4” x 2 1/2” Screw 44 10 1 3/4” Square Inner Cap 45 2 10” Pad 46 2 Press Arm 47 1 Left Arm 48 1 Right Arm 49 2 1” Round Inner Cap 50 4 Long Cable Trap 51 2 2” Square Outer Cap 52 1 Chain 53 3 Cable Clip 54 1 Lat Bar 55 1 Top Frame 56 1 Rear Upright 57 1 Long “U”-Bracket 58 1 Short Cable 59 1 3/8” x 8” Bolt 60 1 5/16” x 6” Bolt 61 2 1/2” x 3/4” Spacer 62 2 Weight Guide 63 1 Weight Tube 64 1 Weight Tube Bumper 65 2 #8 x 3/4” Tap Screw 66 6 Cable Trap 67 1 Small “U”-Bracket 68 1 5/16” x 5” Bolt 69 4 1” Retainer 70 2 1” Round Cover Cap 71 3 3/8” x 3 3/4” Bolt 72 1 5/16” x 1 3/4” Bolt 73 2 Bumper 74 2 1 1/8” x 2 1/2” Plastic Bushing 75 2 1” x 7/8” Plastic Bushing 76 1 Top Weight 77 1 3 1/2” Low Pulley 78 1 Leg Press Plate 79 1 Press Adjustment Tube 80 1 Long Pad Tube 81 2 1” Inner Cap

# 1 User’s Manual

Part List—Model No. WLEMSY82000

R1000A

REMOVE THIS PART LIST/EXPLODED DRAWING FROM THE MANUAL. SAVE THE PART LIST/EXPLODED DRAWING

FOR FUTURE REFERENCE.

Page 14

6855

Exploded Drawing—Model No. WLEMSY82000

R1000A

Page 15

Weslo gym4000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual