Club Weider 16.6ST WESY49200 User manual

QUESTIONS?
As a manufacturer, we are com-
mitted 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 assis-
tance from our factory.
TO AVOID UNNECESSARY
DELAYS, PLEASE CALL DIRECT
TO OUR TOLL-FREE CUSTOMER
HOT LINE. The trained techni-
cians on our customer hot line
will provide immediate assis-
tance, free of charge to you.
CUSTOMER HOT LINE:
1-800-999-3756
Mon.ÐFri., 6 a.m.Ð6 p.m. MST
Model No. WESY49200
Serial No.
Write the serial number in the space
above for reference.
CAUTION
Read all precautions and instruc-
tions in this manual before using
this equipment. Save this manu-
al for future reference.
USER'S MANUAL
Serial Number Decal (Under Seat)
TABLE OF CONTENTS
IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HOW TO USE THE HOME GYM SYSTEM . . . . . . . . . . . . . . . . . .22
WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . .24
TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . .25
CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . .Back Cover
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
Note: A PART IDENTIFICATION CHART and a PART LIST/
EXPLODED DRAWING are attached in the center of this manual.

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. Use the home gym system only on a level
surface. Cover the floor beneath the home
gym system for protection.
4. 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.
5. Keep small children and pets away from the
home gym system at all times.
6. 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.
7. Keep hands and feet away from moving parts.
Always wear athletic shoes for foot protection.
8. Always stand on a foot plate when perform-
ing an exercise that could cause the home
gym system to tip.
9. 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 mili-
tary press arm.
10. If you feel pain or dizziness at any time while
exercising, stop immediately and begin cool-
ing down.
11. 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.
12. Make sure that the cables remain on the pul-
leys 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. Always disconnect the lat bar from the home
gym system when performing an exercise
that does not use the lat bar.
14. Inspect and tighten all parts often. Replace
any worn parts immediately.
15. The decals shown below have been placed
on the home gym system. If a decal is miss-
ing 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.
2
WARNING: To reduce the risk of serious injury, read the following important precau-
tions 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.
Keep hands and
fingers clear of
this area.
¥ Keep clear of
this area.
IMPORTANT PRECAUTIONS
Warning Decal 2
Warning Decal 1
Warning Decal 3

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 1
Warning Decal 3
Warning Decal 2
Leg Press
Plate
Thank you for selecting the versatile CLUB WEIDER¨
16.6ST home gym 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 cardiovas-
cular 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 home gym 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 WESY49200. 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 familiarize yourself with the parts that are
labeled.
Weight Pin
Low Pulley
Station
Military Press Arm

4
ASSEMBLY
1
8
11
51
27
1
4
3
1
51
5
1. Before beginning assembly, be sure that
you have read and understand the infor-
mation in the box above.
Locate and open the parts bag labeled
ÒFRAME ASSEMBLY.Ó
Press two 2Ó Square Outer Caps (51) onto
the Stabilizer (5). Press a 2Ó Square Inner
Cap (27) into the Base (4).
Insert six 5/16Ó x 2 1/2Ó Carriage Bolts (1) up
through the Stabilizer (5). Insert two 5/16Ó x
2 1/2Ó Carriage Bolts up through the Base
(4).
Attach the Base (4) to the Stabilizer (5) with
two 5/16Ó x 2 3/4Ó Bolts (11), two 5/16Ó Flat
Washers (8), and two 5/16Ó 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 and pulley
assembly, and 4) seat and backrest assembly.
The hardware for each stage is packaged sepa-
rately.
¥ 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 pre-
attached 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.
1

5
2. Slide the Assist Upright (74) and the Leg
Press Upright (56) onto the indicated 5/16Ó x
2 1/2Ó 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 5/16Ó
Nylon Locknuts (3) onto the Carriage Bolts.
Do not tighten the Nylon Locknuts yet.
Press a 2Ó Square Inner Caps (27) into the
Leg Press Upright (56). Press a 2Ó Square
Inner Cap into the Assist Upright (74).
Attach the Rubber Bumper (91) to the Leg
Press Upright (56) with the #8 x 1/2Ó Self-tap-
ping Screw (87).
3. Slide the Front Upright (42) onto the 5/16Ó x
2 1/2Ó Carriage Bolts (1) in the Base (4).
Hand-tighten a 5/16Ó Nylon Locknut (3) onto
each Carriage Bolt. Do not tighten the
Nylon Locknuts yet.
Press a 1Ó Square Inner Cap (6) into the
Front Upright (42).
2
27
27
1
1
56
74
3
5
High Sides
of Brackets
3
FRAME ASSEMBLY
42
6
4
1
3
87
91

6
4. Press a 2Ó Square Inner Cap (27) into the end
of the Top Frame (55). Press a 1 3/4Ó Square
Inner Cap (44) into each end of the crossbar
on the Top Frame. Press two 1Ó 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 5/16Ó x 2 3/4Ó Bolts (11) and two
5/16Ó Nylon Locknuts (3).
Attach the Top Frame (55) to the Front
Upright (42) with two 5/16Ó x 2 3/4Ó Bolts (11),
two 5/16Ó Flat Washers (8), and two 5/16Ó
Nylon Locknuts (3).
5. Slide the Rear Seat Frame (100) onto the
indicated 5/16Ó x 2 1/2Ó Carriage Bolts (1) in
the Stabilizer (5). Hand-tighten two 5/16Ó
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
5/16Ó x 2 3/4Ó Bolts (11), two 5/16Ó Flat
Washers (8), and two 5/16Ó Nylon Locknuts
(3).
Attach the Handle (82) to the Rear Seat
Frame (100) with two 5/16Ó x 2 1/2Ó Carriage
Bolts (1) and two 5/16Ó Nylon Locknuts (3).
Tighten all Nylon Locknuts used in steps
1Ð5.
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.
4
27
55
3
3
8
113
44
44
11
11
56 42
Crossbar
51
1
11
82
100
5
56
8
3
3
3
25
25
19
19
5ÑBracket
4ÑBracket
FRAME ASSEMBLY
74
Pin
Grooves
6
Pin
Grooves

7
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 grooves 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 grooves 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.
7Holes
Lubricate
62
65
Pin
108
64
Pin Grooves
Holes
Lubricate
73
65
Pin
63
64
Pin Grooves
25
25
8
FRAME ASSEMBLY

8
9. Attach the upper ends of the Short Weight
Guides (73) to the Top Frame (55) with a 5/16Ó
x 6Ó Bolt (60), two 1/2Ó x 3/4Ó Spacers (61), and
a 5/16Ó 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
ÒARM ASSEMBLY.Ó
Be sure there is a Bushing (98) in each side of
the Stabilizer (5). Press a 2Ó Square Inner Cap
(27) into each end of the Leg Press Arm (96).
Lubricate a 3/8Ó x 3 1/4Ó Bolt (67). Attach the
Leg Press Arm (96) to the Stabilizer (5) with the
Bolt and a 3/8Ó 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 one 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 1Ó x 7/8Ó 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 on each end of the indi-
cated tube in the Base. Make sure that the
pulleys are on the side shown.
Lubricate the 3/8Ó x 8Ó Bolt (59). Attach the
Press Frame (17) to the Base (4) with the Bolt
and a 3/8Ó Nylon Locknut (21).
11 17 Pulleys
must be on
this side
59ÑLubricate
Welded Spacers
21
4
Tube 90
9
10
FRAME ASSEMBLY
ARM ASSEMBLY
61 61
3
3
60
73
62
55
27
Welded
Tube
27
96 21
67ÑLubricate
97
5
98
95
60

9
12. Press a 1Ó Round Inner Cap (49) into one of
the Press Arms (46). Press a 1 3/4Ó Square
Inner Cap (44) into the Press Arm.
Attach the Press Arm (46) to one side of the
Press Frame (17) with two 5/16Ó x 2 1/2Ó Bolts
(22) and two 5/16Ó 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 ÒVÓ-Pulley (50) and a Long Cable
Trap (31) to the Right Arm (48) with a 3/8Ó x
2 1/2Ó Bolt (86) and a 3/8Ó Nylon Locknut (21).
Do not tighten the Nylon Locknut yet.
Attach a ÒVÓ-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 1Ó Retainers (69) and a 1Ó 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 3/4Ó 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 10Ó Pad (45) onto the
lower end of each Arm.
12
13 86
31
31
50
50
21
Welded
Brackets
48
47
ARM ASSEMBLY
44 49
46
46
17
22
3
55 Bracket
Lubricate
Axle
47
69
70
44
45
44
14
69
70
Axle
45
48

10
15. See the inset drawing. Attach the Military
Press Arm (84) to the Pivot Arm (101) with
two 5/16Ó x 2 1/4Ó Bolts (33) and two 5/16Ó
Nylon Locknuts (3).
Press two 1 1/2Ó Square Inner Caps (32) into
the Military Press Arm (84). Press two 1Ó
Round Inner Caps (49) into the Military Press
Arm.
Attach the Pivot Arm (101) to the Assist
Upright (74) with a 3/8Ó x 3 1/4Ó Bolt (67) and
a 3/8Ó Nylon Locknut (21).
16. Press two 1Ó x 2Ó Inner Caps (107) into the
Assist Arm (105).
Attach the Assist Arm (105) to the Leg Press
Upright (56) with a 3/8Ó x 6Ó Bolt (106), two
3/8Ó Flat Washers (9), and a 3/8Ó 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).
15
49
32
84
84
101
101
21
67
5674
33
3
ARM ASSEMBLY
32
16
107
106
105
105
Bracket
56
56
21
9
9
74
74

11
17. Attach the Left Pull-up Arm (75) and the Right
Pull-up Arm (77) to the Assist Upright (74)
with two 5/16Ó x 2 3/4Ó Bolts (11) and two
5/16Ó Nylon Locknuts (3).
Attach the Left Dip Arm (78) and the Right Dip
Arm (79) to the Assist Upright (74) with two
5/16Ó x 2 3/4Ó Bolts (11) and two 5/16Ó 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 1/4Ó Round Inner Caps (109) into
the Left Pull-up Arm (75) and into the Right
Pull-up Arm (77).
Press a 1 1/4Ó 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
ÒCABLE ASSEMBLYÓ and ÒPULLEYS.Ó
During steps 19 through 39, refer to the
CABLE DIAGRAMS on pages 26Ð27 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 (in
inches) 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 1/2Ó Pulley (15). Attach the
Pulley to the Top Frame (55) with a 3/8Ó x
3 3/4Ó Bolt (88) and a 3/8Ó 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.
19
55
21
58
Ball
Hook
17
75 74
78
18
23Ñ75.5Ó
58Ñ148Ó
72Ñ190Ó
99Ñ64Ó
ARM ASSEMBLYCABLE ASSEMBLY
11
109 109
109
109
11
77
80
80
80
80
3
3
3
15
88
109
79

12
20. Wrap the High Cable (58) around a ÒVÓ-Pulley
(50). Attach the ÒVÓ-Pulley and a Long Cable
Trap (31) to the indicated bracket on the Front
Upright (42) with a 3/8Ó x 2 1/2Ó Bolt (86) and
a 3/8Ó Nylon Locknut (21). Be sure that the
Long Cable Trap is positioned to hold the
Cable in place.
21. Route the High Cable (58) around the ÒVÓ-
Pulley (50) on the Left Arm (47). Be sure that
the Cable is in the groove of the Pulley
and that the Long Cable Trap (31) is posi-
tioned to hold the Cable in place. Tighten
the 3/8Ó x 2 1/2Ó Bolt (86) and the 3/8Ó Nylon
Locknut (not shown).
22. Route the High Cable (58) around the ÒVÓ-
Pulley (50) on the Right Arm (48). Be sure
that the Cable is in the groove of the ÒVÓ-
Pulley and that the Long Cable Trap (31) is
turned to hold the Cable in place. Tighten
the 3/8Ó x 2 1/2Ó Bolt (86) and the 3/8Ó Nylon
Locknut (not shown).
23. Attach the Pulley Bracket (20) to the Top
Frame (55) with the 5/16Ó x 5Ó Bolt (68) and a
5/16Ó Nylon Locknut (3). Do not overtighten
the Nylon Locknut; the Pulley Bracket
must be able to move freely.
See the inset drawing. Route the High Cable
(58) around the 3 1/2Ó Pulley (15) attached to
the Pulley Bracket (20). Tighten the 3/8Ó x 2Ó
Bolt (12) and a 3/8Ó Nylon Locknut (not
shown). 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.
23
20 86
86
31
31
50
50
21
58
58
21
22
CABLE ASSEMBLY
42
47
86
31 50
58
20
68
3
55
48
Bracket
58
15
66
12

13
24. See the inset drawing. Attach a 3 1/2Ó Pulley
(15) and a Cable Trap (66) to the upper hole in
a Long ÒUÓ-Bracket (57) with a 3/8Ó x 2Ó Bolt
(12) and a 3/8Ó Nylon Locknut (21). Be sure
that the Cable Trap is inside the Long ÒUÓ-
Bracket. Note: This may come pre-assem-
bled.
Route the High Cable (58) through the Long
ÒUÓ-Bracket (57) and the 3 1/2Ó Pulley (15)
shown in the inset drawing. Be sure that the
Cable is in the groove of the Pulley and that
the Cable and Pulley move smoothly.
25. Wrap the High Cable (58) around a 3 1/2Ó
Pulley (15). Attach the Pulley to the bracket on
the Top Frame (55) with a 3/8Ó x 2Ó Bolt (12)
and a 3/8Ó Nylon Locknut (21). Be sure that
the Cable is in the groove of the Pulley and
that the Cable and Pulley move smoothly.
26. Note: This assembly step shows how to
complete the assembly of several pre-
attached parts.
The 5/8Ó x 9/16Ó Spacer (7) has been pre-
attached on the outside of the 3 1/2Ó Low
Pulley (102) for shipping purposes. Remove
the 3/8Ó Nylon Locknut (21), the Spacer, and
the Pulley from the 3/8Ó x 3 3/4Ó Bolt (88). Do
not remove the Bolt. The Bolt has been
shown removed for part identification.
Reattach the 3 1/2Ó Low Pulley (102), with the
5/8Ó x 9/16Ó Spacer (7) between the Pulley and
the Press Frame (17). Do not tighten the 3/8Ó
Nylon Locknut (21) yet. Be sure that the
3/8Ó x 3 3/4Ó Bolt (88), the 3/8Ó Flat Washer
(9), the 5/8Ó x 9/16Ó Spacer (7), the 3 1/2Ó
Low Pulley (102), and the 3/8Ó Nylon
Locknut (21) are oriented as shown.
24
58
15
15
66
21
12
57
Bracket
55
21
12
15
58
25
26
CABLE ASSEMBLY
58
57
21
17 102
7
988

14
27. Locate the Low Cable (23). Route the Low
Cable under the 3 1/2Ó Low Pulley (102). Be
sure that the end of the Cable with the ball
is on the indicated side of the Press Frame
(17) and that the Cable is between the
Pulley and the crossbar on the Press
Frame. Tighten the 3/8Ó Nylon Locknut (21)
and the 3/8Ó x 3 3/4Ó Bolt (not shown).
28. Route the Low Cable (23) around the 3 1/2Ó
Pulley (15) attached to the lower hole in the
Front Upright (42). See the inset drawing.
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 3/8Ó Nylon Locknut (21)
and the 3/8Ó x 3 3/4Ó Bolt (88).
29. Route the Low Cable (23) around the 3 1/2Ó
Pulley (15) attached to the upper hole in the
Press Frame (17). 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 3/8Ó Nylon
Locknut (21) and the 3/8Ó x 3 1/2Ó Bolt (not
shown).
30. Route the Low Cable (23) around the 3 1/2Ó
Pulley (15) attached to the upper hole in the
Front Upright (42). See the inset drawing.
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 3/8Ó Nylon Locknut (21)
and the 3/8Ó x 3 3/4Ó Bolt (88).
30
27
23
28
Inset shows view
from other side
29
CABLE ASSEMBLY
21
17
Ball
42
88
23
23
21
15
15
42
66
Inset shows view
from other side
42
88
23
23 15
15
66
42
21
23
17
66
15
102
Crossbar
21

15
31. Attach the end of the Low Cable (23) to the
Long ÒUÓ-Bracket (57) with a 1/4Ó Nylon
Locknut (2) and a 1/4Ó 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 Nylon Locknut, as
shown in the inset drawing.
32. Attach the High Cable (58) to a Small ÒUÓ-
Bracket (71) with a 1/4Ó Nylon Locknut (2) and
a 1/4Ó Flat Washer (10). Do not completely
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 ÒUÓ-Bracket (71) to the Short
Weight Tube (108) with a 5/16Ó x 1 3/4Ó Bolt
(24) and a 5/16Ó Nylon Locknut (3).
33. Locate the Military Press Cable (72). Attach
the Military Press Cable to the other Small
ÒUÓ-Bracket (71) with a 1/4Ó Nylon Locknut (2)
and a 1/4Ó 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 ÒUÓ-Bracket (71) to the Long
Weight Tube (63) with a 5/16Ó x 1 3/4Ó Bolt
(24) and a 5/16Ó Nylon Locknut (3).
33
31
10
58
71
10
32
CABLE ASSEMBLY
57
23
3
24
63
71
10
2
3
72
2
2
10
57
23
58
10
2
71
72
10
2
71
2
24
108

16
34. Wrap the Military Press Cable (72) around a
ÒVÓ-Pulley (50). Attach the ÒVÓ-Pulley to the
Top Frame (55) with a 3/8Ó x 2 1/2Ó Bolt (86)
and a 3/8Ó Nylon Locknut (21).
Wrap the Military Press Cable (72) around a 3
1/2Ó Pulley (15). Attach the Pulley to the indi-
cated bracket on the Assist Arm (105) with a
3/8Ó x 1 3/4Ó Bolt (76) and a 3/8Ó Nylon
Locknut (21). Be sure that the Cable is
between the Pulley and the Assist Arm and
that the Cable and Pulley move smoothly.
35. Wrap the Military Press Cable (72) around a
ÒVÓ-Pulley (50). Attach the ÒVÓ-Pulley and a
Long Cable Trap (31) to the Assist Upright
(74) with a 3/8Ó x 4 1/2Ó Bolt (112), a 3/8Ó Flat
Washer (9), and a 3/8Ó Nylon Locknut (21).
Be sure that the Long Cable Trap is turned
to hold the Cable in place and that the
Cable is routed around the Pulley as
shown.
Wrap the Military Press Cable (72) around a
3 1/2Ó Pulley (15). Attach the Pulley to the
other bracket on the Assist Arm (105) with a
3/8Ó x 1 3/4Ó Bolt (76) and a 3/8Ó Nylon
Locknut (21). Be sure that the Cable is
between the Pulley and the Assist Arm and
that the Cable and Pulley move smoothly.
34
CABLE ASSEMBLY
Bracket
105
76
50
15
21
21
55
86
72
35
105
9
21
21
74
50
31
15
76
72
Bracket
112

17
36. Slide a 5/16Ó Flat Washer (8) onto a 5/16Ó x
2 3/4Ó Bolt (11). Insert the Bolt through the indi-
cated hole in the Pivot Arm (101). The Bolt
must be inserted from the side shown.
Fully tighten a 5/16Ó Nylon Jam Nut (93) onto
the Bolt.
Wrap the Military Press Cable (72) around a
3 1/2Ó Pulley (15). Attach the Pulley and a
Cable Trap (66) to the Pivot Arm (101) with
the 3/8Ó x 3 3/4Ó Bolt (88), a 3/8Ó Flat Washer
(9), and a 3/8Ó Nylon Locknut (21). Be sure
that the Pulley is on the side shown and
that the Cable Trap is positioned to hold
the Cable in place.
37. See inset drawing A. Attach a 3 1/2Ó Pulley
(15) and a Cable Trap (66) to the upper hole
in a Long ÒUÓ-Bracket (57) with a 3/8Ó x 2Ó
Bolt (12) and a 3/8Ó Nylon Locknut (21). Be
sure that the Cable Trap is inside the Long
ÒUÓ-Bracket. (Note: This may come pre-
assembled.)
Route the Military Press Cable (72) through
the Long ÒUÓ-Bracket (57) and the 3 1/2Ó
Pulley (15). Be sure that the Cable is in the
groove of the Pulley and that the Cable
and Pulley move smoothly.
See inset drawing B. Slide the end of the
Military Press Cable (72) onto the end of the
5/16Ó x 2 3/4 Bolt (11). Thread another 5/16Ó
Nylon Jam Nut (93) onto the Bolt. Do not
fully tighten the second Jam Nut. There
must be room between the two Jam Nuts
for the end of the Cable to pivot.
37
CABLE ASSEMBLY
72
15
21
57
A
B
12
15
66
57
93
72
36
88
11
72
21
66
101
15
9
93
8
11

18
38. Locate the Leg Press Cable (99). Attach the
end of the Leg Press Cable to the Long ÒUÓ-
Bracket (57) with a 1/4Ó Nylon Locknut (2) and
a 1/4Ó Flat Washer (10). Do not completely
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.
Wrap the Leg Press Cable (99) around a
3 1/2Ó Pulley (15). Attach the Pulley to the Leg
Press Upright (56) with the 3/8Ó x 3 3/4Ó Bolt
(88), a 3/8Ó Flat Washer (9), and a 3/8Ó Nylon
Locknut (21). The ball on the Cable must be
on the indicated side of the Pulley. Be sure
that the Cable and Pulley move smoothly
and that the Cable is between the Pulley
and the welded rod.
39. Attach the Press Bracket (94) to the Leg
Press Arm (96) with a 5/16Ó x 3Ó Bolt (111)
and a 5/16Ó Nylon Locknut (3).
Wrap the Leg Press Cable (99) around a 3 1/2Ó
Pulley (15). Attach the Pulley to the Press
Bracket (94) with the 3/8Ó x 2Ó Bolt (12) and a
3/8Ó Nylon Locknut (21).
Slide a 5/16Ó Flat Washer (8) onto a 5/16Ó x
2 3/4Ó Bolt (11). Insert the Bolt through the
lowest hole in the Rear Seat Frame (100)
from the indicated side. (Note: The three
holes are for cable adjustment.) Tighten a
5/16Ó Nylon Jam Nut (93) onto the Bolt. Slide
the end of the Leg Press Cable (99) onto the
end of the Bolt. Thread another 5/16Ó Nylon
Jam Nut onto the Bolt. Do not fully tighten
the second Jam Nut. There must be room
between the two Jam Nuts for the end of
the Cable to pivot.
39
CABLE ASSEMBLY
11
111
96
94
12
21
100
93
8
3
99
15
38
56
57
Ball
9
21
15
2
88
2
10
57
99
99
Welded
Rod
10

19
40. Locate and open the parts bag labeled
ÒSEAT ASSEMBLY.Ó
Insert a 1/4Ó x 2 1/2Ó Carriage Bolt (92)
through the center hole in a Seat Plate (37).
Attach the Seat Plate to the Rear Backrest
(85) with two 1/4Ó x 1/2Ó Screws (18).
Insert the 1/4Ó x 2 1/2Ó Carriage Bolt (92)
through the indicated hole in the Leg Press
Upright (56). Tighten a 1/4Ó Nylon Locknut (2)
with a 1/4Ó Flat Washer (10) onto the Carriage
Bolt. Attach the top of the Rear Backrest (85)
to the Leg Press Upright with a 1/4Ó x 2 1/2Ó
Screw (43) and a 1/4Ó Flat Washer (10).
41. Attach one end of a Seat (13) to the Rear
Seat Frame (100) with two 1/4Ó x 1/2Ó Screws
(18). Attach the other end of the Seat to the
Rear Seat Frame with a 1/4Ó Flat Washer (10)
and a 1/4Ó x 2 1/2Ó Screw (43).
42. Attach the Assist Seat (104) and the Angle
Bracket (110) to the Assist Arm (105) with four
1/4Ó Flat Washers (10) and four 1/4Ó x 2 1/2Ó
Screws (43).
SEAT ASSEMBLY
42
40
41
85
2
10
18 92
56
37
43
18
18
13
10
43
10
10
43
104
105
100
110

20
43. Attach the Front Backrest (41) to the Front
Upright (42) with two 1/4Ó x 2 1/2Ó Screws (43)
and two 1/4Ó Flat Washers (10). The Backrest
must be oriented as shown.
44. Press a 1 1/2Ó Square Inner Cap (32) into the
Front Seat Frame (36).
Insert a 1/4Ó x 2Ó Carriage Bolt (38) through
the center hole in the Seat Plate (37). Attach
the Seat Plate to the Seat (13) with two 1/4Ó x
1/2Ó Screws (18).
Insert the 1/4Ó x 2Ó Carriage Bolt (38) through
the indicated hole in the Front Seat Frame
(36). Tighten a 1/4Ó Nylon Locknut (2) with a
1/4Ó Flat Washer (10) onto the Carriage Bolt.
Attach the other end of the Seat (13) to the
Front Seat Frame (36) with a 1/4Ó Flat Washer
(10) and a 1/4Ó x 2Ó Machine Screw (81).
45. Press a 1 1/2Ó Square Inner Cap (32) into the
Leg Lever (29).
Lubricate the 5/16Ó x 2 1/4Ó Bolt (33). Attach
the Leg Lever (29) to the Front Seat Frame
(36) with the Bolt and a 5/16Ó Nylon Locknut
(3).
Insert the 5/16Ó x 2Ó Eyebolt (35) into the Leg
Lever (29) from the direction shown. Tighten a
5/16Ó Nylon Locknut (3) with a 5/16Ó Flat
Washer (8) onto the Eyebolt.
46. Rest the Front Seat Frame (36) on the indicat-
ed pin in the Front Upright (42). Attach the
Front Seat Frame to the Front Upright with a
5/16Ó x 2 3/4Ó Carriage Bolt (14) and the Seat
Knob (40).
SEAT ASSEMBLY
46
43
41
Thick
End
42
44
45
10
13
38
32
36
10
81
37
2
3
8
3
29
LubricateÑ33
35
32
18
43
36
36
42
40
14
Pin