Weider 831159380 User Manual PRO 9645 Manuals And Guides 99020060
WEIDER Weight System Manual 99020060 WEIDER Weight System Owner's Manual, WEIDER Weight System installation guides
User Manual: Weider 831159380 831159380 WEIDER WEIDER PRO 9645 - Manuals and Guides View the owners manual for your WEIDER WEIDER PRO 9645 #831159380. Home:Fitness Equipment Parts:Weider Parts:Weider WEIDER PRO 9645 Manual
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PATE:', _";;_'._HOING
V IDER
USER'S MANUAL
Model No. 831.159380
Serial No.
The serial number can be found in the
location shown below. Write the serial
number in the space above.
Seria{ Numbar Decal
I:"
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1-800-73d-dg7P
SW/ARS
SEARS, ROEBUCK AND CO., HOFFMAN ESTATES, IL 60179
TABLE OF CONTENTS
IMPORTANT PRECAUTIONS
..............................................................
BEFORE YOU BEGIN ...................................................................
ASSEMBLY ..... °...........................................................
HOW TO USE THE HOME GYM SYSTEM ..............................
WEIGHT RESISTANCE CHART ........................................................
TROUBLE-SHOOTING
AND MAINTENANCE
................................................
CABLE DIAGRAMS ....................................................................
ORDERING REPLACEMENT PARTS ................................................
FULL 90 DAY WARRANTY
........................................
_.. ............
2
3
4
22
:..24
25
26
Back Cover
Back Cover
Note: A PART IDENTIFICATION CHART and a PART LIST/EXPLODED DRAWING are attached to the center of
this manual. Remove the PART IDENTIFICATION CHART and the PART LIST/EXPLODED DRAWING before
beginning assembly.
2
BEFORE YOU BEGIN
free HELPLINE at 1-800-736-6879, Monday through
5aturaay, 7 a.m. un_ii 7 p.m. Central Time (excluding
holidays). To help us assist you, please note the product model number and serial number before calling.
The modet number is 831.159380. The serial number
can be found on a decal attached to the WEIOEPP
PRO 9645 (see the front cover of this manual).
Thank you for selecting the versatile WEtDEF_ PRO
9645 Home Gym System. ,'The PRO 96.+5 o,'fe,-sa
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
PRO 9645 will help you to achieve the specific results
you want.
Before reading further, please review the drawing
below and familiadze yourself with the parts that are
labeled.
For your benefit, read this manual carefully before
using the WEIDEFP' PRO 9645 Home Gym System,
tf you have additional questions, please call our toll-
l.at Bar
ASSEMBLED
DIMENSIONS:
Height: 78 in.
Width:
86 in.
Length:
66 in.
High Pulley Station
Pull-up Handles
Butterfly Arms
Press Arm
Dip Handles
_,
Backrests
- Leg Press
Plate
Assist Arm
"Press Arm
Leg Lever
Weight Stacks
Station
J
Foot Plate
Weight Pin
3
ASSEMBLY
Before beginning assembly, carefully read the
following information and Instructions:
• As you assemble the PRO 9645 be sure that all
parts are oriented as shown in the drawings.
• Place all parts of the PRO 9645 in a cleared area
and remove the packing matadals; do not dispose of the packing materials until assembly is
completed.
• Tighten all parts as you assemble them, unless
instructed to do otherwise.
THE FOLLOWING TOOLS (NOT INCLUDED) ARE
REQUIRED FOR ASSEMBLY:
• 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 separately.
• Two (2) adjustable wrenches
• One (1) standard screwdriver
• One (1) phillips screwdriver
• Wait until you begin each assembly stage to open
the parts bag labeled for that assembly stage.
• One (1) rubber mallet
• Lubricant, such as grease or petroleum jelly,
and soapy water will also be needed.
• For help identifying the small parts used in
assembly, use the PART IDENTIFICATION
CHART located in the center of this manual.
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.
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.
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
Cap (27) into the Base (4).
ffl_!?
11
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
51
(4).
I
Attach the Base (4) to the Stabilizer (5) with
two 5/16" x 2 3/4" Bolts (11), two 5/16" Flat
Washers (8), and two 5/16" Nylon Locknuts
(3). Do not tighten the Nylon Locknuts
yet.
4
27
4
2_
Slide the Assist Upright (74) and the Leg
Press Upright (56) onto the indicated 5/16" x
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) onio the Carriage 8oils.
Do not tighten the Nylon Loeknuts yet.
2
74
Afl_ch _he Rubber Bumper (91) to the Leg
Press lJpdght (56) with the #8 x 1/2" Self-tapping Screw (87).
Slide the Front Upright (42) onto the 5/16" x
2 1/2" Cardage 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.
Front Upright (42).
{TfDi_
_<
<
i<'>7
27
n Sides
of _rackets
Press two 2" Square Inner Caps (27) into the
Leg Press Upright (56). Press a 2" Square
Inner Cap into the Assist Upright (74).
3.
.,_--_
+
•
5
Press a 2" Square Inner Cap (27) into the end
of the Top Frame (55). Press a 13/4" Square
Inner Cap (44) into each end of the crossbar
on the Top Frame. Press two 1" Round Inner
Caps (49) into the top of the crossbar.
.
4
11
55
49
44
27
Attach the Top Frame (55) to the Assist
Updght (74) and the Leg Press Upright (56)
with two 5/16" x 2 3/4" Bolts (11) and two
5/16" Nylon Lock,nuts (3).
Crossbar
Attach the Top Frame (55) to the Front
Updght (42) with two 5/16" x 2 3/4" Bolts (11),
two 5/16" Flat Washers (8), and two 5/16"
Nylon Locknuts (3).
.
Slide the Rear Seat Frame (100) onto the
indicated 5/16" x 21/2" 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.
5
100
Attach the other end of the Rear Seat Frame
(100) to the Leg Press Upright (56) with two
5/16" x 23/4" Bolts (11), two 5/16" Flat
Washers (8), and .two 5/16" Nylon Locknuts (3).
56-----8
Attach the Handle (82) to the Rear Seat
Frame (100) with two 5/16" x 21/2" Carriage
Botts (1) and two 5/16" Nylon Locknuts (3).
_/_23-_-_,..,
Tighten all Nylon Locknuts used in steps
1-5.
.
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
":
6
Pin _//_"-,I
/_
(5).
I 25,o "
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.
!!
1o
5---Bracket_
Be careful not to tip either stack of
Weights (25) until step 8 is complete.
4--Bracket _
6
Press a Weight Tube Bumper (64) into the
end of the Short Weight Tube (I08). Insert the
Weight Tube into the front stack of Weights
!25). Be sur_ that the pin on the Weight
Tube i;sslt_lng 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.
25
,
Press a Weight Tube Bumper (64) into the
end of the Long Wei_si_:- _e (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.
8
Holes
_73
Lubricate the inside of the holes in the other
Top Weight I._5"_.Set the Top Weiqht onto the
rear stack of Weights (25). Insert bo_h Short
Weight Guides (73) into the stack of Weights.
Be sure that the holes in the Weight
Guides are at the top, as shown.
!,
I
Lubricate
7
Attach the upper ends
Guides (73) to the Top
x 6" Bolt (60), two 1/2"
a 5/16" Nylon Locknut
g*
of the Short Weight
Frame (55) with a 5/16"
x 3/4" Spacers (61), and
(3).
9
61
3 61
60
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 beg labeled
"ARM ASSEMBLY."
!
lO
Be 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).
Tube
97
Lubricate a 3/8" x 3 1/4" Bolt (67). Attach the
Leg Press Ann (96) to the Stabilizer (5) with the
Bolt and a 3/8" Nylon Locknut (21). Do not overtighten the Nylon LocknuL 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 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 on each end of the Indicated tube in the Base. Make sure that the
27
%/67--Lubricate
11
_
this side
t_
59--Lubricate
pulleys are on the side shown.
21"_-_"_'_Welded
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).
8
90
Spacers
" _
!2. Press a 1" Round Inner Cap (49) into one of
....= ,_:_ss Arms, -6;. Press a 1 3/4" Square
!nner Cap (44) into the Press Arm.
Attach the Pre_ _.rm (46) to one side o_ the
Press Frame (i ,') with two 5/16" x 2 1/2" Bolts
(22) and two 5/16" Nylon Locknuts (3).
Assemble the other Press Arm (46) in :ha
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.
13
86.._--_
Welded
/L
31
:
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.
7
Attach a."V"-Pulley (50) and a Long Cable
Trap (31) to the Left Arm (47) in the same
manner.
48--
14. Lubdc-_ta both axles on the Top Frame (55).
14
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
Indtc_t_.d bracket on the Top Frame (55).
Tap two 1" Retainers (69) and a 1" Rounc;
Cover Cap (70) onto the axle. Be sure tE :the teeth on the Retainers bend toward the
48
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 1(7 Pad (45) onto the
lower end of each Arm.
Axle1
I"
9
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).
15
9
•
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. Slide two 5" Plastic Handgdps (83) onto
the Military Press Arm.
Attach the Pivot Arm (101) to the Assist
Upright (74) with a 3/8" x 3 1/4" Bott (67) and
a 3/8" Nylon Locknut (21).
16. Press two 1" x 2" Inner Caps (107) into the
Assist Arm (105).
67
.
32
. _--56
16
/,
Attach the Assist Arm (105) to the Leg Press
Upright (56) with a 3/8" x 6" Bolt (106), two
3/8" Flat 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 Ls9 P_ess Upright (5_). T?I_
Assist Arm must also be below the welded
bracket on the Assist Upright (74).
Bracket
105
""74
56"_
i
_""
./56
,, lil i ,000
i
10
L-
17. Attach the Le_ F_ .Jp Arm :75) and the Fl!ghl
Pull-up Arm (77) to me Assis_ Upright (74)
with two 5/16" x 2 3/4" Bolts (!1) and two
5/16" ;',_y!on!.cc=',nu_s (3).
80
75
\
74
\
]i
Attach the Left Dip Arm (78) and the Right Dip
Arm (79) to the Assist Upright (74) with two
_16"x 2 3/4" Bolts (11) and two 5116" 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 Handgdp (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 (?'7).
Press a 1 1/4" Round Inner Cap (109) into the
Left Dip Arm (78), and into the Right Dip Arm
(79).
ii !' _"_i _i_
_ _L_i
•
_ _#_
18. Locate and open the parts bags labeled
"CABLE ASSEMBLY" and "PULLEYS."
18
_ _ i _II_ !
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
approximate length of each Cable is listed (in
inches) after the key number in the drawing.
,_ <
IMPORTANT: While assembling the cables,
....
•. ",-b_r, ",.hebolts _n_ nuts
a_a_hl_It.i
_;;_'.;_uiieys, The pulleys must be
able iO i.ur_'l _i'a_iy.
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 31'8"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.
11
88
20. Wrap the High Cable (58) around a "V"-Pulley
(50). Attach the "V"-Pulley and a Long Cable
Trap (31) to the indicated bracket on the Front
Upright (42) with a 3/8" x 2 1/2" Bolt (86) and
e 3/8" 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 "V"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 posEtioned to hold the Cable in place. 13ghten
the 3/8" x 2 1/2" Bolt (86) and the 3/8" Nylon
Locknut (not shown).
2O
86_
31
21
86
31
5O
58
47
_
22. Route the High Cable (58) around the "V"Pulley (50) on the Right Arm (48). Be sure
that the Cable Is in the groove of the "V"Pulley and that the Long Cable Trap (31) Is
turned to hold the Cable in place. Tighten
the 3/8" x 2 112" Bolt (86) and the 3/8" Nylon
Locknut (not shown).
22
23. Attach the Pulley Bracket (20) to the Top
Frame (55) with the 5/16" x 5" Bolt (68) and a
5/16" Nylon Locknut (3). Do not overtighten
the Nylon Locknut; the Pulley Bracket
must be able to move freely.
23
i_
See the inset drawing. Route the High Cable
(58) around the 3 1/2" Pulley (15) attached to
the Pulley Bracket (20). Tighten the 3/8" x 2"
Bolt (12) and a 3/8" 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.
12
31
86
50
_ :_
24. See
drawing.
Attach
_-3 upper
ij2" Pulley
(15) the
and inset
a Cable
Trap (66)
to the
hole ;n
24
a Long "U"-Bracket (57) with a _8" x 2" Bolt
(12) and a 318" Nylon Locknut (21). Be sure
that the Cable Trap is inside the Long "U"Bracket• Note: This may come pro-assembled.
Route the High Cable (58) through the Long
"U"-Bracket (57) and the 3 1/2" 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 1/2"
Pulley (15). Attach the Pulley to the bracket on
the Top Frame (55) with a 3/8" x 2" Bolt (12)
and a 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.
26. Note: This assembly step shows how to
complete the assembly of several preattached parts.
?:c
25
Bracket
26
The 5/8" x 9116" Spacer (7) has been proattached on the outside of the 3 1/2" Low
Pulley (102) for shipping purposes. Remove
the 3/8" Nylon Locknut (21), the Spacer, and
the Pulley from the 3/8" x 3 3/4" Bolt (88). Do
*_ ,'_._:'..,,_._',:e ,?.,:{t• ;':_o Bolt has been
shown removed for pa_ identification.
Reattach _e 3 1/2' Low Pulley (102), with the
5/'8" x 9/16" Spacer (7) between the Pulley and
the Press Frame (17). Do not tighten the 3/8"
Nylon Locknut/q!)
y_.. Be s:_r_ that the
3/8" x 3 3/4" Bolt (88), the 3/8" Flat _,',_sher
(9), the 5/8" x 9/16" Spacer (7), the 3 ;/2"
Low Pulley (102), and the 3/8" Nylon
Locknut (21) are oriented as shown.
13
58
•j12
27. Locate the Low Cable (23). Route the Low
Cable under the 3 1/2" Low Pulley (102). Be
sure that the end of the Cable with the ball
Is on the Indicated side of the Press. Frame
17102
(17) and that the Cable Is between the
. Pulley and the crossbar on the Press
Frame. "tighten the 3/8" Nylon Locknut (21)
and the 3/8" x 3 3/4" Bolt (not shown).
_
23
Ball
--17
<
28. Route the Low Cable (23) around the 3 1/2"
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, "Rghten the 3/8" Nylon Locknut (21)
and the 3/8" x 3 3/4" Bolt (88).
88-42--
6
Inset shows view
from other side
23
29. Route the Low Cable (23) around the 3 1/2"
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. _ghten the 3/8" Nylon
Locknut (21) and the 3/8" x 3 1/2" Bolt (not
shown).
23
--66
--17
ii
J
30. Route the Low Cable (23) around the 3 1/2"
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 3/8" Nylon Locknut (21)
and the 3/8" x 3 3/4" Bolt (88).
6
Inset shows view
from other side
J
14
31. Attach the end of the Low Cable (23) 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 Nylon Locknut, as
shown In the Inset drawing.
32. Attach the High Cable (58) to a Small "U"Bracket (71) with a 114" 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 only a
couple of turns, as shown In the Inset
drawing.
Attach the Small =U"-Bracket (71) to the Short
Weight Tube (108) with a 5/16" x 1 3/4" Bolt
(24) and a 5/16" Nylon Locknut (3).
3.
Locate the Military Press Cable (72). Attach
the Military Press Cable to the other Small
"U"-Bracket (71) with a 1/4" Nylon Locknut (2)
and a 1/4" Rat 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 "U"-Bracket (71) to the Long
Weight Tube (63) with a 5/16" x 1 3/4" Bolt
(24) and a 5/16" Nylon Locknut (3).
15
34. Wrap the Military Press Cable (72) arour, :
%t"-Pulley (50). Attach the %'-Pulley to ::he
Top Frame (55) with a 3/8" x 2 1/2" Bolt (86)
and a 3/8" Nylon Locknut (21).
34
Wrap the Military Press Cable (72) around a 3
1/2" Pulley (15). Attach the Pulley to the indtcatad bmckat on the Assist .,_rm !'. 0,m 'v!th a
3/8" x 1 3/4" Bolt (76) and a 3/8" Nylon
Locknut (21). Be sure that the Cable is
between the Pulley and the Assist Arm and
that the Cable and. Pulley move smoothly.
Bracket
105
35. Wrap the Military Press Cable (72) around a
"V"-Putley (50). Attach the _/"-Pulley and a
Long Cable Trap (31) to the Assist Upright
(74) with a 3/8" x 4 112" Bolt (112), a 3/8" Flat
Washer (9), and a 3/8" 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,
35
21
Wrap the Military Press Cable (72) around a
3 1/2" Pulley (15). Attach the Pulley to the
other bracket on the Assist Arm (105) with a
3/8" x 1 3/4" Bolt (76) and a 3/8" Nylon
Locknut (21). Be sure that the Cable Is
between the Pulley and the Assist Arm and
that the Cable and Pulley move smoothly.
16
105
"
36. Slide a 5/16" Flat Washer (8) onto a 5116" x
2 3/4" Bolt (11). Insert the Bolt through the indicated hole in the Pivot Arm (101). The Bolt
must be inserted from the side shown.
Fully tighten a 5/16" Nylon Jam Nut (93) onto
the Boil
36
Wrap the Military Press Cable (72) around a
3 1/2" Pulley (15). Attach the Pulley and a
Cable Trap (66) to the Pivot Arm (101) with
the 3/8" x 3 3/4" Bolt (88), a 3/8" Flat Washer
(9), and a 3/8" 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
37. See inset drawing A. Attach a 3 1/2" Pulley
(15) and a Cable Trap (66) to the upper hole
in a Long "U"-Bracket (57) with a 318" x 2"
Bolt (12) and a 3/8" Nylon Locknut (21). Be
sure that the Cable Trap is inside the Long
"U"-Bracket.
(Note: This may come preassembled.)
Route the Military Press Cable (72) through
the Long "U"-Bracket (57) and the 3 1/2"
Pulley (15). Be sure that the Cable Is In the
groove of the Pulley and that the Cable
and Pulley move smoothly.
93\
See inset drawing B, Slide the end of the
Military Press Cable (72) onto the end of the
5/16" x 2 3/4 Bolt (11). Thread another 5/16"
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.
\
17
72
38. Locate the Leg Press Ca_, _ (99). Attach the
end of the Leg Press Cable :a the Long "U"Bracket (57) with a 1/4" Nylon Locknut (2) and
a 1/4" Ftat Washer (10). Do not completely
tighten the Nylon L_cknut, !_ shcdd be
threaded onto the end of : ' ; CaL;ie only a
couple of turns, as shown Jnthe inset
drawing.
38
€
Wrap the Leg Press Cable (99) around a
3 1/2" Pu!tey (15). Attach the Pulley to the Leg
Press Updght (56) with the 3/8" x 3 3/4" Bolt
(88), a 3/8" FIaL Washer (9), and a 3/8" 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.
Bail
Rod
99_
39. Attach the Press Bracket (94) to the Leg
Press Arm (96) with a 5/16" x 3" Bolt (111)
and a 5/16" Nylon Locknut (3).
!;_":_,}',:b" ' ._,,':_'" '"" C,2_':': "_':_ t:':: :d _-3 1/2"
Pulley (15). Attach the Pulley to the Press
Bracket (94) with the 3/8" x 2" Bolt (12) and a
3/6" Nylon Locknut (21).
Slide a 5/16" Flat Washer (8) onto a 5/16" x
2 3/4" Bolt (11). Insert the Bolt through the
lowest hole in the Rear Seat Frame (100)
from the indicated side. (Note: The three
57
39
96
12
5/16" Nyion Jam Nut (93) onto the Bolt. Slide
the end of the Leg Press Cable (99) onto the
end of the Bolt. Thread another 5/16" 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.
93
40. Locate and open the parts bag labeled
"SEAT ASSEMBLY,"
40
fnsert a 1/4" x 2 1/2" Carriage Bolt (92)
through the center hole in a Seat Plate (37).
Attach the Seat Plate to the Rear Backrest
85
(85) with two 1/4" x I/2" Screws (18).
Insert the !/4" x 2 1/2" Carriage Bolt (92)
through the indicated hole in the Leg Press
Upright (56). Tighten a 1/4" Nylon Locknut (2)
with a 1/4" Flat Washer (10) onto the Carriage
Bolt. Attach the top of the Rear Backrest (85)
to the Leg Press Updght with a 1/4" x 2 1/2"
Screw (43) and a 1/4" Flat Washer (10).
37 92
41. Attach one end of a Seat (13) to the Rear
Seat Frame (100) with two 1/4" x 1/2" Screws
(18). Attach the other end of the Seat to the
Rear Seat Frame with a 1/4" Flat Washer (10)
and a 1/4" x 2 1/2" Screw (43).
42. Attach the Assist Seat (104) and the Angle
Bracket (110) to the Assist Arm (105) with four
1/4" Flat Washers (10) and four 1/4" x 2 1/2"
Screws (43).
41
42
11
4.3
19
43. Attach the Front Backrest (41) to the Front
Upright (42) with two 1/4" x 2 1/2" Screws (43)
and two 1/4" Flat Wsshers (10). The Backrest
must be oriented as shown.
4.3
f
f
_
4
44.
-
Thick
Press a 1 1/2" Square =n,
' ",er ,_"-_ _,_2)into
"^
the
Front Seat Frame (36).
End
44
Insert a 1/4" x 2" Carriage Bolt (38) through
the center hole in the Seat Plate (37). Attach
the Seat Plate to the Seat (13) with two 1/4" x
1/2" Screws (18).
Insert the 1/4" x 2" Carriage Bolt (38) thro_:gh
the indicated hole in the Front Seat Frame
(36). "Nghten a 1/4" Nylon Locknut (2) with a
1/4" Flat Washer (!0) onto the Carriage Bolt.
Attach the other end of the Seat (13) to the
Front Seat Frame (36) with a 1/4" Flat Washer
(10) and a 1/4" x 2" Machine Screw (81).
36
10
45. Press a 1 1/2" Square inner Cap (32) into the
•,_] Lever (29).
45
Lubricate the 5/16" x 2 1/4" Bolt (33). Attach
the Leg Lever (29) to the Front Seat Frame
(36) with the Bolt and a 5/16" Nylon Locknut
_36
(3).
Lubdcate--33,_.,-!
Insert the 5/16" x 2" Eyebolt (35) into the Leg
Lever (29) from the direction shown. Tighten a
5/16" Nylon Locknut (3) with a 5/16" Flat
Washer (8) onto the Eyeboit.
46. Res_ the Front Seat Frame (38) cn _:_ _n_ic_ted pin in the Front Upright (42). Attach the
Front Seat Frame to the Front Upright with a
5/16" x 2 3/4" Carriage Bolt (14) and the Seat
Knob (40).
=s_ _
i_
i_i
_
,?_
0
_
2
47.
Press two 3/4" Round Inner Caps (34) into
each Pad Tube (28).
Insert a Pad Tube (28) into the Front Seat
Frame (36). Slide a Foam Pad (30) onto each
end of the Pad Tube.
Insert the other Pad Tube (28) into the Leg
Lever (29). Slide a Foam Foam Pad (30) onto
each end of the Pad Tube.
m
48, Remove the backing from the PRO 9645
decal and apply it to the home gym system as
shown.
Make sure that all parts have been propedy
tightened. The use of the remaining parts will
be explained in HOW TO USE THE HOME
GYM SYSTEM, beginning on page 22 of this
manual.
48
.PRO 9645
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 DIAGRAMS on pages 26 and
27 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 TROUBLE-SHOOTiNG
AND MAINTENANCE on p_ge 25.
21
HOW TO USE THE HOME GYM SYSTEM
The instructions below describe how each part of the home gym system can be adiusted. Refer _o the .=,xer3ise
poster accompanying this manual to see how the home gym system shoutd be set up for each exercise.
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, tP,0 effectivenes.s of the exercise will be reduced.
CHANGING THE WEIGHT
SETTING
The PRO 9645 features two weight stacks. The front
weight stack is connected to the upper and lower pulleys, the press arm, and the butterfly arms. The rear
weight stack is connected to the military press arm,
assist arm, and leg press.
26
To change the weight setting of either weight stack,
insert a Weight Pin (26) under the desired Weight
(25). 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 either 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
settlng. Use the WEIGHT RESISTANCE CHART on
page 24 to find the approximate
tance at each weight station.
25
amount of resis26
AT-rACHING THE LAT BAR OR NYLON STRAP TO
THE HIGH PULLEY STATION
Attach the Let Bar (54) to the High Cable (58) with a
Cable Clip (53). For some exercises, the Chain (52)
should be attached between the Lat Bar and the High
Cable with two Cable Clips. Adjust the length of the
C;-_,ti_,L.._,_'_._,;;.he Lat _lar and the High 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.
39
ATTACHING THE LAT BAR OR NYLON STRAP TO
THE LOW PULLEY STATION
23
53
Attach the Lat Bar (54) to the Low Cable (23) with a
Cable Clip (53). For some exercises, the Chain (52)
should be attached between the Lat Bar and the Low
52
53
Cable with two Cable Clips. Adjust the length of the
Chain between the Lat Bar and the Low 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.
22
AI-I'ACHING AND REMOVING
THE SEAT
To attach the Seat (13), set the bracket on the Front
Seat Frame (36) onto the indicated pins on the Front
Upright (42), Attach the Front Seat Frame to the Front
Upright with the 5/16" x 2 3/4' Carriage Bolt (14) and
the Seat Knob (40).
For some exercises, the Seat (13) must be removed.
First, be sure that the chain is not attached to the leg
lever. Next, remove the Seat Knob (40) and the 5/16"
x 2 3/4" Carriage Bolt (14) from the Seat Frame (36).
Lift the Front Seat Frame off the Front Upright (42).
ATTACHING THE LEG LEVER TO THE LOW
PULLEY STATION
To use the Leg Lever (29), the seat must be attached
to the front upright (see ATTACHING AND REMOVING THE SEAT above).
52
Attach one end of the Chain (52) to the Short Cable
(23) with a Cable Clip (53). Attach the other end of
the Chain to the Eyebolt (35) with a Cable Clip.
129
ADJUSTING THE LEG PRESS PLATE
Remove the Press Pin (97) from the Leg Press Plate
(95) and the Leg Press Arm (96).
Welded
Tube
Align the welded tubes on the Leg Press Plate (95)
with the desired set of holes in the Leg Press Arm
(96). Re-insert the Press Pin (97) through the welded
tubes on Leg Press Plate and the holes in the Leg
Press Arm.
97
96
23
WEIGHT RESISTANCE
CHART
This chart shows the approximate weight resistance at each weight station. "Top" refers to the 5.5 lb. too weight.
The other numbers refer to the 12.5 Ib, weight plates. The butterfly ann resistance listed is the resistance for
each butterfly arm.
WEIGHT
ARM
ARM
LEVER
PULLEY
(Ibs.)
PRESS
Obs.)
BUTTERFLY
(Ibe.)
LEG
(Ibs.)
HIGH
Top
31
17
25
23
36
30
36
11
1
59
35
50
36
67
51
78
38
2
81
40
71
54
95
74
123
66
3
104
70
97
70
123
97
171
95
4
132
80
111
88
155
115
219
117
5
154
110
131
98
191
135
265
142
6
196
115
156
120
220
164
299
186
7
206
130
172
135
252
183
333
213
8
227
140
184
144
273
194
387
232
9
-
-
218
440
256
lO
....
246
455
293
PLATES
i
-
24
PULLEY
(Ibs.)
LOW
PRESS ARM
(Ibs.)
MILITARY
PRESS
(lbs.)
LEG
ARM
(Ibs.)
ASSIST
TROUBLE-SHOOTING
AND MAINTENANCE
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, If any slack is felt when using the
front weight stack, both the High Cable (58) and the Low Cable (23) will need to be tightened. If any slack is felt
when using the rear weight stack, both the Military Press Cable (72) and the Leg Press Cable (99) will need to
be tightened,
To tighten the cables, insert the weight pin into the middle of
the weight stack. Slack can be removed from these cables
several ways:
•
See drawing 1. "13ghtenthe 1/4" Nylon Locknut (2) that
connects the end of the Low Cable (23) to the Long "U"Bracket (57).
The Leg Press Cable (99) can be tightened in the same
manner.
See drawing 1. Move the 3 1/2" Pulley (15) to,the other
hole in one of the Long =U"-Brackets (57). Remove the
3/8" Nylon Locknut (21) and the 3/8" x 2" Bolt (12) from
the Cable Trap (66), Pulley, and Long "U"-Bracket. Reattach the Pulley and Cable Trap. Be sure that the Cable
Trap is in the proper position and that the Cable and
Pulley move smoothly.
The other Long "U"-Bracket (57) can be adjusted in the
same manner.
•
See drawing 2.33ghten the 1/4" Nylon Locknut (2) that
,., _h_ H,._h Cable (58) to the ..me=t ,., Bracket (71).
3
The Military Press Cable (72) can be tightened in the
same manner.
See Drawing 3. If additional slack is felt while using the
Leg Press Arm (96), then the end of the Leg Press Cable
(99) must be moved to the next hole in the Rear Seat
Frame (100). Remove the 5/16" x 2 3/4" Bolt (11), the
5/16" Washer (8), the end of the Cable, and both 5/16"
Nylon Jam Nuts (93) from the Rear Seat Frame. Reattach the Bolt, the Washer, the end of the Cable, and
both Nylon Jam Nuts to the next hole in the Rear Seat
Frame.
Do not overtighten
/99
\
\
the cables; the top weight will be lifted off the weight stack.
If a cable tends to slip off the pulleys often, it may have become twisted. Remove the cable and re-install it.
If the cables need to be replaced, see ORDERING
REPLACEMENT
25
PARTS on the back cover of this manual.
CABLE DIAGRAMS
The cable diagrams on these pages show the proper routing of the High Cable (58), the Low Cable (23), the
Military Press Cable (72), and the Leg Press Cable (99). Use the diagrams to be sure that the four cablesand
the cable traps have been assembled correctly. It the cables have not been correctly routed, the home gym system will not function properly and damage may occur. The insets show the proper positioning of the cable traps.
The cable traps should be positioned so that the cables will not come off the pulleys. Be sure that the cable
traps do not touch or bind the cables.
High Cable (58) and Low Cable (23)
l---High Pulley
4
!1
h Cable (58)
I
=U"-Bracket
\
Front Weight Stack---8
4
3
2
26
:_.
Military Press Cable (72) and Leg Press Cable (99)
Cable (72)
,tArm
1--Long "U"-Bracket
2
Rear Weight Stack--1
4--Rear
Leg Press Cable (99)
/4
5
27
,
i$
Seat Frame
This chart is provided to help you identify the small parts used in assembly. Important: Some parts
may have been pre-aeeembled for shipping purposes. If you cannc_ find a part In the parts bags,
check to see If It has been pre-aesembled. The number in parenthesis below each part refers to the
key number of the part. The second number refers to the quantity needed for assembly.
Please Note: The assembly is divided 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
separately. WAIT UNTIL YOU BEGIN EACH ASSEMBLY STAGE TO
OPEN THE PARTS BAG LABELED FOR THAT ASSEMBLY STAGE.
831.159380
R0896A
_
1/4" Nylon Locknut (2)-6
1/4" x 2" Machine Screw (81)-1
@_
5/16" Nylon Locknut (3)--36
_\\\\\\\\\\\\\\\\\\\\\W4
1/4" x 2 1/2" Carriage Bolt (92)-1
5/16" Nyton Jam Nut (93)-4
5/16" x 2 1/2" Bolt (22)--4
3/8" Nylon Locknut (21)-23
3/8" x 2" Bolt (12)-5
1/4" Flat Washer (10)-15
5/16" x 2 1/4" Bolt (33)-3
5/16" Flat Washer (8)-9
1/4"x 2 1/2" Screw (43)--8
3/8" F!'_,t W._.sh£r (9)-9
0
rn
3/8" x 2 1/2" Bolt (86)-4
E\\\\_,\I
-
i
°
5/16" x2 3/4" Bolt (11)-14
E\\\\\\\\&\\\\\\\\\ I
5/16" x 2 3/4" Cardage Bolt (14)-1
5/16"
X 3" Bolt (111)-1
3/8" x 3 1/4" Bolt (67)-2
1/4" x 1/2" Screw (18)-6
3/8" x 3 1/2" Bolt (16)-1
3/8" x 3 3/4" Bolt (88)-6
5/16" x 5' Bolt (68)-1
E
1" Retainer
1 1/8" x 2 1/2" Plastic Bushing
(69)-4
(89)-2
J
1" x 7/8" Plastic
Bushing
(90)-2
3 1/2" Pulley (15)-13
(Not shown to scale)
"V"-Pulley (50)-5
(Not shown to scale)
=
5/16" x 2" Eyebolt (35)--1
3/4" Round inner Gap (34)--4
1" Round Inner Cap (49)-6
1" Round Cover Cap (70)-2
1" Square inner Cap (6)-1
J
1" x 2" Inner Cap (107)-2
1 3/4" Squ_re Inner Cap (44)--6
2" Square Inner Cap (27)-8
2" Square Outer Cap (51)-2
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