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

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:" (_ U I p M EN T

I[_,,|1 | ;i-."B n Re| _i,.Si

HEI-,P LI N E!

1-800-73d-dg7P

USER'S MANUAL

SW/ARS

SEARS, ROEBUCK AND CO., HOFFMAN ESTATES, IL 60179

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

FULL 90 DAY WARRANTY ........................................ _.. ............ 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.

BEFORE YOU BEGIN

Thank you for selecting the versatile WEtDEF_ PRO

9645 Home Gym System. ,'ThePRO 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.

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-

free HELPLINE at 1-800-736-6879, Monday through

5aturaay, 7 a.m. un_ii 7p.m. Central Time (excluding

holidays). To help us assist you, please note the prod-

uct 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).

Before reading further, please review the drawing

below and familiadze yourself with the parts that are

labeled.

l.at Bar ASSEMBLED

DIMENSIONS:

Height: 78 in.

Width: 86 in.

Length: 66 in.

High Pulley Station

Pull-up Handles Butterfly Arms

Dip Handles

Press Arm

_, Backrests

- Leg Press

Plate

Assist Arm "Press Arm

Leg Lever

Weight Stacks

Station

Weight Pin Foot Plate

ASSEMBLY

Before beginning assembly, carefully read the

following information and Instructions:

•Place all parts of the PRO 9645 in a cleared area

and remove the packing matadals; do not dis-

pose 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 apart is not in the parts

bag, check to see if it has been pre-attached.

•As you assemble the PRO 9645 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.

ffl_!?

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

"FRAME ASSEMBLY."

Press two 2" Square Outer Caps (51) onto

Cap (27) into the Base (4).

Insert six 5/16" x 2 1/2" Carriage Bolts (1) up

through the Stabilizer (5). Insert two 5/16" x

2 1/2" Carriage Bolts up through the Base

(4).

Attach the Base (4) to the Stabilizer (5) with

two 5/16" x 23/4" Bolts (11), two 5/16" Flat

Washers (8), and two 5/16" Nylon Locknuts

(3). Do not tighten the Nylon Locknuts

yet.

{TfDi_

_< i<'>7 +

< •

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.

Press two 2" Square Inner Caps (27) into the

Leg Press Upright (56). Press a 2" Square

Inner Cap into the Assist Upright (74).

Afl_ch _he Rubber Bumper (91) to the Leg

Press lJpdght (56) with the #8 x 1/2" Self-tap-

ping Screw (87).

3. 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).

.,_--_ 27

n Sides

of _rackets

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.

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).

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" x21/2" Carriage Bolts (1) in

the Stabilizer (5). Hand-tighten two 5/16"

Nylon Locknuts (3) onto the Carriage Bolts.

Do not tighten the Nylon Locknuts yet.

Attach the other end of the Rear Seat Frame

(100) to the Leg Press Upright (56) with two

5/16" x 23/4" Bolts (11), two 5/16" Flat

Washers (8), and .two 5/16" Nylon Locknuts (3).

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).

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

(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.

55 11 49

Crossbar

56------

100

_/_23-_-_,.., ":

Pin _//_"-,I /_

I25,o"!!

5---Bracket_

4--Bracket _

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 aTop

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.

,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.

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.

Holes

_73

Lubricate

g* Attach the upper ends of the Short Weight

Guides (73) to the Top Frame (55) with a 5/16"

x 6" Bolt (60), two 1/2" x 3/4" Spacers (61), and

a 5/16" Nylon Locknut (3).

Attach the upper ends of the Long Weight

Guides (62) to the Top Frame (55) in the same

manner.

10. Locate and open the parts beg labeled

"ARM ASSEMBLY."

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).

Lubricate a 3/8" x3 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 over-

tighten 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 a1" 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 Indi-

cated tube in the Base. Make sure that the

pulleys are on the side shown.

Lubricate the 3/8" x 8" Bolt (59). Attach the

Press Frame (17) to the Base (4) with the Bolt

and a3/8" Nylon Locknut (21).

61 3 61

< !

Tube

%/67--Lubricate

_this side

t_59--Lubricate

21"_-_"_'_Welded 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.

Attach a"V"-Pulley (50) and a Long Cable

Trap (31) to the Right Arm (48) with a 3/8" x

2 1/2' Bolt (86) and a 3/8" Nylon Locknut (21).

Do not tighten the Nylon Locknut yet.

Attach a."V"-Pulley (50) and a Long Cable

Trap (31) to the Left Arm (47) in the same

manner.

14. Lubdc-_ta 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

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

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 a1(7 Pad (45) onto the

lower end of each Arm.

13 86.._--_ 31

Welded /L :7

48--

Axle1

15. See the inset drawing. Attach the Military

Press Arm (84) to the Pivot Arm (101) with

two 5/16" x 2 1/4" Bolts (33) and two 5/16"

Nylon Locknuts (3).

Press two 1 1/2" Square Inner Caps (32) into

the Military Press Arm (84). Press two 1"

• Round Inner Caps (49) into the Military Press

Arm. 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).

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).

•.32

67 . _--56

Bracket

/, 105

""74 56"_

_"" ./56

,, lil i,000i

L-

ii !' _"_i _i_

_ _L_i _ _#_

• _ _ i _II_!

,_ <

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).

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 a1 1/4" Round Inner Cap (109) into the

Left Dip Arm (78), and into the Right Dip Arm

(79).

18. Locate and open the parts bags labeled

"CABLE ASSEMBLY" and "PULLEYS."

During steps 19 through 39, refer to the

CABLE DIAGRAMS on pages 26-27 of this

manual to verify proper cable routing. Before

beginning this section, fully unwind the four

Cables. Identify the four Cables by comparing

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

33/4" Bolt (88) and a31'8"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.

75 74

80 \ \

_ i_

20. Wrap the High Cable (58) around a"V"-Pulley

(50). Attach the "V"-Pulley and aLong Cable

Trap (31) to the indicated bracket on the Front

Upright (42) with a 3/8" x 2 1/2" Bolt (86) and

e3/8" 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 posE-

tioned to hold the Cable in place. 13ghten

the 3/8" x 2 1/2" Bolt (86) and the 3/8" Nylon

Locknut (not shown).

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).

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.

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.

86_ 31

86 31

31 86 50

:_ (15) and a Cable Trap (66) to the upper hole ;n

_ 24. See the inset drawing. Attach _-3 ij2" Pulley

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-assem-

bled.

?:c

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 31/2"

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 pre-

attached parts.

The 5/8" x 9116" Spacer (7) has been pro-

attached 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.

Bracket 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

(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).

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).

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).

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).

17102

_Ball

--17

88--

42--

Inset shows view

from other side

--66

--17

Inset shows view

from other side

31. Attach the end of the Low Cable (23) to the

Long "U"-Bracket (57) with a 1/4" Nylon

Locknut (2) and a1/4" 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 a114" Nylon Locknut (2) and

a1/4" 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 a5/16" 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 a1/4" Rat 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 (71) to the Long

Weight Tube (63) with a 5/16" x1 3/4" Bolt

(24) and a 5/16" Nylon Locknut (3).

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).

Wrap the Military Press Cable (72) around a 3

1/2" Pulley (15). Attach the Pulley to the indt-

catad 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.

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,

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.

Bracket

105

16 "

36. Slide a 5/16" Flat Washer (8) onto a 5116" x

23/4" 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 5/16" Nylon Jam Nut (93) onto

the Boil

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. See inset drawing A. Attach a31/2" 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 pre-

assembled.)

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.

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.

\72

93\

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.

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), a3/8" FIaL Washer (9), and a3/8" 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.

39. Attach the Press Bracket (94) to the Leg

Press Arm (96) with a5/16" x3" 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" x2" Bolt (12) and a

3/6" Nylon Locknut (21).

Slide a 5/16" Flat Washer (8) onto a 5/16" x

23/4" Bolt (11). Insert the Bolt through the

lowest hole in the Rear Seat Frame (100)

from the indicated side. (Note: The three

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.

€

Bail

Rod

99_ 57

40. Locate and open the parts bag labeled

"SEAT ASSEMBLY,"

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) 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 a1/4" 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).

41. Attach one end of aSeat (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 a1/4" 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).

37 92

4.3

=s__

i_i_ ,?_

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.

44.

45.

Press a1 1/2" Square ' " "- "^

=n,,er ,_ _ _,_2)into the

Front Seat Frame (36).

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).

Press a11/2" Square inner Cap (32) into the

•,_] Lever (29).

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

(3).

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_t-

ed 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).

4.3

f -

_ Thick

End

10 2

_36

Lubdcate--33,_.,-!

47. Press two 3/4" Round Inner Caps (34) into

each Pad Tube (28).

Insert aPad 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 aFoam Foam Pad (30) onto

each end of the Pad Tube.

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.

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 cor-

rect 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 MAINTE-

NANCE on p_ge 25.

.PRO 9645

HOW TO USE THE HOME GYM SYSTEM

The instructions below describe how each part of the home gym system can be adiusted. Refer _othe .=,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 cor-

rect 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 pul-

leys, the press arm, and the butterfly arms. The rear

weight stack is connected to the military press arm,

assist arm, and leg press.

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 amount of resis-

tance at each weight station.

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.

ATTACHING THE LAT BAR OR NYLON STRAP TO

THE LOW PULLEY STATION

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

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.

53 52

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 REMOV-

ING THE SEAT above).

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.

ADJUSTING THE LEG PRESS PLATE

Remove the Press Pin (97) from the Leg Press Plate

(95) and the Leg Press Arm (96).

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.

52 129

Welded

Tube

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

PLATES

Top

iPRESS BUTTERFLY LEG HIGH LOW MILITARY LEG ASSIST

ARM ARM LEVER PULLEY PULLEY PRESS ARM PRESS ARM

(Ibs.) Obs.) (Ibe.) (Ibs.) (Ibs.) (Ibs.) (lbs.) (Ibs.)

31 17 25 23 36 30 36 11

59 35 50 36 67 51 78 38

81 40 71 54 95 74 123 66

104 70 97 70 123 97 171 95

132 80 111 88 155 115 219 117

154 110 131 98 191 135 265 142

196 115 156 120 220 164 299 186

206 130 172 135 252 183 333 213

227 140 184 144 273 194 387 232

- - - 218 440 256

.... 246 455 293

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. 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.

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).

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. Re-

attach the Bolt, the Washer, the end of the Cable, and

both Nylon Jam Nuts to the next hole in the Rear Seat

Frame.

/99

Do not overtighten 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 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 sys-

tem 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

h Cable (58)

=U"-Bracket

Front Weight Stack---8

26 :_.

Military Press Cable (72) and Leg Press Cable (99)

Cable (72)

,tArm

1--Long "U"-Bracket

Rear Weight Stack--1

4--Rear Seat Frame

Leg Press Cable (99)

/4 ,i$

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

@_ 5/16" Nylon Locknut (3)--36

5/16" Nyton Jam Nut (93)-4

3/8" Nylon Locknut (21)-23

1/4" Flat Washer (10)-15

1/4" x2" Machine Screw (81)-1

_\\\\\\\\\\\\\\\\\\\\\W4

1/4" x2 1/2" Carriage Bolt (92)-1

5/16" x 2 1/2" Bolt (22)--4

3/8" x 2" Bolt (12)-5

5/16" x 2 1/4" Bolt (33)-3

5/16" Flat Washer (8)-9

3/8" F!'_,t W._.sh£r (9)-9

- i °

1/4"x 21/2" Screw (43)--8

3/8" x21/2" Bolt (86)-4

E\\\\_,\I

5/16" x2 3/4" Bolt (11)-14

E\\\\\\\\&\\\\\\\\\ I

5/16" x 2 3/4" Cardage Bolt (14)-1

3/8" x 3 1/4" Bolt (67)-2

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

1" Retainer (69)-4

1 1/8" x 2 1/2" Plastic Bushing (89)-2

1" x 7/8" Plastic Bushing (90)-2

5/16" X 3" Bolt (111)-1

1/4" x 1/2" Screw (18)-6

31/2" 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 3/4" Squ_re Inner Cap (44)--6

1" Round Cover Cap (70)-2

1" Square inner Cap (6)-1

1" x 2" Inner Cap (107)-2

2" Square Inner Cap (27)-8 2" Square Outer Cap (51)-2

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

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