Weider WESY9648 User's Manual
Contents
1. 22 WEIGHT RESISTANCE CHART ai o nana a ee a pIE i e E a a I e 24 TROUBLE SHOOTING AND MAINTENANCE 25 CABLE DIAGRAMS e DIR UP ERN OG RU D EPI 26 ORDERING REPLACEMENT 5 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 WEIDER is a registered trademark of ICON Health amp Fitness Inc LIMITED WARRANTY ICON Health amp Fitness Inc ICON warrants this product to be free from defects in workmanship and material under normal use and service conditions for a period of ninety 90 days from the date of pur chase This warranty extends only to the original purchaser ICON s obligation under this warranty is lim ited to replacing or repairing at ICON s option the product at one of its authorized service centers All products for which warranty claim is made must be received by ICON at one of its authorized service cen ters with all freight and other transportation charges prepaid accompanied by sufficient proof of purchase All returns must be pre authorized by ICON This warranty does not extend to any product or damage to a product caused by or attributable to freight damage abuse misuse improper or2. 22 ATTACHING AND REMOVING THE SEAT To attach the Seat 13 set the bracket on the Seat Frame 36 onto the indicated pins on the Front Upright 42 Attach the 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 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 23 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 u
3. OL 1 2 3 4 61 5 16 x 2 Eyebolt 35 3 4 Round Inner Cap 34 1 Round Inner Cap 49 E 1 Round Cover Cap 70 1 Square Inner Cap 6 V 1 3 4 Square Inner Cap 44 1 1 2 Square Inner 32 2 Square Inner Cap 27 Ji ML S 2 Square Outer Cap 51 NW 5 y WW 7 mm 8 x 1 2 Self tapping Screw 87 3 8 x 3 1 2 Bolt 16 MW E 3 8 x 3 3 4 Bolt 88 NN 1 x 7 8 Plastic Bushing 90 5 16 x 5 Bolt 68 Cable Clip 53 1 Retainer 69 1 1 8 x 2 1 2 Plastic Bushing 89 8 3 1 2 Pulley 15 Not shown to scale 2 lt V Pulley 50 Not shown to scale NN 5 16 x 6 Bolt 60 QW 3 8 x 8 Bolt 59 PART LIST Model No WESY96480 Key No Qty 10 0 34 00 00 gt 09 Description 5 16 x 2 1 2 Carriage Bolt 1 4 Nylon Locknut 5 16 Nylon Locknut Base Stabilizer 1 Square Inner Cap 5 8 x 9 16 Spacer 5 16
4. Insert 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 1 2 Screws 18 Insert the 1 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 Upright with a 1 4 x 2 1 2 Screw 43 and a 1 4 Flat Washer 10 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 18 SEAT ASSEMBLY 39 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 Washers 10 The Backrest must be oriented as shown 40 Press a 1 1 2 Square Inner Cap 32 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 through the indicated hole in the Front Seat Frame 36 Tighten a 1 4 Nylon Locknut 2 with a 1 4 Flat Washer 10 onto the Carriage Bolt Attach the other end of the Seat 13 to the
5. Nylon Locknuts 3 onto the Carriage Bolts Do not tighten the Nylon Locknuts yet Press two 2 Square Inner Caps 27 into the Leg Press Upright 56 Press a 2 Square Inner Cap into the VKR Upright 74 Attach the Rubber Bumper 91 to the Leg Press Upright 56 with the 8 x 1 2 Self tap ping Screw 87 Slide the Front Upright 42 onto the 5 16 x 2 1 2 Carriage Bolts 1 in the Base 4 Hand tighten a 5 16 Nylon Locknut 3 onto each Carriage Bolt Do not tighten the Nylon Locknuts yet Press a 1 Square Inner Cap 6 into the Front Upright 42 N High Sides of Brackets 1 56 FRAME ASSEMBLY 4 Press a 2 Square Inner Cap 27 into the end of the Top Frame 55 Press a 1 3 4 Square Inner Cap 44 into each end of the crossbar on the Top Frame Press two 1 Round Inner Caps 49 into the top of the crossbar Attach the Top Frame 55 to the VKR Upright 74 and the Leg Press Upright 56 with two 5 16 x 2 3 4 Bolts 11 and two 5 16 Nylon Locknuts 3 Attach the Top Frame 55 to the Front Upright 42 with two 5 16 x 2 3 4 Bolts 11 two 5 16 Flat Washers 8 and two 5 16 Nylon Locknuts 3 Slide the Rear Seat Frame 100 onto the indicated 5 16 x 2 1 2 Carriage Bolts 1 in the Stabilizer 5 Hand tighten two 5 16 Nylon Locknuts 3 onto the Carriage Bolts Attach the other end of the Rear Seat Frame 100 to the Leg Press Upright
6. pared to give the following information 1 The MODEL NUMBER of the product WESY96480 2 The NAME of the product WEIDER PRO 9648 Home Gym System 3 The SERIAL NUMBER of the product see the front cover of this manual 4 The KEY NUMBER and DESCRIPTION of the part s see the PART LIST and EXPLODED DRAWING attached at the center of this manual Part No 149262 H02755 C Printed in Canada 1998 ICON Health amp Fitness Inc
7. 56 with two 5 16 x 2 3 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 2 1 2 Carriage Bolts 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 eight Weights 25 onto each set of Weight Bumpers 19 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 Grooves FRAME ASSEMBLY 7 Press a Weight Tube Bumper 64 into the end of a Weight Tube 63 Insert the Weight Tube into the front stack of Weights 25 Be sure that the pin on the Weight Tube is sit ting 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 Press a Weight Tube Bumper 64 into the end of the other 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
8. 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 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 page 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 page 25 21 HOW TO USE THE HOME GYM SYSTEM The instructions below describe how each part of the home gym system can be adjusted Refer to the exercise poster accompanying this manual to see how the home gym system should 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 the effectiveness of the exercise will be reduced CHANGING THE WEIGHT SETTING The PRO 9648 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 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
9. Front Seat Frame 36 with a 1 4 Flat Washer 10 and a 1 4 x 2 Machine Screw 81 41 Press a 1 1 2 Square Inner Cap 32 into the Leg 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 Eyebolt 42 Rest the Front Seat Frame 36 on the indi cated 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 19 SEAT ASSEMBLY VKR ASSEMBLY 43 44 45 Press two 3 4 Round Inner Caps 34 into each Pad Tube 28 Insert a Pad Tube 28 into the 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 Locate and open the parts bag labeled VKR ASSEMBLY Press 1 1 2 Square Inner Caps 32 into the ends of the Left VKR Arm 79 and the Right VKR Arm 80 Attach the Left VKR Arm 79 and the Right VKR Arm 80 to the VKR Upright 74 with two 5 16 x 3 Bolts 75 and two 5 16 Nylon Locknuts 3 Attach the VKR Backrest 77 to the VKR Upright 74 with two 1 4 x 2 1 2 Screws 43 and two
10. 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 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 25 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 cables and the cable traps have been assembled correctly If 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
11. abnormal usage or repairs not provided by an ICON authorized service center products used for commercial or rental pur poses or products used as store display models No other warranty beyond that specifically set forth above is authorized by ICON ICON is not responsible or liable for indirect special or consequential damages arising out of or in con nection with the use or performance of the product or damages with respect to any economic loss loss of property loss of revenues or profits loss of enjoyment or use costs of removal installation or other consequential damages of whatsoever nature Some states do not allow the exclusion or limitation of inci dental or consequential damages Accordingly the above limitation may not apply to you The warranty extended hereunder is in lieu of any and all other warranties and any implied warranties of merchantability or fitness for a particular purpose is limited in its scope and duration to the terms set forth herein Some states do not allow limitations on how long an implied warranty lasts Accordingly the above limitation may not apply to you This warranty gives you specific legal rights You may also have other rights which vary from state to state ICON HEALTH amp FITNESS INC 1500 S 1000 W LOGAN UT 84321 9813 IMPORTANT PRECAUTIONS WARNING To reduce the risk of serious injury read the following important precautions before using the home gym system It is the
12. and Low Cable 23 1 High Pulley 2 TOP VIEW 6 High Cable 58 A3 5 Long U Bracket Low Cable 23 Front Weight Stack 8 1 Low Pulley 26 Military Press Cable 72 and Leg Press Cable 99 ej Military Press Cable 72 4 6 Pivot Arm G 1 1 U Bracket 3 2 e 4 Rear Weight Stack 1 ear Welg ac 4 Rear Seat Frame NS Leg Press Cable 99 27 H 1 4 Nylon Locknut 2 ZN H 5 16 Nylon Locknut 3 H 5 16 Nylon Jam Nut 93 __ 3 8 Nylon Locknut 21 1 4 Flat Washer 10 5 16 Flat Washer 8 3 8 Flat Washer 9 9 3 8 x 1 3 4 Bolt 24 AAA 1 4 x 2 Carriage Bolt 38 eee 1 4 x 2 1 2 Carriage Bolt 92 QN 1 4 x 2 Machine Screw 81 5 16 x 2 1 2 Bolt 22 NW 3 8 x 2 Bolt 12 5 16 2 1 4 33 1 4 x 2 1 2 Screw 43 5 16 x 2 1 2 Carriage Bolt 1 WW E NN 5 16 x 2 3 4 Bolt 11 AAA 5 16 x 2 3 4 Carriage Bolt 14 AAA m 5 16 x 3 Bolt 75
13. 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 Lubricate Lubricate Pin Grooves FRAME ASSEMBLY ARM ASSEMBLY 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 with a 5 16 x 6 Bolt 60 two 1 2 x 3 4 Spacers 61 and a 5 16 Nylon Locknut 3 10 Locate and open the parts bag 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 x 3 1 4 Bolt 67 Attach the Leg Press Arm 96 to the Stabilizer 5 with the Bolt and a 3 8 Nylon Locknut 21 Do not over tighten the Nylon Locknut The Leg Press Arm must be able to pivot freely Align the welded tubes on the Leg Press Plate 95 with 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 Press a 1 x 7 8 Plastic Bushing 90 onto each welded spacer on the Press Frame 17 Slide the Press F
14. responsibility of the owner to ensure 9 Do not use the VKR station when either that all users of the home gym system are weight stack is in use adequately informed of all precautions 10 Always wear athletic shoes for foot protec The home gym system is intended for home tion use only do not use the home gym system in an commercial rental or institutional setting 11 Always stand on a foot plate when perform ing an exercise that could cause the home Read all instructions in this manual and in gym system to tip the accompanying literature before using the home gym system 12 Keep your hands away from the leg press upright when the military press arm is being Use the home gym system only on a level used Your hand could become pinched surface Cover the floor beneath the home between the leg press upright and military gym system for protection press arm Inspect and tighten all parts often Replace 13 Make sure that the cables remain on the pul any worn parts immediately leys at all times If the cables bind while you are exercising stop immediately and make Keep small children and pets away from the sure that the cables are on all of the pulleys home gym system at all times 14 Always disconnect the lat bar from the home Never release the press arm butterfly arms gym system when performing an exercise military press arm leg lever leg press plate that does not use the lat bar lat bar or nylon strap while weights are raised The w
15. the upper end of the Right Arm is behind the indicated bracket on the Top Frame 55 Tap two 1 Retainers 69 and a 1 Round Cover Cap 70 onto the axle Be sure that the teeth on the Retainers bend toward the Round Cover Cap as shown in the inset drawing Attach the Left Arm 47 in the same manner Press 1 3 4 Square Inner Caps 44 into the lower ends of the Right and Left Arms 47 48 Wet the lower end of each Arm with soapy water Slide a 10 Pad 45 onto the lower end of each Arm 10 Brackets Bracket ARM ASSEMBLY CABLE ASSEMBLY 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 indicated end of the Military Press Arm 84 Press two 1 Round Inner Caps 49 into the Military Press Arm Slide two 5 Plastic Grips 83 onto the Military Press Arm Attach the Military Press Arm 84 to the VKR Upright 74 with a 3 8 x 3 1 4 Bolt 67 and a 3 8 Nylon Locknut 21 Locate and open the parts bags labeled CABLE ASSEMBLY and PULLEYS During steps 16 through 36 refer to the CABLE DIAGRAMS on pages 26 27 of this manual to verify proper cable routing Before beginning this section fully unwind the four Cables Identify the four Cables by comparing the lengths and ends of the Cables The appro
16. 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 indi cated Weight Tube 63 with a 5 16 x 1 3 4 Bolt 24 and a 5 16 Nylon Locknut 3 0 O 0 0 Q 9 A 31 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 Flat Washer 10 Do not com pletely tighten the Nylon Locknut It should be threaded onto the end of the Cable only a couple of turns as shown in the inset drawing Attach the Small U Bracket 71 to the indi cated Weight Tube 63 with a 5 16 x 1 3 4 Bolt 24 and a 5 16 Nylon Locknut 3 15 CABLE ASSEMBLY 32 Wrap the Military Press Cable 72 around 3 1 2 Pulley 15 Attach the Pulley to the Top Frame 55 with a 3 8 x 2 Bolt 12 and a 3 8 Nylon Locknut 21 See the inset drawing Wrap the Long Cable 72 around a 3 1 2 Pulley 15 Attach the Pulley and a Cable Trap 66 to the bracket on the Stabilizer 5 with a 3 8 x 2 Bolt 12 and a 3 8 Nylon Locknut 21 Be sure that the Cable Trap is turned to hold the Cable in place 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
17. 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 setting Use the WEIGHT RESISTANCE CHART on page 24 to find the approximate amount of resis tance at each weight station ATTACHING THE LAT BAR OR NYLON STRAP TO THE HIGH PULLEY STATION Attach the Lat 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 Chain between the Lat Bar 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
18. 1 4 Flat Washers 10 Attach a VKR Armrest 78 to the Right VKR Arm 80 with two 1 4 x 2 Machine Screws 81 and two 1 4 Flat Washers 10 Attach a VKR Armrest 78 to the Left VKR Arm 79 in the same manner 20 46 Remove the adhesive backing from the PRO 9648 decal and apply it to the Front Upright 42 under the plate with the WEIDER MAN as shown below Three decals as the one shown to the left have been placed on the weight bench If a decal is missing Misuse of this product or if it is not legible please call our may result in serious Customer Service Department toll injury free at 1 800 999 3756 Monday e Read user s manual through Friday 6 a m until 6 p m and follow all warnings Mountain Time to order a replace and operating instruc ment decal Apply the replacement tions prior to use decal to the location shown Do not allow children on or around machine Replace label if damaged illegible or removed WARNING Decal WARNING Decal WARNING Decal WEIDER Plate 47 Make sure that all parts have been properly tightened The use of the remaining parts will be explained in HOW TO USE THE HOME GYM SYSTEM
19. 2 1 2 Bolt 8 x 1 2 Self tapping Screw 3 8 x 3 3 4 Bolt 1 1 8 x 2 1 2 Plastic Bushing 1 x 7 8 Plastic Bushing Rubber Bumper 1 4 x 2 1 2 Carriage Bolt 5 16 Nylon Jam Nut Press Bracket Leg Press Plate Leg Press Arm Press Pin Bushing Leg Press Cable Rear Seat Frame Pivot Arm User s Manual Exercise Poster Note indicates a non illustrated part Specifications are subject to change without notice d o He si E 08v96AS3M ON IPPON SNIMVHUG WEIGHT RESISTANCE CHART This chart shows the approximate weight resistance at each weight station Top refers to the 6 5 Ib top weight The other numbers refer to the 12 5 Ib weight plates The butterfly arm resistance listed is the resistance for each butterfly arm WEIGHT PRESS BUTTERFLY LEG HIGH LOW MILITARY LEG ARM ARM LEVER PULLEY PULLEY PRESS ARM PRESS PLATES Ibs Ibs Ibs Ibs Ibs Ibs Ibs The actual resistance at each weight station may vary due to differences in individual weight plates as well as friction between the cables pulleys and weight guides 24 ORDERING REPLACEMENT PARTS To order replacement parts simply 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 be pre
20. 4 Bolt 88 a 3 8 Flat Washer 9 and a 3 8 Nylon Locknut 21 Be sure that the Nylon Locknut is on the side shown and that the Cable Trap is posi tioned to hold the Cable in place 16 CABLE ASSEMBLY 34 See inset drawing A Attach a 3 1 2 Pulley 15 and a Cable Trap 66 to the upper hole in the Long U Bracket 57 with a 3 8 x 2 Bolt 12 and a 3 8 Nylon Locknut 21 Be sure that the Cable Trap is inside the 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 a 5 16 Flat Washer 8 onto a 5 16 x 2 3 4 Bolt 11 Insert the Bolt through the Pivot Arm 101 from the indicated side Tighten a 5 16 Nylon Jam Nut 93 onto the Bolt Slide the end of the Military Press Cable 72 onto the end of the Bolt Thread another 5 16 Nylon Jam Nut onto the Bolt Do not fully tighten the sec ond Jam Nut There must be room between the two Jam Nuts for the end of the Cable to pivot 35 Locate the Leg Press Cable 99 Attach the end of the Leg Press Cable to the Long U Bracket 57 with a 1 4 Nylon Lockn
21. Flat Washer 3 8 Flat Washer 1 4 Flat Washer 5 16 x 2 3 4 Bolt 3 8 x 2 Bolt Seat 5 16 x 2 3 4 Carriage Bolt 3 1 2 Pulley 3 8 x 3 1 2 Bolt Press Frame 1 4 x 1 2 Screw Weight Bumper Pulley Bracket 3 8 Nylon Locknut 5 16 x 2 1 2 Bolt Low Cable 5 16 x 1 3 4 Bolt Weight Weight Pin 2 Square Inner Cap Pad Tube Leg Lever Foam Pad Long Cable Trap 1 1 2 Square Inner Cap 5 16 x 2 1 4 Bolt 3 4 Round Inner Cap 5 16 x 2 Eyebolt Front Seat Frame Seat Plate 1 4 x 2 Carriage Bolt Nylon Strap Seat Knob Front Backrest Front Upright 1 4 x 2 1 2 Screw 1 3 4 Square Inner Cap 10 Pad Press Arm Left Arm Right Arm 1 Round Inner Cap V Pulley 2 Square Outer Cap Chain Key No 53 54 55 56 57 58 59 60 Qty 2 WANANNA HANANNNNANAANAA ADW R0998A Description Cable Clip Lat Bar Top Frame Leg Press Upright Long U Bracket High Cable 3 8 x 8 Bolt 5 16 x 6 Bolt 1 2 x 3 4 Spacer Long Weight Guide Weight Tube Weight Tube Bumper Top Weight Cable Trap 3 8 x 3 1 4 Bolt 5 16 x 5 Bolt 1 Retainer 1 Round Cover Cap Small U Bracket Military Press Cable Short Weight Guide VKR Upright 5 16 x 3 Bolt 3 1 2 Low Pulley VKR Backrest VKR Armrest Left VKR Arm Right VKR Arm 1 4 x 2 Machine Screw Handle 5 Plastic Grip Military Press Arm Rear Backrest 3 8 x
22. Model No WESY96480 Serial No Write the serial number in the space above for reference lt Serial Number Decal Under Seat QUESTIONS As a manufacturer we are mitted to providing complete qmm customer satisfaction If you have DM questions or find that there are missing or damaged parts we will guarantee you complete sat isfaction through direct assis tance from our factory IZ TO AVOID UNNECESSARY E DELAYS PLEASE CALL DIRECT iL 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 o Mon Fri 6 6 p m MST CAUTION Read all precautions and instruc U 9 E 9 U AL tions in this manual before using this equipment Save this manual for future reference PATENT PENDING TABLE OF CONTENTS LIMITED WARRANTY zen rU 2 IMPORTANT PRECAUTIONS 3 BEFORE YOU BEGIN kem n e elk Baa he e ars 4 ee Pity aD tries tet A tod Mtm Lr Ate Md 5 HOW TO USE THE HOME GYM SYSTEM
23. an be found on a decal attached to the WEIDER PRO 9648 see the front cover of this manual Before reading further please review the drawing below and familiarize yourself with the parts that are labeled ASSEMBLED DIMENSIONS Height 76 in Width 89 in Length 64 Military Press Arm Backrests Leg Lever Leg Press Low Pulley Station Foot Plate Plate Weight Stacks ASSEMBLY Before beginning assembly carefully read the As you assemble the PRO 9648 be sure that all following information and instructions parts are oriented as shown in the drawings Place all parts of the PRO 9648 in a cleared area Tighten all parts as you assemble them unless and remove the packing materials do not dis instructed to do otherwise pose of the packing materials until assembly is completed THE FOLLOWING TOOLS NOT INCLUDED ARE REQUIRED FOR ASSEMBLY The assembly is broken into five stages 1 frame 9 assembly 2 press and butterfly arm assembly Two 2 adjustable wrenches 3 cable and pulley assembly 4 seat and back Y rest assembly and 5 VKR assembly The hard 1 standard screwdriver ware for each stage is packaged separately One 1 phillips screwdriver Wait until you begin each assembly stage to open One 1 rubber mallet L the parts bag labeled for that assembly stag
24. e Lubricant such as grease or petroleum jelly For help identifying the small parts used in and soapy water will also be needed assembly use the PART IDENTIFICATION CHART located in the center of this manual Assembly will be more convenient if you have the Note Some small parts may have been pre following tools A socket set a set of open end or attached for shipping If a part is not in the parts closed end wrenches or a set of ratchet wrenches bag check to see if it has been pre attached 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 the indicated locations on the Stabilizer 5 Press a 2 Square Inner Cap 27 into the end of the Base 4 Insert six 5 16 x 2 1 2 Carriage Bolts 1 up through the Stabilizer 5 Insert two 5 16 x 2 1 2 Carriage Bolts up through the Base 4 Attach the Base 4 to the Stabilizer 5 with two 5 16 x 2 3 4 Bolts 11 two 5 16 Flat Washers 8 and two 5 16 Nylon Locknuts 3 Do not tighten the Nylon Locknuts yet FRAME ASSEMBLY FRAME ASSEMBLY 2 Slide the VKR Upright 74 and the Leg Press Upright 56 onto the indicated 5 16 x 2 1 2 Carriage Bolts 1 in the Stabilizer 5 The high side of the brackets on the VKR Upright and Leg Press Upright should be on the side shown Hand tighten four 5 16
25. e Tighten the 3 8 x 2 1 2 Bolt 86 and the 3 8 Nylon Locknut not shown 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 12 CABLE ASSEMBLY 22 23 24 See the inset drawing Attach a 3 1 2 Pulley 15 and a Cable Trap 66 to the upper hole in a Long U Bracket 57 with a 3 8 x 2 Bolt 12 and a 3 8 Nylon Locknut 21 Be sure that the Cable Trap is inside the Long U Bracket Note This may come pre assem bled 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 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 Note T
26. eights will fall with great force 15 If you feel pain or dizziness at any time while Keep hands and feet away from moving parts exercising stop immediately and begin cool ing down 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 BEFORE YOU BEGIN Thank you for selecting the versatile WEIDER PRO 9648 Home Gym System The PRO 96468 offers a selection of weight stations designed to develop every major muscle group of the body Whether your goal is to tone your body build dramatic muscle size and strength or improve your cardiovascular system the PRO 96468 will help you to achieve the specific results you want For your benefit read this manual carefully before using the WEIDER PRO 9648 Home Gym System If you have additional questions please call our Lat Bar High Pulley Station VKR Arms Butterfly Arms Press Arm 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 WESY96480 The serial number c
27. he 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 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 Tighten the 3 8 Nylon Locknut 21 and the 3 8 x 3 1 2 Bolt not shown 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 N NSNN 14 Inset shows view from other side 23 88 66 42 Inset shows view from other side CABLE ASSEMBLY 29 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 30 Attach the High Cable 58 to a Small U Bracket 71 with a 1 4 Nylon Locknut 2 and a 1 4 Flat Washer 10 Do not completely
28. his assembly step shows how to complete the assembly of several pre attached parts The 5 8 x 9 16 Spacer 7 has been pre attached on the outside of the 3 1 2 Low Pulley 76 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 not remove the Bolt The Bolt has been shown removed for part identification Reattach the 3 1 2 Low Pulley 76 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 21 yet Be sure that the 3 8 x 3 3 4 Bolt 88 the 3 8 Flat Washer 9 the 5 8 x 9 16 Spacer 7 the 3 1 2 Low Pulley 76 and the 3 8 Nylon Locknut 21 are oriented as shown 13 Bracket 2 CABLE ASSEMBLY 25 26 27 28 Locate the Low Cable 23 Route the Low Cable under the 3 1 2 Low Pulley 76 attached to the lower hole in the Press Frame 17 Be sure that the end of the Cable with the ball is on the indicated side of the Press Frame 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 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 t
29. rame 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 a 3 8 Nylon Locknut 21 292 Lubricate must be on this side 59 Lubricate ARM ASSEMBLY 12 Press a 1 Round Inner Cap 49 into one of the Press Arms 46 Press a 1 3 4 Square Inner Cap 44 into the Press Arm Attach the Press Arm 46 to one side of the Press Frame 17 with two 5 16 x 2 1 2 Bolts 22 and two 5 16 Nylon Locknuts 3 Assemble the other Press Arm 46 in the same manner 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 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
30. se 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 Tighten the 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 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 Tighten the 1 4 Nylon Locknut 2 that connects the end of the High Cable 58 to the Small U Bracket 71
31. ut 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 Wrap the Leg Press Cable 99 around a 3 1 2 Pulley 15 Attach the Pulley to the Leg Press Upright 56 with the 3 8 x 3 1 2 Bolt 16 a 3 8 Flat 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 17 CABLE ASSEMBLY SEAT ASSEMBLY 36 37 38 Attach the Press Bracket 94 to the Leg Press Arm 96 with a 5 16 x 3 Bolt 75 and a 5 16 Nylon Locknut 3 Wrap the Leg Press Cable 99 around a 3 1 2 Pulley 15 Attach the Pulley to the Press Bracket 94 with the 3 8 x 2 Bolt 12 and a 3 8 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 holes are for cable adjustment Tighten a 5 16 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 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 Locate and open the parts bag labeled SEAT ASSEMBLY
32. ximate 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 Locate the High Cable 58 Wrap the High Cable around a 3 1 2 Pulley 15 Attach the Pulley to the Top Frame 55 with a 3 8 x 3 3 4 Bolt 88 and a 3 8 Nylon Locknut 21 Be sure that the end of the Cable with the ball is on the indicated side of the Pulley and that the Cable is between the Pulley and the hook 11 47 o Ene CABLE ASSEMBLY 20 21 Wrap the High Cable 58 around a V Pulley bO 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 a 3 8 Nylon Locknut 21 Be sure that the Long Cable Trap is positioned to hold the Cable in place 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 posi tioned to hold the Cable in place Tighten the 3 8 x 2 1 2 Bolt 86 and the 3 8 Nylon Locknut not shown 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 plac
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