Weider WESY9645 User's Manual
Contents
1. ASSEMBLY Before beginning assembly carefully read the following information and instructions e Place all parts of the PRO 9645 in a cleared area and remove the packing materials do not dis pose of the packing materials unti assembly is completed The assembly is broken into four stages 1 frame assembly 2 arm assembly 3 cable and pulley assembly and 4 seat and backrest assembly The hardware for each stage is packaged sepa rately Wait until you begin each assembly stage to open the parts bag labeled for that assembly stage For help identifying the small parts used in assembly use the PART IDENTIFICATION CHART located in the center of this manual Note Some small parts may have been pre attached for shipping If a part is not in the parts bag check to see if it has been pre attached 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 Stabilizer 5 Press a 2 Square Inner 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 2 3 4 Bolts 11 two 5 16 Flat Washers 8 and two 5 16 Nylon Locknuts 3 Do not tighten the Nylon Locknuts y2. LP Er a waa x iS gt 13 14 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 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 Le
3. The Nylon Strap 39 can be attached in the same manner 22 ATTACHING 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 23 WEIGHT RESISTANCE CHART This chart shows the approximate weight resistance at each weight station Top refers to the 6 5 16 top weight The other numbers
4. PATENT PENDING Model No WESY96450 Serial No Write the serial number in the space above for reference Serial Number Decal Under Seat QUESTIONS As a manufacturer we are com mitted to providing complete customer satisfaction If you have GUSStions Gr find tnai there are missing or damaged parts we will guarantee you complete sat isfaction through direct assis tance from our factory TO AVOID UNNECESSARY DELAYS PLEASE CALL DIRECT TO OUR TOLL FREE CUSTOMER HOT LINE The trained techni cians on our customer hot line will provide immediate assis tance free of charge to you CUSTOMER HOT LINE 1 800 999 3756 Mon Fri 6 a m 6 p m MST CAUTION Read all precautions and instrue tions in this manual before using this eguipment Save this manual for future reference a o 83 oe be RE dt TABLE OF CONTENTS IMPORTANT PRECAUTIONS 2 BEFORE YOU BEGIN suck AES re AAA ea ee ESS 3 ASSEMBLY Ge Ree eR E Ke ES 4 HOWTOUSETHEHOMEGYMSYSTEM 22 WEIGHT RESISTANCE CHART 24 TROUBLE SHOOTING AND MAINTENANCE 25 CABLE DIAGRAMS 66 5 A ii we eee dele hea nee eiet 26 ORDERINGREPLACEMENTPARTS Back Cover LIMITED
5. 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 102 and the 3 8 Nylon Locknut 21 are oriented as shown 13 paT 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 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 10 attached to the Upper NOIS 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 plac
6. Short Weight Tube 1 1 4 Round Inner Cap Angle Bracket 5 16 x 3 Bolt 3 8 x 4 1 2 Bolt User s Manual Exercise Poster Note indicates a non illustrated part Specifications are subject to change without notice
7. 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 Front Seat Frame 36 with a 1 4 Flat Washer 10 and a 1 4 x 2 Machine Screw 81 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 35 Lubricate 33 1 3 K Dr 3 Rest the Front Seat Frame 36 on the indicat ed pin in the Front Upright 42 Attach the Front Seat Frame to the Front Upright with a 5 16 x 2 3 4 Carriage Bolt 14 and the Seat Knob 40 20 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 EAT ASSEMBLY 48 Remove the backing from the PRO 9645 decal and apply it to the home gym system as shown Make sure that all part
8. Locknuts yet Press a 1 Square Inner Cap 6 into the Front Upright 42 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 Assist 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 5 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 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 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 6 Set two Weight Bumpers 19 on the bracket 6 on the Base 4 as shown Set two Weight Pin Bumpers 19 on the bracket on the Stabilizer Grooves 5 Stack ten Weights 25 onto the bracket on the Stabilizer 5 S
9. WARRANTY iii AAAH Back Cover Note A PART IDENTIFICATION CHART and a PART LIST EKPLODED DRAWING are attached to the center of this manual Remove the PART IDENTIFICATION CHART and the PART LIST EXPLODED DRAWING before beginning assembly upright when the military press arm is beir 19 used Your hand could become pinched ie a o o ooo See between the leg Pres P and the mili Read all instructions in this manual and in tary press arm ae the accompanying literature before using the E ag mme aym system dr Keen v vour hands awav Tom the assist mEn upright when the assist arm is being used E Use the home gym system only on a level Your hand could become pinched between surface Cover the floor beneath the home the assist oo angi the pe arm a gym system for protection SE LA ways be sure that your body weight is fully T Inspect and tighten all parts often Replace supported by the dip arms or the pull up n lu arms before kneeling on the assist arm The assist arm can drop quickly v when your body fre weight 16 placed on it 1 8 Aes stand 0 ona foot plate when pet 1 iyik feel a or dizziness at any time aa ing an exercise that could cause the home exercising stop immediately and begin cool gym system to a z ANA En mes coe Important ft persons over the age of 35 or persons with health elon
10. 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 arounda V Pulley 50 Attach the V Pulley to the 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 indi cated 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 Wrap the Military Press Cable 72 around a V Pullav 50 Attach the V Pulley and a Long Cable Trap 31 to the Assist Upright 74 with a 3 8 x 4 1 2 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 15 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 16 36 Slide a 5 16 Flat Washer 8 onto a 5 16 x 2 3 4 Bolt 11 Insert the Bolt through the indi cated hole in the Pivot Arm 101 The Bolt must be inserted from
11. 8 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 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 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 3 4 Bolt 88 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 Attach the Press Bracket 94 to the Leg Press Arm 96 with a 5 16 x 3 Rolt 111 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 anda 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 th
12. ER PRO 9645 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 LIMITED WARRANTY vw m r r ICON Hoalth amp Fitness Inc ICON warrants this product to be free fiom 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 or 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
13. Thi Read all instructions before using ICON assumes no responsibility for persona ny or 7 BEFORE YOU BEGIN Thank you for selecting the versatile WEIDER PRO Customer Service Department toll free at 1 800 999 9645 Home Gym System The PRO 9645 offers a 3756 Monday through Friday 6 a m until 6 p m selection of weight stations designed to develop every Mountain Time excluding holidays To help us assist major muscle group of the body Whether your goalis you please note the product model number and serial to tone your body build dramatic muscle size and number before calling The model number is strength or improve your cardiovascular system the WESY96450 The serial number can be found ona PRO 9645 will help you to achieve the specific results decal attached to the WEIDER PRO 9645 see the you want front cover of this manual For your benefit read this manual carefully before Before reading further please review the drawing using the WEIDER PRO 9645 Home Gym System below and familiarize yourself with the parts that are If you have additional questions please call our labeled Lat Bar ASSEMBLED DIMENSIONS Height 78 in Width 86 in Length 66 in High Pulley Station Butterfly Arms Military Press Arm Pull up Handles Dip Handles Backrests DEED i Leg Press Plate Assist Arm Press Arm Leg Lever Weight Stacks Low Pulley Station Weight Pin Foot Plate
14. d 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 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 Chaln 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 witha 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 Chaln between the Lat Bar and the Low Cable so the Lat Bar is in the correct starting posltlon for the exercise to be performed
15. d that the Cable Trap 66 is turned to hold the Cable in place 12 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 Bracket 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 camnlete the assembly of several nre attached parts The 5 8 x 9 16 Spacer 7 has been pre 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 not remove the Bolt The Bolt has been shown removed for part identification Reattach the 3 1 2 Low Pulley 102 with the F 5 8 x 9 16 Spacer 7 between the Pulley and WA the Press Frame 17 Do not tighten the 3 8 RO Nylon Locknut
16. e Puiley and that the Cable is between the Pulley and the hook 11 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 a 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 posl 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 22 Route the High Cable 58 around the Pulley 00 on the Aight Arm 40 DE 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 1 2 Bolt 86 and the 3 8 Nylon VP 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 an
17. e 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 14 G pA Y ZO B p Crossbar 23 15 88 66 42 Inset shows view from other side 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 a 1 4 Flat Washer 10 Do not completely tighten the Nylon Locknut 11 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 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 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 GABLE ASSEMBLY f t GU f f f 33 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 gt 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
18. e two Jam Nuts for the end of the Cable to pivot 18 40 Locate and open the parts bag labeled SEAT ASSEMBLY 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 41 Attach one end of a Seat 13 to the Rear Seat Fraine 100 with iwo 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 00 UW DB lt L Attach the Assist Seat 104 and the Angle Bracket 110 to the Assist Arm 105 with four 1 4 Fiat Washers 10 and four 1 4 x 2 1 2 Screws 43 19 _ 48 Attach the Front Backrest 41 to the Front Do 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 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
19. eight Guides 62 to the Top Frame 55 in the same manner 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 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 8011 and a 3 8 Nylon Locknut 21 N ep Re gt gt NN Bay w 67 Lubricate Gu PI 2 P 7 pe P must be on this side 59 Lubricate 12 Yo we st AE thee hat bee al vi v hatte BD Len SR Fo CAA hy ma i yt venn SyaT PE A pisi ad wa ou te pAg wi At gt
20. et One 1 rubber mallet 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 2 One 1 standard screwdriver e One 1 phillips screwdriver e 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 2 Slide the Assist 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 Assist Upright and Leg Press Upright should be on the side shown Hand tighten four 5 16 lt Nylon Locknuts 3 onto the Carriage Bolts High Sides Do not tighten the Nylon Locknuts yet of Brackets Press two 2 Square Inner Caps 27 into the Leg Press Upright 56 Press a 2 Square Inner Cap into the Assist 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 Rase 4 Hand tighten a 5 16 Nylon Locknut 3 onto each Carriage Bolt Do not tighten the Nylon
21. ft 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 Welded Brackets Lubricate Axle 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 Handgrips 83 onto the Military Press Arm Attach the Pivot Arm 101 to the Assist Upright 74 with a 3 8 x 3 1 4 Bolt 67 and a 3 8 Nylon Locknut 21 E LIL X i i a i 1 1 1 16 Press two 1 x 2 Inner Caps 107 into the Amamimb Auman ZA NE NDIII FNS N BW pe 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 Leg Press Upright 56 The Assist Arm must also be below the welded bracket on the Assist Upright 74 10 17 Attach the Left Pull up Arm 75 and the Right Pull up Arm 77 to the Assist Upright 74 with two 5 16 x 2 3 4 Bolts 11 and two 5 16 Nylon Locknuts 3 Attach the Left Dip Arm 78 and the Right Dip Arm 79 to the Assist Upright 74
22. ing 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 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 thai the Cabie and Pulley move smoothly The other Long U Bracket 57 can be adjusted in the same manner e 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 The Military Press Cable 72 can be tightened in the same manner e 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 welght stack If a cable tends to slip off the pulleys often it may have become twisted Remove the cable a
23. ly 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 WESY96450 ROS96A H ve ion Losna ey 1 4 x 2 Machine Screw 81 1 5 16 Nylon Locknut 3 36 1 4 x 2 1 2 Carriage Bolt 92 1 5 16 x 2 1 2 Bolt 22 4 PN O 3 8 Nylon Locknut 21 23 NI 1 4 Flat Washer 10 15 3 8 x 2 Bolt 12 5 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 Fiat Washer 9 9 AUNE 5 16 x 2 1 2 Carriage Bolt 1 10 3 8 x 2 1 2 Bolt 86 4 mn 5 16 x 2 3 4 Bolt 11 14 5 16 x 2 3 4 Carriage Bolt 14 1 3 8 x 4 1 2 Bolt 112 1 5 16 x 1 3 4 Bolt 24 2 3 8 x 1 3 4 Bolt 76 2 1 4 x 2 Carriage Bolt 38 1 NN li is 5 16 x 3 Bolt 111 1 3 8 x 3 1 4 Bolt 67 2 ANN 3 8 x 3 1 2 Bolt 16 1 1 4 x 1 2 Screw 18 6 amp YA 3 8 x 3 3 4 Bolt 88 6 5 16 x 5 Bolt 68 1 Cable Clip 53 3 1 Retainer 69 4 DIA ji OL 3 8 x 8 Bolt 59 1 1 1 8 x 2 1 2 Plastic Bushing 89 2 5 1 6 x 6 Bolt 60 2 3 8 x 6 Bolt 106 1 lt 1 x 7 8 Plastic Bushing 90 2 3 1 2 Pulley 15 13 Not shown to scale V Pulley 50 5 Not shown
24. nd 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 and Low Cable 23 Bi mes 1 High Pulley imc UZ C l 2 ji High Cable 58 2 5 Long U Bracket Low Cable 23 Front Weight Stack 8 Military Press Cable 72 and Leg Press Cable 99 Military Press Cable 72 8 Pivot Arm Rear Weight Stack 1 Leg Press Cable 99 27 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 pared to give the following information 1 The MODEL NUMBER of the product WESY96450 2 The NAME of the product WEID
25. 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 Part No 133407 RO996A Printed in Canada 1996 ICON Health amp Fitness Inc REMOVE THIS PART IDENTIFICATION CHART FROM THE MANUAL This chart is provided to help you identify the small parts used in assembly Important Some parts may have been pre assembled for shipping purposes If you cannot find a part in the parts bags check to see if it has been pre assembied 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 assemb
26. refer to the 12 5 16 weight plates The butterfly arm resistance listed is the resistance for each butterfly arm WEIGHT PRESS BUTTERFLY LEG HIGH LOW MILITARY LEG ASSIST ARM ARM LEVER PULLEY PULLEY PRESSARM PRESS ARM PLATES Ibs 065 Ibs 065 ibs Ibs lbs ibs 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 24 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 middie of the weight stack Slack can be removed from these cables several ways e See draw
27. s have been properly 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 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 17 there is any slack in the cables or chain as an exercise is performed the effectiveness of the exerclse 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 an
28. t 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 Cable Clip Lat Bar Top Frame Leg Press Upright Long U Bracket Key No Qty aot dt b OH MH st oe MH os oe PG Hee oe AH oe PON Qe 4 AAO AAD AAA PON A A 1 P 1 AP oa RO996A Description High Cable 3 8 x 8 Bolt 5 16 x 6 Bolt 1 2 x 3 4 Spacer Long Weight Guide Long 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 Assist Upright Left Pull up Arm 3 8 x 1 3 4 Bolt Right Pull up Arm Left Dip Arm Right Dip Arm Long Handgrip 1 4 x 2 Machine Screw Handle 5 Plastic Handgrip Military Press Arm Rear Backrest 3 8 x 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 3 1 2 Low Pulley Handle Cap Assist Seat Assist Arm 3 8 x 6 Bolt 1 x 2 Inner Cap
29. tack 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 7 Press a Weight Tube Bumper 64 into the end of the Short Weight Tube 108 Insert the Weight Tube into the front stack of Weights 25 Be sure that the pin on the Weight Tube Is sitting In the pin grooves in the top Weight i TE 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 Welght Guides are at the top as shown 8 Press a Weight Tube Bumper 64 into the end of the LONG Weight Tube 63 inseri ihe Weight Tube into the rear stack of Weights 25 Be sure that the pin on the Weight Tube Is sitting In the pin grooves in the top Weight Lubricate the inside of the holes in the other Top Weight 65 Set the Top Weight onto the rear stack of Weights 25 Insert both Short Weight Guides 73 into the stack of Weights Be sure that the holes in the Weight Guides are at the top as shown Pin Grooves NI aI yg 8 I N Q 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 W
30. the side shown Fully tighten a 5 16 Nylon Jam Nut 93 onto the Bolt _ 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 See inset drawing A Attach a 3 1 2 Pulley 15 and a Cabie trap 66 to the upper nole 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 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 e must be room between the two Jam Nuts for the end of the Cabie to pivot 17 BEREN Uh te po be ve wee od 3 n rt LLI wae ne D rat WA pie Phan ya we 2 wh LLI ke ji wig FG wre 0 Arn Coad T za eo sedis 3
31. to scale OL OC 5 8 x 9 16 Spacer 7 1 1 2 x 3 4 Spacer 61 4 3 4 Round Inner Cap 34 4 OM Q a 1 Round Inner Cap 49 6 5 16 x 2 Eyebolt 35 1 1 Round Cover Cap 70 2 KA PEE 1 1 2 Square Inner Cap 32 4 1 pre Inner Cap ae 1 1 x 2 Inner Cap 107 2 i i EE 7 2 Square Inner Cap 27 8 2 Square Outer Cap 51 2 REMOVE THIS PART LIST EXPLODED DRAWING CHART FROM THE MANUAL m 2 U ER O g m g O gt i Q A O m 0 5 O Ja PART LIST Model No WESY96450 Key No Qty 10 OOnN 01 1 N Ar NA 1 0 NN Nas 4 4 4 4 7 1 1 21 4 03 nA AGANO 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 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 31 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 Fron
32. with two 5 16 x 2 3 4 Bolts 11 and two 5 16 Nylon Locknuts 3 gt Wet the end of the Left Pull up Arm 75 with M soapy water Slide a Long Handgrip 80 onto S the Left Pull up Arm Sa LLI re 0 Nn Slide a Long Handgrip 80 onto the Right Pull up Arm 77 onto the Left Dip Arm 78 and onto the Right Dip Arm 79 in the same manner Press two 1 1 4 Round Inner Caps 109 into the Left Pull up Arm 75 and into the Right Pull up Arm 77 Press a 1 1 4 Round Inner Cap 109 into the Left Dip Arm 78 and into the Right Dip Arm 79 Locate and open the parts bags labeled CADLE ASSEMBLY anu PULLEYS During steps 19 through 39 refer to the CABLE DIAGRAMS on pages 26 27 of this manual to verify proper cable routing Before 447 beginning this section fully unwind the four 4 Cables Identify the four Cables by comparing the lengths and ends of the Cables The Om er I a 90 approximate length of each Cable is listed in inches after the key number in the drawing IMPORTANT While assembling the cables do not overtighten the bolts and nuts attaching the pulleys The pulleys must be able to turn freely 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 th
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