Weider 831.159380 User Manual

Model No. 831.159380 Serial No.

The serial number can be found in the location shown below. Write the serial number in the space above.

CAUTION

Read all precautions and instructions in this manual before using this equipment. Save this manual for future reference.

USER'S MANUAL

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

Serial Number Decal

PATENT PENDING

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 them before beginning assembly.

IMPORTANT PRECAUTIONS

WARNING:To reduce the risk of serious injury, read the following important precautions before using the home gym system.

1. It is the responsibility of the owner to ensure that all users of the home gym system are adequately informed of all precautions.

2. The home gym system is intended for home use only. Do not use the home gym system in any commercial, rental, or institutional setting.

3. Read all instructions in this manual and in the accompanying literature before using the home gym system.

4. Use the home gym system only on a level

surface. Cover the floor beneath the home gym system for protection.

5. Inspect and tighten all parts often. Replace

any worn parts immediately.

6. Keep small children and pets away from the

home gym system at all times.

7. Always stand on a foot plate when perform-

ing an exercise that could cause the home gym system to tip.

8. Keep your hands away from the leg press

upright when the military press arm is being used. Your hand could become pinched between the leg press upright and the military press arm.

9. Never release the press arm, butterfly arms, military press arm, leg lever, leg press plate, lat bar or nylon strap when weights are raised. The weights will fall with great force.

10. Keep hands and feet away from moving parts. Always wear athletic shoes for foot protection.

11. Keep your hands away from the assist upright when the assist arm is being used. Your hand could become pinched between the assist upright and the assist arm.

12. Always be sure that your body weight is fully supported by the dip arms or the pull-up arms before kneeling on the assist arm. The assist arm can drop quickly when your body weight is placed on it.

13. Make sure that the cables remain on the pulleys at all times. If the cables bind while you are exercising, stop immediately and make sure that the cables are on all of the pulleys.

14. Always disconnect the lat bar from the home gym system when performing an exercise that does not use the lat bar.

15. If you feel pain or dizziness at any time while exercising, stop immediately and begin cooling 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. SEARS assumes no responsibility for personal injury or property damage sustained by or through the use of this product.

BEFORE YOU BEGIN

ASSEMBLED DIMENSIONS: Height: 78 in. Width: 86 in. Length: 66 in.

Foot Plate

Low Pulley

Station

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Military Press Arm

Assist Arm

Press Arm

Weight Stacks

Backrests

Dip Handles

Pull-up Handles

Leg Press

Plate

Thank you for selecting the versatile WEIDER®PRO 9645 Home Gym System. The PRO 9645 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 9645 will help you to achieve the specific results you want.

For your benefit, read this manual carefully before using the WEIDER®PRO 9645 Home Gym System.

If you have additional questions, please call our toll-

free HELPLINE at 1-800-736-6879, Monday through Saturday, 7 a.m. until 7 p.m. Central Time (excluding holidays). To help us assist you, please note the product model number and serial number before calling. The model number is 831.159380. The serial number can be found on a decal attached to the WEIDER

PRO 9645 (see the front cover of this manual).

Before reading further, please review the drawing below and familiarize yourself with the parts that are labeled.

Weight Pin

ASSEMBLY

1. Before beginning assembly, be sure that

you have read and understand the information in the box above.

Locate and open the parts bag labeled “FRAME ASSEMBLY.”

Press two 2” Square Outer Caps (51) onto 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

yet.

FRAME 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 materials; do not dispose of the packing materials until assembly is completed.

• The assembly is broken into four stages: 1) frame assembly, 2) arm assembly, 3) cable and pulley assembly, and 4) seat and backrest assembly. The hardware for each stage is packaged separately.

• 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 preattached for shipping. If a part 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.

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”

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 Assist Upright (74).

Attach the Rubber Bumper (91) to the Leg Press Upright (56) with the #8 x 1/2” Self-tapping Screw (87).

3. 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).

High Sides

of Brackets

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 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 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.

Crossbar

100

5—Bracket

4—Bracket

FRAME ASSEMBLY

Grooves

7. Press a Weight Tube Bumper (64) into the end of the Short Weight Tube (108). Insert the Weight Tube into the front stack of Weights (25). Be sure that the pin on the Weight

Tube is sitting in the pin grooves in the top Weight.

Lubricate the inside of the holes in a Top Weight (65). Set the Top Weight onto the front stack of Weights (25). Insert both Long Weight Guides (62) into the stack of Weights. Be

sure that the holes in the Weight Guides are at the top, as shown.

8. Press a Weight Tube Bumper (64) into the end of the Long Weight Tube (63). Insert the Weight Tube into the rear stack of Weights (25). Be sure that the pin on the Weight

Tube is sitting in the pin grooves in the top Weight.

Lubricate the inside of the holes in the other Top Weight (65). Set the Top Weight onto the rear stack of Weights (25). Insert both Short Weight Guides (73) into the stack of Weights.

Be sure that the holes in the Weight Guides are at the top, as shown.

Holes

Lubricate

108

Pin Grooves

Holes

Lubricate

Pin Grooves

FRAME ASSEMBLY

9. 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 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).

11. Press a 1” x 7/8” Plastic Bushing (90) onto each welded spacer on the Press Frame (17). Slide the Press Frame into place onto the Base (4). Note: This will be a tight fit. The Plastic

Bushings should fit on each end of the indicated tube in the Base. Make sure that the 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).

Pulleys

must be on

this side

59—Lubricate

Welded Spacers

Tube

FRAME ASSEMBLYARM ASSEMBLY

Welded

Tube

67—Lubricate

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.

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. 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 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.

Welded

Brackets

ARM ASSEMBLY

Bracket

Lubricate Axle

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).

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 Leg Press Upright (56). The Assist Arm must also be below the welded bracket on the Assist Upright (74).

101

5674

ARM ASSEMBLY

107

106

105

Bracket

+ 23 hidden pages