Weider PRO 9645 User Manual

QUESTIONS?

As a manufacturer, we are com­mitted to providing complete
customer satisfaction. If you
have questions, or if there are
missing or damaged parts, we
will guarantee complete satisfac­tion through our Customer
Service Department.

Please CALL:

Or WRITE:
ICON Health & Fitness Ltd.
Unit 4
Revie Road Industrial Estate
Revie Road
Leeds
LS11 8JG

Model No. WEEVSY62000
Serial No.

Write the serial number in the
space above for reference.

CAUTION

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

USER'S MANUAL

TM

Serial Number Decal (Under Seat)

www.weiderfitness.com

Visit our website at

0345-089009

Class HC Fitness Product

2

TABLE OF CONTENTS

IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

HOW TO USE THE HOME GYM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

TROUBLE-SHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

Note: APART IDENTIFICATION CHART and a PART LIST/EXPLODED DRAWING are attached in the centre 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 & Fitness, Inc.

3

WARNING:To reduce the risk of serious injury, read the following important precautions

before using the home gym system.

IMPORTANT PRECAUTIONS

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. Read all instructions in this manual before
using the home gym system.

3. Use the home gym system only on a level

surface. Cover the floor beneath the home
gym system to protect of the floor.

4. Inspect and tighten all parts often. Replace

any worn parts immediately.

5. Keep children under the age of 12 and pets

away from the home gym system at all times.

6. 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.

7. Keep hands and feet away from moving parts.

Always wear athletic shoes for foot protection.

8. 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.

9. Always stand on a foot plate when perform-

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

10. Inspect all cables before each use. Make

sure that the cables remain on the pulleys at
all times. If the cables bind whilst you are
exercising, stop immediately and make sure
that the cables are on all of the pulleys.
Replace all cables every two years.

11. 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.

12. 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.

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

14. If you feel pain or dizziness at any time
whilst exercising, stop immediately and
begin cooling down.

15. The decals shown at
the right (1) and
below (2) have been
attached to the home
gym system in the
locations shown on
page 4. If a decal is
missing or illegible,
please call 0345­089009 to order a
free replacement
decal. Apply the
decal in the location
shown.

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.

4

BEFORE YOU BEGIN

ASSEMBLED
DIMENSIONS:
Height: 198 cm
Width: 218 cm
Length: 168 cm

Foot Plate

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Assist Arm

Press Arm

Weight Stacks

Backrests

Dip Handles

Pull-up Handles

Warning Decal 1

Warning Decal 1

Warning Decal 2

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. If you have additional

questions, please call our Customer Service
Department. To help us assist you, please note the
product model number and serial number before call­ing. The model number is WEEVSY62000. The serial
number can be found on a decal attached to the
home gym system (see the front cover of this manual).

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

Weight Pin

Low Pulley Station

Military Press Arm

5

1

8

8

11

51

27

1

4

3

1

51

5

1. Before beginning assembly, be sure that

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

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

Press two 2” Square Outer Caps (51) onto
the Stabiliser (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 Stabiliser (5). Insert two 5/16” x 2
1/2” Carriage Bolts up through the Base (4).

Attach the Base (4) to the Stabiliser (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 home gym system in a

cleared area and remove the packing materials;
do not dispose of the packing materials until
assembly is completed.

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

• Wait until you begin each assembly stage to open
the parts bag labelled for that assembly stage.

• For help identifying the small parts used in
assembly, use the PART IDENTIFICATION

CHART located in the centre 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 home gym system 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 adjustable spanners

• One standard screwdriver

• One phillips screwdriver

• One 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: Asocket set, a set of open-end or
closed-end wrenches, or a set of ratchet wrenches.

1

ASSEMBLY

6

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 Stabiliser (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 a 2” Square Inner Cap (27) into the Leg
Press Upright (56). Press a 2” Square Inner
Cap into the Assist Upright (74).

Attach a Rubber Bumper (91) to the Leg
Press Upright (56) with a #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).

2

27

1

1

56

74

3

5

High Sides

of Brackets

3

FRAME ASSEMBLY

42

6

4

1

3

87

91

7

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 Round Inner
Caps (111) 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 Stabiliser (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 (3) used in
steps 1–5.

6. Set two Weight Bumpers (19) on the bracket
on the Base (4) as shown. Set two Weight
Bumpers on the bracket on the Stabiliser (5).

Stack ten Weights (25) onto the bracket on
the Stabiliser (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.

4

27

55

3

3

8

111

44

44

11

11

56

42

Crossbar

5

1

1

11

82

100

5

56

8

3

3

3

25

25

19

19

5—Bracket

4—Bracket

FRAME ASSEMBLY

74

Pin

Grooves

6

Pin

Grooves

8

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.

7

Holes

Lubricate

62

65

Pin
108

64

Pin Grooves

Holes

Lubricate

73

65

Pin

63

64

Pin Grooves

25

25

8

FRAME ASSEMBLY

9

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 labelled

“ARM ASSEMBLY.”

Press one 2” Square Inner Cap (27) into the end
of the Leg Press Arm (96). Be sure there is a
Bushing (98) in each side of the Stabiliser (5).

Lubricate a 3/8” x 3 1/4” Bolt (67). Attach the
Leg Press Arm (96) to the Stabiliser (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.

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 on 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
holes 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).

11

17

Holes must

be on this

side

59—Lubricate

Welded Spacers

21

4

Tube

90

9

10

FRAME ASSEMBLYARM ASSEMBLY

61

61

3

3

60

73

62

55

27

96

67—Lubricate

5

98

98

60

21

10

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. Make sure that

the teeth on the Retainers bend toward the
Round Cover Cap, as shown in the inset
drawing. If the Retainers need to be
removed, new ones will have to be ordered.

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.

12

13

86

31

31

50

50

21

Welded

Brackets

48

47

ARM ASSEMBLY

44

49

46

46

17

22

3

55

Bracket

Lubricate

Axle

47

69

70

44

45

44

14

69

70

Axle

45

48

11

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 a Rubber Bumper (91) to the indicated
hole in the Assist Arm (105) with a #8 x 1/2”
Self-tapping Screw (87).

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).

15

49

32

83

84

84

101

101

21

67

5674

33

3

ARM ASSEMBLY

32

16

107

106

105

105

Bracket

56

56

21

9

9

74

74

87

91