Weider WESY96400 User Manual

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USER'S MANUAL

PATENT PENDING

QUESTIONS?

As a manufacturer, we are committed to providing complete customer satisfaction. If you have questions, or find that there are missing or damaged parts, we will guarantee you complete satisfaction through direct assistance from our factory.

TO AVOID UNNECESSARY DELAYS, PLEASE CALL DIRECT TO OUR TOLL-FREE CUSTOMER HOT LINE. The trained technicians on our customer hot line will provide immediate assistance, free of charge to you.

CUSTOMER HOT LINE:

1-800-999-3756

Mon.–Fri., 6 a.m.–6 p.m. MST

Model No. WESY96400 Serial No.

Write the serial number in the space above for reference.

Serial Number Decal (Under Seat)

CAUTION

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

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TABLE OF CONTENTS

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

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

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

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

Note: APART 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 & Fitness, Inc.

ICON Health & 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 purchase. This warranty extends only to the original purchaser. ICON's obligation under this warranty is limited 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 centers 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 purposes, 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 connection 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 incidental 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 & FITNESS, INC., 1500 S. 1000 W., LOGAN, UT 84321-9813

LIMITED WARRANTY

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IMPORTANT PRECAUTIONS

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

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.

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 and in the accompanying literature 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 for protection.

4. Inspect and tighten all parts often. Replace

any worn parts immediately.

5. Keep small children 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 while weights are raised. The weights will fall with great force.

7. Do not use the VKR station when either

weight stack is in use.

8. Always wear athletic shoes for foot protec-

tion.

9. Keep hands and feet away from moving parts.

10. Always stand on a foot plate when performing an exercise that could cause the home gym system to tip.

11. 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 military press arm.

12. 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.

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 while exercising, stop immediately and begin cooling down.

15. The home gym system is intended for home

use only. Do not use the home gym system in any commercial, rental, or institutional setting.

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BEFORE YOU BEGIN

ASSEMBLED DIMENSIONS: Height: 76 in. Width: 89 in. Length: 64 in.

Foot Plate

Low Pulley Station

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Military Press Arm

Press Arm

Weight Stacks

Backrests

VKR Arms

Leg Press

Plate

Thank you for selecting the versatile WEIDER®PRO 9640 Home Gym System. The PRO 9640 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 9640 will help you to achieve the specific results you want.

For your benefit, read this manual carefully before using the WEIDER

PRO 9640 Home Gym System.

If you have additional questions, please call our

Customer Service Department toll-free at 1-800-9993756, 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 WESY96400. The serial number can be found on a decal attached to the WEIDER

PRO 9640 (see the

front cover of this manual). Before reading further, please review the drawing

below and familiarize yourself with the parts that are labeled.

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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 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

Before beginning assembly, carefully read the following information and instructions:

• Place all parts of the PRO 9640 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 five stages: 1) frame assembly, 2) arm assembly, 3) cable and pulley assembly, 4) seat and backrest assembly, and 5) VKR 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 9640 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: Asocket set, a set of open-end or closed-end wrenches, or a set of ratchet wrenches.

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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”

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-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

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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).

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.

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 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.

Crossbar

100

5—Bracket

4—Bracket

FRAME ASSEMBLY

Grooves

Pin Grooves

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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 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 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 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

Pin Grooves

Holes

Lubricate

Pin Grooves

FRAME ASSEMBLY

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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) 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).

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

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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

Page 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 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).

16. 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 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.

17. 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.

Ball

Hook

101

5674

23—79”

58—147”

72—194”

99—63”

ARM ASSEMBLYCABLE ASSEMBLY

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18. 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.

19. 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 positioned to hold the Cable in place. Tighten

the 3/8” x 2 1/2” Bolt (86) and the 3/8” Nylon Locknut (not shown).

20. Route the High Cable (58) around the “V”Pulley (50) on the Right Arm (48). Be sure

that the Cable is in the groove of the “V”Pulley and that the Long Cable Trap (31) is turned to hold the Cable in place. Tighten

the 3/8” x 2 1/2” Bolt (86) and the 3/8” Nylon Locknut (not shown).

21. 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.

CABLE ASSEMBLY

Bracket

Page 13

22. 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-assembled.

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.

23. 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.

24. Note: This assembly step shows how to complete the assembly of several preattached parts.

The 5/8” x 9/16” Spacer (7) has been preattached 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.

Bracket

CABLE ASSEMBLY

Page 14

25. 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).

26. 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).

27. 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).

28. 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).

Inset shows view

from other side

CABLE ASSEMBLY

Ball

Inset shows view

from other side

Crossbar

Page 15

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

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 indicated Weight Tube (63) with a 5/16” x 1 3/4” Bolt (24) and a 5/16” Nylon Locknut (3).

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 indicated Weight Tube (63) with a 5/16” x 1 3/4” Bolt (24) and a 5/16” Nylon Locknut (3).

CABLE ASSEMBLY

10 2

Page 16

32. Wrap the Military Press Cable (72) around a 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.

33. 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 Nylon Locknut is on the side shown and that the Cable Trap is positioned to hold the Cable in place.

CABLE ASSEMBLY

101

Bracket

Page 17

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 preassembled.)

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 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 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.

CABLE ASSEMBLY

Ball

101

Welded

Rod

Page 18

36. 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.

37. 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).

38. 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).

CABLE ASSEMBLYSEAT ASSEMBL Y

100

Page 19

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 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 indicated 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).

Thick

End

SEAT ASSEMBL Y

Page 20

43. 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.

44. 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).

45. Attach the VKR Backrest (77) to the VKR Upright (74) with two 1/4” x 2 1/2” Screws (43) and two 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.

SEAT ASSEMBL Y

VKR ASSEMBLY

Page 21

46. Remove the adhesive backing from the PRO 9640 decal and apply it to the Front Upright (42) under the “WEIDER” nameplate as shown.

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, 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.

WEIDER

Nameplate

PRO 9640

Decal

Page 22

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 correct 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 9640 features two weight stacks. The front weight stack is connected to the upper and lower pulleys, 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 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 resistance 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.

Page 23

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 REMOVING 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.

Welded

Tube

Page 24

WEIGHT RESISTANCE CHART

This chart shows the approximate weight resistance at each weight station. “Top” refers to the 6.5 lb. top weight. The other numbers refer to the 12.5 lb. 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 (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.)

Top 20 10 15 16 30 29 40

14522363060 5080 2 70 33 54 52 100 72 146 3 99 42 75 68 130 95 166 4 128 48 96 87 170 120 210 5 153 60 115 100 200 140 240 6 184 69 137 120 255 160 268 7 204 79 146 135 270 180 325 8 247 91 176 155 320 205 360

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.

Page 25

TROUBLE-SHOOTING AND MAINTENANCE

Inspect and tighten all parts each time you use the home gym system. Replace any worn parts immediately. The home gym system can be cleaned using a damp cloth and mild non-abrasive detergent. Do not use solvents.

TIGHTENING THE CABLES

Woven cable, the type of cable used on the home gym system, can stretch slightly when it is first used. If there is slack in the cables before resistance is felt, the cables should be tightened. If any slack is felt when using the front weight stack, both the High Cable (58) and the Low Cable (23) will need to be tightened. If any slack is felt when using the rear weight stack, both the Military Press Cable (72) and the Leg Press Cable (99) will need to be tightened.

To tighten the cables, insert the weight pin into the middle of the weight stack. Slack can be removed from these cables several ways:

• See drawing 1. 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. Reattach 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).

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. Reattach 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.

23 or 99

100

Page 26

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 system 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.

Low Cable (23)

—Low Pulley

—Long “U”-Bracket

TOP VIEW

—High Pulley

High Cable (58)

Front Weight Stack—

High Cable (58) and Low Cable (23)

Page 27

Military Press Cable (72)

Leg Press Cable (99)

Rear Weight Stack—1

4—

Rear Seat Frame

6—

Pivot Arm

1—

Long “U”-Bracket

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

Page 28

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 prepared to give the following information:

1. The MODEL NUMBER of the product (WESY96400).

2. The NAME of the product (WEIDER

PRO 9640 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).

Page 29

WESY96400 R1296A

Please Note: The assembly is divided into five stages: 1) frame assembly, 2) arm assembly, 3) cable and pulley assembly, 4) seat and backrest assembly, and 5) VKR 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.

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-assembled. 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.

REMOVE THIS PART IDENTIFICATION

CHART FROM THE MANUAL

Page 30

1/2" x 3/4" Spacer (61)–4

3/4" Round Inner Cap (34)–4

1" Square Inner Cap (6)–1

5/16" x 2" Eyebolt (35)—1

1" Round Inner Cap (49)–8

1" Round Cover Cap (70)–2

1 1/2" Square Inner Cap (32)–6

2" Square Inner Cap (27)–8

1 3/4" Square Inner Cap (44)–6

2" Square Outer Cap (51)–2

Page 31

1/4" x 1/2" Screw (18)–6

#8 x 1/2" Self-tapping Screw (87)–1

3/8" x 8" Bolt (59)–1

1" Retainer (69)–4

5/16" x 6" Bolt (60)–2

(Not shown to scale)

3 1/2" Pulley (15)–13

3/8" x 3 1/4" Bolt (67)–2

3/8" x 3 1/2" Bolt (16)–2

3/8" x 2" Bolt (12)–7

5/16" x 2 1/4" Bolt (33)–3

5/16" x 5" Bolt (68)–1

3/8" x 3 3/4" Bolt (88)–5

1/4" x 2 1/2" Screw (43)–6

1/4" x 2 1/2" Carriage Bolt (92)–1

Cable Clip (53)–3

5/16" x 2 1/2" Bolt (22)–4

5/16" x 2 1/2" Carriage Bolt (1)–10

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

1" x 7/8" Plastic Bushing (90)–2

3/8" x 2 1/2" Bolt (86)–3

5/16" x 2 3/4" Bolt (11)–10

5/16" x 2 3/4" Carriage Bolt (14)–1

"V"-Pulley (50)–3

(Not shown to scale)

5/16" x 3" Bolt (75)–3

1/4" Nylon Locknut (2)–6

5/16" Nylon Locknut (3)–34

5/16" Nylon Jam Nut (93)–4

3/8" Nylon Locknut (21)–20

1/4" Flat Washer (10)–17

5/16" Flat Washer (8)–9

3/8" Flat Washer (9)–6

3/8" x 1 3/4" Bolt (24)–2

1/4" x 2" Carriage Bolt (38)–1

1/4" x 2" Machine Screw (81)–5

Page 32

REMOVE THIS PART LIST/EXPLODED

DRAWING FROM THE MANUAL!

Page 33

PART LIST—Model No. WESY96400 R1296A

Note: “#” indicates a non-illustrated part. Specifications are subject to change without notice.

Key No. Qty. Description

1 10 5/16” x 2 1/2” Carriage Bolt 2 6 1/4” Nylon Locknut 3 34 5/16” Nylon Locknut 4 1 Base 5 1 Stabilizer 6 1 1” Square Inner Cap 7 1 5/8” x 9/16” Spacer 8 9 5/16” Flat Washer

9 6 3/8” Flat Washer 10 17 1/4” Flat Washer 11 10 5/16” x 2 3/4” Bolt 12 7 3/8” x 2” Bolt 13 2 Seat 14 1 5/16” x 2 3/4” Carriage Bolt 15 13 3 1/2” Pulley 16 2 3/8” x 3 1/2” Bolt 17 1 Press Frame 18 6 1/4” x 1/2” Screw 19 4 Weight Bumper 20 1 Pulley Bracket 21 20 3/8” Nylon Locknut 22 4 5/16” x 2 1/2” Bolt 23 1 Low Cable 24 2 5/16” x 1 3/4” Bolt 25 16 Weight 26 2 Weight Pin 27 8 2” Square Inner Cap 28 2 Pad Tube 29 1 Leg Lever 30 4 Foam Pad 31 3 Long Cable Trap 32 6 1 1/2” Square Inner Cap 33 3 5/16” x 2 1/4” Bolt 34 4 3/4” Round Inner Cap 35 1 5/16” x 2” Eyebolt 36 1 Front Seat Frame 37 2 Seat Plate 38 1 1/4” x 2” Carriage Bolt 39 1 Nylon Strap 40 1 Seat Knob 41 1 Front Backrest 42 1 Front Upright 43 6 1/4” x 2 1/2” Screw 44 6 1 3/4” Square Inner Cap 45 2 10” Pad 46 2 Press Arm 47 1 Left Arm 48 1 Right Arm 49 8 1” Round Inner Cap 50 3 “V”-Pulley 51 2 2” Square Outer Cap 52 1 Chain

Key No. Qty. Description

53 3 Cable Clip 54 1 Lat Bar 55 1 Top Frame 56 1 Leg Press Upright 57 2 Long “U”-Bracket 58 1 High Cable 59 1 3/8” x 8” Bolt 60 2 5/16” x 6” Bolt 61 4 1/2” x 3/4” Spacer 62 2 Long Weight Guide 63 2 Weight Tube 64 2 Weight Tube Bumper 65 2 Top Weight 66 8 Cable Trap 67 2 3/8” x 3 1/4” Bolt 68 1 5/16” x 5” Bolt 69 4 1” Retainer 70 2 1” Round Cover Cap 71 2 Small “U”-Bracket 72 1 Military Press Cable 73 2 Short Weight Guide 74 1 VKR Upright 75 3 5/16” x 3” Bolt 76 1 3 1/2” Low Pulley 77 1 VKR Backrest 78 2 VKR Armrest 79 1 Left VKR Arm 80 1 Right VKR Arm 81 5 1/4” x 2” Machine Screw 82 1 Handle 83 10 5” Plastic Grip 84 1 Military Press Arm 85 1 Rear Backrest 86 3 3/8” x 2 1/2” Bolt 87 1 #8 x 1/2” Self-tapping Screw 88 5 3/8” x 3 3/4” Bolt 89 2 1 1/8” x 2 1/2” Plastic Bushing 90 2 1” x 7/8” Plastic Bushing 91 1 Rubber Bumper 92 1 1/4” x 2 1/2” Carriage Bolt 93 4 5/16” Nylon Jam Nut 94 1 Press Bracket 95 1 Leg Press Plate 96 1 Leg Press Arm 97 1 Press Pin 98 2 Bushing

99 1 Leg Press Cable 100 1 Rear Seat Frame 101 1 Pivot Arm

# 1 User’s Manual # 1 Exercise Poster

Page 34

1043

100

101

EXPLODED DRAWING—Model No. WESY96400 R1296A