PATENT PENDING Model No. WESY96400 Serial No. Write the serial number in the space above for reference. Serial Number Decal (Under Seat) 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.
TABLE OF CONTENTS LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 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. 10. Always stand on a foot plate when performing an exercise that could cause the home gym system to tip. 2. Read all instructions in this manual and in the accompanying literature before using the home gym system. 11.
BEFORE YOU BEGIN 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. Customer Service Department toll-free at 1-800-9993756, Monday through Friday, 6 a.m. until 6 p.m.
ASSEMBLY Before beginning assembly, carefully read the following information and instructions: • As you assemble the PRO 9640 be sure that all parts are oriented as shown in the drawings. • 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. • Tighten all parts as you assemble them, unless instructed to do otherwise.
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. 2 27 27 87 High Sides of Brackets 91 74 Press two 2” Square Inner Caps (27) into the Leg Press Upright (56).
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. 4 11 55 49 44 8 27 3 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).
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. 7 Holes 62 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.
. 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). 61 61 3 3 60 73 62 10. Locate and open the parts bag labeled “ARM ASSEMBLY.” 10 27 95 Welded Tube 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).
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. 12 44 49 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). 46 22 Assemble the other Press Arm (46) in the same manner. 46 3 17 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.
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). 15 49 32 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.
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. 18 86 31 58 50 Bracket 42 21 19. Route the High Cable (58) around the “V”Pulley (50) on the Left Arm (47).
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. 22 58 66 CABLE ASSEMBLY 15 21 Route the High Cable (58) through the Long “U”-Bracket (57) and the 3 1/2” Pulley (15) shown in the inset drawing.
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). 25 21 76 23 Ball 17 Crossbar 26.
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. 29 57 2 2 10 23 10 57 23 CABLE ASSEMBLY 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).
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. 32 55 15 21 12 72 72 12 Bracket 66 CABLE ASSEMBLY 15 21 5 33.
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.) 34 15 57 CABLE ASSEMBLY 12 B 101 11 8 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.
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). 36 CABLE ASSEMBLY 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). 96 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.
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. 39 42 41 43 10 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).
SEAT ASSEMBLY 43. Press two 3/4” Round Inner Caps (34) into each Pad Tube (28). 43 Insert a Pad Tube (28) into the Seat Frame (36). Slide a Foam Pad (30) onto each end of the Pad Tube. 34 30 28 Insert the other Pad Tube (28) into the Leg Lever (29). Slide a Foam Foam Pad (30) onto each end of the Pad Tube. 34 29 30 44. Locate and open the parts bag labeled “VKR ASSEMBLY.” 44 75 80 Press 1 1/2” Square Inner Caps (32) into the ends of the Left VKR Arm (79) and the Right VKR Arm (80).
46. Remove the adhesive backing from the PRO 9640 decal and apply it to the Front Upright (42) under the “WEIDER” nameplate as shown. 46 42 WEIDER Nameplate PRO 9640 Decal 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.
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.
ATTACHING AND REMOVING THE SEAT 40 36 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). 13 42 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).
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 ARM BUTTERFLY ARM LEG LEVER HIGH PULLEY LOW PULLEY MILITARY PRESS ARM LEG PRESS PLATES (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.) (lbs.
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.
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.
Military Press Cable (72) and Leg Press Cable (99) 2 Military Press Cable (72) 6—Pivot Arm 4 5 1—Long “U”-Bracket 3 2 Rear Weight Stack—1 4—Rear Seat Frame 3 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 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.
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-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.
1/2" x 3/4" Spacer (61)–4 5/16" x 2" Eyebolt (35)—1 3/4" Round Inner Cap (34)–4 1" Round Inner Cap (49)–8 1" Round Cover Cap (70)–2 1" Square Inner Cap (6)–1 1 3/4" Square Inner Cap (44)–6 1 1/2" Square Inner Cap (32)–6 2" Square Inner Cap (27)–8 2" Square Outer Cap (51)–2
1/4" x 2" Machine Screw (81)–5 1/4" x 2" Carriage Bolt (38)–1 3/8" x 1 3/4" Bolt (24)–2 3/8" Flat Washer (9)–6 5/16" Flat Washer (8)–9 1/4" Flat Washer (10)–17 3/8" Nylon Locknut (21)–20 5/16" Nylon Jam Nut (93)–4 5/16" Nylon Locknut (3)–34 5/16" x 3" Bolt (75)–3 5/16" x 2 3/4" Carriage Bolt (14)–1 5/16" x 2 3/4" Bolt (11)–10 3/8" x 2 1/2" Bolt (86)–3 5/16" x 2 1/2" Bolt (22)–4 5/16" x 2 1/2" Carriage Bolt (1)–10 1/4" x 2 1/2" Screw (43)–6 1/4" x 2 1/2" Carriage Bolt (92)–1 5/16" x 2 1/4" B
81 REMOVE THIS PART LIST/EXPLODED DRAWING FROM THE MANUAL!
PART LIST—Model No. WESY96400 Key No. Qty.
32 49 83 77 78 10 81 75 80 10 2 3 74 57 83 99 83 27 32 75 21 15 10 11 12 66 54 51 3 52 5 10 2 3 65 8 51 25 26 79 11 78 43 11 60 1 53 19 61 64 12 15 21 39 83 66 2 16 10 10 1 15 3 8 43 3 91 87 3 24 27 11 8 63 71 72 73 3 21 21 66 67 88 1 82 3 101 15 8 10 43 3 18 11 92 37 1 11 8 11 11 18 9 56 27 9 83 21 3 98 83 100 21 99 93 33 93 13 18 85 72 84 93 49 32 15 21 94 96 15 66 12 3 20 10 2 21 57
