TM
PATENT PENDING
USER'S 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.
Serial Number Decal
CAUTION
Read all precautions and instruc-
tions in this manual before
using this equipment. Save this
manual for future reference.
SEARS, ROEBUCK AND CO., HOFFMAN ESTATES, IL 60179
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BEFORE YOU BEGIN
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.
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 prod-
uct 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.
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-
Lat Bar
ASSEMBLED
DIMENSIONS:
Height: 78 in.
Width: 86 in.
Length: 66 in.
High Pulley Station
Butterfly Arms
Pull-up Handles
Dip Handles
Military Press Arm
Backrests
Leg Press
Plate
Assist Arm
Press Arm
Leg Lever
Weight Stacks
Weight Pin
Low Pulley
Station
Foot Plate
3
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ASSEMBLY
Before beginning assembly, carefully read the
following information and instructions:
• As you assemble the PRO 9645 be sure that all
parts are oriented as shown in the drawings.
• 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 com-
pleted.
• Tighten all parts as you assemble them, unless
instructed to do otherwise.
THE FOLLOWING TOOLS (NOT INCLUDED) ARE
REQUIRED FOR ASSEMBLY:
• 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.
• Two (2) adjustable wrenches
• One (1) standard screwdriver
• One (1) phillips screwdriver
• One (1) rubber mallet
• Wait until you begin each assembly stage to open
the parts bag labeled for that assembly stage.
• Lubricant, such as grease or petroleum jelly,
and soapy water will also be needed.
• 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.
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.
1. Before beginning assembly, be sure that
you have read and understand the infor-
mation in the box above.
1
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).
11
51
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).
8
5
1
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.
51
1
3
4
1
27
4
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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.
2
27
27
87
91
High Sides
of Brackets
74
Press two 2” Square Inner Caps (27) into the
Leg Press Upright (56). Press a 2” Square
Inner Cap into the Assist Upright (74).
56
27
Attach the Rubber Bumper (91) to the Leg
Press Upright (56) with the #8 x 1/2” Self-tap-
ping Screw (87).
3
5
1
1
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.
3
Press a 1” Square Inner Cap (6) into the Front
Upright (42).
42
6
3
4
1
5
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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.
11
4
49
55
44
8
27
3
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).
Crossbar
44
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).
11
56
42
74
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.
5
1
100
3
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
11
56
Washers (8), and two 5/16” Nylon Locknuts (3).
8
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).
3
3
82
Tighten all Nylon Locknuts used in steps
1–5.
5
1
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).
6
Pin
Grooves
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.
25
25
19
5—Bracket
Pin
Be careful not to tip either stack of
Weights (25) until step 8 is complete.
Grooves
19
4—Bracket
6
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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.
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.
65
Lubricate
Pin
108
64
Pin Grooves
25
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.
8
Holes
73
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.
Lubricate
65
Pin
63
64
Pin Grooves
25
7
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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).
9
61
61
3
3
55
60
Attach the upper ends of the Long Weight
Guides (62) to the Top Frame (55) in the same
manner.
73
60
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).
97
96
5
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.
21
27
67—Lubricate
27
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).
98
11
17
Pulleys
must be on
this side
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 indi-
cated tube in the Base. Make sure that the
pulleys are on the side shown.
59—Lubricate
21
Welded Spacers
90
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).
4
Tube
8
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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.
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.
31
50
86
13
31
50
47
Welded
Brackets
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.
21
Attach a “V”-Pulley (50) and a Long Cable
Trap (31) to the Left Arm (47) in the same
manner.
48
14. Lubricate both axles on the Top Frame (55).
14
Bracket
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).
47
Lubricate
Axle
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.
48
69
45
70
Attach the Left Arm (47) in the same manner.
44
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.
44
45
Axle
69
70
9
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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
32
49
32
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.
21
74
84
83
101
67
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).
56
33
101
84
3
16. Press two 1” x 2” Inner Caps (107) into the
Assist Arm (105).
16
Bracket
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).
56
74
56
106
107
74
9
9
105
21
10
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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).
17
74
75
113
Attach the Left Dip Arm (78) and the Right
Dip Arm (79) to the Assist Upright (74) with
two 5/16” x 2 3/4” Bolts (11) and two 5/16”
Nylon Locknuts (3).
3
11
109
77
109
Wet the ends of the Left and Right Pull-up
Arms (75, 77) with soapy water. Slide a Long
Foam Handgrip (113) onto each Pull-up Arm.
Press two 1 1/4” Round Inner Caps (109) into
each Pull-up Arm.
3
11
113
78
109
3
80
Wet the ends of the Left and Right Dip Arms
(78, 79) with soapy water. Slide a Short
Handgrip (80) onto each Dip Arm. Press a
1 1/4” Round Inner Cap (109) into each Dip
Arm.
80
109
79
109
18. Locate and open the parts bags labeled
“CABLE ASSEMBLY” and “PULLEYS.”
18
23—79”
During steps 19 through 39, 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.
58—150”
72—192”
99—64”
IMPORTANT: While assembling the cables,
do not overtighten the bolts and nuts
attaching the pulleys. The pulleys must be
able to turn freely.
19
21
58
55
19. 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.
88
15
Ball
Hook
11
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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.
20
86
31
50
58
Bracket
42
21
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 posi-
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).
21
31
86
50
58
47
86
22. 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).
22
50
31
58
48
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.
23
20
68
55
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.
66
12
15
3
58
12
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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.
24
58
66
15
15
21
57
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.
58
12
12
57
25. 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.
25
Bracket
58
55
15
21
26. Note:This assembly step shows how to
complete the assembly of several pre-
attached parts.
26
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
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 (102), and the 3/8” Nylon
9
88
Locknut (21) are oriented as shown.
7
17
102
21
13
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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).
27
21
102
23
Ball
17
Crossbar
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).
23
88
42
28
15
42
15
66
Inset shows view
from other side
21
23
29. 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).
29
23
15
21
66
17
30. 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).
15
30
23
88
42
23
15
42
21
66
Inset shows view
from other side
14
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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.
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.
31
57
2
2
10
23
10
57
23
32
32. 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.
58
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).
3
71
108
24
10
2
58
10
71
33
2
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-
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.
72
71
3
24
63
72
10
10
2
Attach the Small “U”-Bracket (71) to the Long
Weight Tube (63) with a 5/16” x 1 3/4” Bolt
(24) and a 5/16” Nylon Locknut (3).
71
2
15
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34. Wrap the Military Press Cable (72) around a
“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).
34
55
50
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.
86
72
21
76
15
Bracket
105
35
35. Wrap the Military Press Cable (72) around a
“V”-Pulley (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
is routed around the Pulley as shown.
74
21
31
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.
50
21
9
72
11
105
76
Bracket
15
16
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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 the side shown.
Fully tighten a 5/16” Nylon Jam Nut (93) onto
the Bolt.
36
21
93
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.
9
8
101
72
11
88
15
66
37. See inset drawing A. 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.)
37
15
A
66
21
57
12
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.
B
93
72
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
must be room between the two Jam Nuts
for the end of the Cable to pivot.
1
57
15
72
17
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38. 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.
38
2
57
56
10
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.
99
Ball
88
15
9
21
Welded
Rod
2
10
57
99
39
39. Attach the Press Bracket (94) to the Leg
Press Arm (96) with a 5/16” x 3” Bolt (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) and a
3/8” Nylon Locknut (21).
96
12
3
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.
11
8
94
99
111
15
21
100
93
18
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40. Locate and open the parts bag labeled
“SEAT ASSEMBLY.”
40
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).
85
56
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).
92
37
18
43
2
10
41. 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).
41
13
100
18
18
10
43
42. Attach the Assist Seat (104) and the Angle
Bracket (110) to the Assist Arm (105) with
four 1/4” Flat Washers (10) and four 1/4” x 2
1/2” Screws (43).
42
104
110
105
10
10
43
19
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43. 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.
43
42
41
10
43
Thick
End
44. Press a 1 1/2” Square Inner Cap (32) into the
Front Seat Frame (36).
44
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).
13
38
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.
37
32
18
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).
36
10
81
2
45. Press a 1 1/2” Square Inner Cap (32) into the
Leg Lever (29).
45
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).
36
3
Lubricate—33
35
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.
29
8
3
32
42
46. 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).
46
40
36
14
Pin
20
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47. Press two 3/4” Round Inner Caps (34) into
each Pad Tube (28).
47
36
Insert a Pad Tube (28) into the Front Seat
Frame (36). Slide a Foam Pad (30) onto each
end of the Pad Tube.
30
34
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
30
29
48. Remove the backing from the PRO 9645
decal and apply it to the home gym system as
shown.
48
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.
PRO 9645
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
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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. IMPOR-
TANT: When attaching the lat bar or nylon strap, make sure that the attachments are in the correct start-
ing 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 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, and leg press.
26
25
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.
25
26
52
ATTACHING THE LAT BAR OR NYLON STRAP TO
THE HIGH PULLEY STATION
53
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.
58
53
54
The Nylon Strap (39) can be attached in the same
manner.
39
ATTACHING THE LAT BAR OR NYLON STRAP TO
THE LOW PULLEY STATION
23
53
52
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.
53
39
The Nylon Strap (39) can be attached in the same
manner.
54
22
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ATTACHING AND REMOVING THE SEAT
40
36
13
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).
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).
Lift the Front Seat Frame off the Front Upright (42).
14
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).
53
29
35
52
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.
53
23
ADJUSTING THE LEG PRESS PLATE
Remove the Press Pin (97) from the Leg Press Plate
(95) and the Leg Press Arm (96).
95
Welded
Tube
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.
97
96
23
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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
PLATES
PRESS
ARM
(lbs.)
BUTTERFLY
ARM
LEG
LEVER
(lbs.)
HIGH
PULLEY
(lbs.)
LOW
PULLEY
(lbs.)
MILITARY
PRESS ARM
(lbs.)
LEG
PRESS
(lbs.)
ASSIST
ARM
(lbs.)
(lbs.)
Top
1
31
59
17
35
25
50
23
36
54
70
88
98
120
135
144
–
36
67
30
51
36
11
38
78
2
81
40
71
95
74
123
171
219
265
299
333
387
440
455
66
3
104
132
154
196
206
227
–
70
97
123
155
191
220
252
273
–
97
95
4
80
111
131
156
172
184
–
115
135
164
183
194
218
246
117
142
186
213
232
256
293
5
110
115
130
140
–
6
7
8
9
10
–
–
–
–
–
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.
24
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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
1
15
several ways:
66
•
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).
21
57
12
The Leg Press Cable (99) can be tightened in the same
manner.
2
23 or 99
•
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 that the Cable and
Pulley move smoothly.
2
72
2
58
71
71
The other Long “U”-Bracket (57) can be adjusted in the
same manner.
2
•
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).
3
The Military Press Cable (72) can be tightened in the
same manner.
96
100
11
•
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.
8
99
93
93
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.
25
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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)
2
3
1—High Pulley
7
5
4
6
High Cable (58)
5—Long “U”-Bracket
Low Cable (23)
Front Weight Stack—
8
4
3
1
—Low Pulley
2
26
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Military Press Cable (72) and Leg Press Cable (99)
2
Military Press Cable (72)
8—Pivot Arm
6
7
1—Long “U”-Bracket
3
2
4
Rear Weight Stack—1
4—Rear Seat Frame
3
Leg Press Cable (99)
5
27
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5/16" x 2" Eyebolt (35)—1
1/2" x 3/4" Spacer (61)–4
5/8" x 9/16" Spacer (7)–1
3/4" Round Inner Cap (34)–4
1" Round Inner Cap (49)–6
1" Round Cover Cap (70)–2
1 1/2" Square Inner Cap (32)–4
1" Square Inner Cap (6)–1
1" x 2" Inner Cap (107)–2
1 3/4" Square Inner Cap (44)–6
2" Square Inner Cap (27)–8
2" Square Outer Cap (51)–2
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1/4" Nylon Locknut(2)–6
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
5/16"Nylon Jam Nut(93)–4
3/8" Nylon Locknut (21)–23
1/4" Flat Washer (10)–15
3/8" x 2" Bolt (12)–5
5/16" x 2 1/4" Bolt (33)–3
1/4" x 2 1/2" Screw (43)–8
5/16" Flat Washer (8)–9
3/8" Flat Washer (9)–9
5/16" x 2 1/2" Carriage Bolt (1)–10
3/8" x 2 1/2" Bolt (86)–4
5/16" x 2 3/4" Bolt (1)–14
5/16" x 2 3/4" Carriage Bolt (14)–1
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5/16" x 3" Bolt (111)–1
1/4" x 1/2" Screw (18)–6
3/8" x 3 1/4" Bolt (67)–2
3/8" x 3 1/2" Bolt (16)–1
3/8" x 3 3/4" Bolt (88)–6
5/16" x 5" Bolt (68)–1
Cable Clip (53)–3
1" Retainer (69)–4
1 1/8" x 2 1/2" Plastic Bushing (89)–2
1" x 7/8" Plastic Bushing (90)–2
3 1/2" Pulley (15)–13
(Not shown to scale)
"V"-Pulley (50)–5
(Not shown to scale)
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PART LIST—Model No. 831.159380
R1096A
Key
No.
Part
No.
Key
No.
Part
No.
Qty.
Description
Qty.
Description
59 128292
60 128293
61 131516
62 130361
63 133376
64 122691
65 126866
66 133381
67 120354
68 128297
69 108778
70 120808
71 133371
72 133397
73 131911
74 133377
75 133383
76 013399
77 133382
78 133384
79 133385
80 133369
81 128276
82 133378
83 119702
84 133386
85 133372
86 013581
87 102308
88 118471
89 126891
90 126808
91 122950
92 121422
93 100427
94 133387
95 133388
96 133389
97 131522
98 131910
99 133398
100 133354
101 133353
102 124590
103 133390
104 133391
105 133392
106 118522
107 127231
108 133394
109 124819
110 133231
111 126145
112 013485
113 134434
1
2
4
2
1
2
2
7
2
1
4
2
2
1
2
1
1
2
1
1
1
2
1
1
8
1
1
4
1
6
2
2
1
1
4
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
6
1
1
1
2
1
1
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
2
3
4
5
6
7
8
9
100291
012139
012056
133351
133352
120696
121845
014073
014132
10
6
36
1
1
1
1
9
9
15
14
5
2
1
13
1
1
6
4
1
23
4
1
2
18
2
8
2
1
4
4
4
3
4
1
1
2
1
1
1
1
1
8
6
2
2
1
1
6
5
2
1
3
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
10 014063
11 119377
12 013601
13 133379
14 123385
15 134031
16 120003
17 133360
18 123148
19 115644
20 133359
21 012149
22 127948
23 133395
24 102073
25 120294
26 122693
27 108874
28 133373
29 133358
30 103805
31 133361
32 103833
33 121421
34 119170
35 129051
36 133380
37 133362
38 128281
39 115177
40 119192
41 133357
42 133356
43 128283
44 113666
45 120596
46 133355
47 133364
48 133366
49 120733
50 115164
51 120822
52 116868
53 103087
54 133367
55 133368
56 133370
57 133375
58 133396
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
Short 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
Seat
5/16” x 2 3/4” Carriage Bolt
3 1/2” 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
Front 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
High Cable
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
Short Weight Tube
1 1/4” Round Inner Cap
Angle Bracket
5/16” x 3” Bolt
3/8” x 4 1/2” Bolt
Long Handgrip
User’s Manual
1
1
1
2
#
#
133393
125056
Exercise Poster
1
Note: “#” indicates a non-illustrated part. Specifications are subject to change without notice.
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EXPLODED DRAWING—Model No. 831.159380
R1096A
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The model number and serial number of your WEIDER® PRO 9645
are listed on a decal attached to the frame. See the front cover of
this manual to find the location of the decal.
Model No. 831.159380
All replacement parts are available for immediate purchase or
special order when you visit your nearest SEARS Service Center.
To request service or to order parts by telephone, call the toll-free
numbers listed at the left.
QUESTIONS?
If you find that:
• you need help assembling or
operating the WEIDER® PRO 9645
When requesting help or service, or ordering parts, please be pre-
pared to provide the following information:
• a part is missing
• The MODEL NUMBER of the product (831.159380).
• or you need to schedule repair
service
• The NAME of the product (WEIDER® PRO 9645 Home Gym
System).
call our toll-free HELPLINE
1-800-736-6879
Monday–Saturday, 7 am–7 pm
Central Time (excluding holidays)
• The PART NUMBER of the PART (see the PART LIST and the
EXPLODED DRAWING at the center of this manual).
• The DESCRIPTION of the PART (see the PART LIST and the
EXPLODED DRAWING at the center of this manual).
REPLACEMENT PARTS
If parts become worn and need to
be replaced, call the following toll-
free number
1-800-FON-PART
(1-800-366-7278)
FULL 90 DAY WARRANTY
For 90 days from the date of purchase, if failure occurs due to defect in material or workmanship in this
SEARS WEIGHT SYSTEM EXERCISER, contact the nearest SEARS Service Center throughout the
United States and SEARS will repair or replace the WEIGHT SYSTEM EXERCISER, free of charge.
This warranty does not apply when the WEIGHT SYSTEM EXERCISER is used commercially or for
rental purposes.
This warranty gives you specific legal rights, and you may also have other rights which vary from state
to state.
SEARS, ROEBUCK AND CO., DEPT. 817WA, HOFFMAN ESTATES, IL 60179
Part No. 133393 R1096A
Printed in Canada © 1996 Sears, Roebuck and Co.
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