Weider PRO 9645 User manual

PATE:', _";;_'._HOING
V IDER
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.
Seria{ Numbar Decal
I:" (_ U I p M EN T
I[_,,|1 | ;i-."B n Re| _i,.Si
HEI-,P LI N E!
1-800-73d-dg7P
USER'S MANUAL
SW/ARS
SEARS, ROEBUCK AND CO., HOFFMAN ESTATES, IL 60179

TABLE OF CONTENTS
IMPORTANT PRECAUTIONS .............................................................. 2
BEFORE YOU BEGIN ................................................................... 3
ASSEMBLY ..... °........................................................... 4
HOW TO USE THE HOME GYM SYSTEM .............................. 22
WEIGHT RESISTANCE CHART ........................................................ :..24
TROUBLE-SHOOTING AND MAINTENANCE ................................................ 25
CABLE DIAGRAMS .................................................................... 26
ORDERING REPLACEMENT PARTS ................................................ Back Cover
FULL 90 DAY WARRANTY ........................................ _.. ............ Back Cover
Note: A PART IDENTIFICATION CHART and a PART LIST/EXPLODED DRAWING are attached to the center of
this manual. Remove the PART IDENTIFICATION CHART and the PART LIST/EXPLODED DRAWING before
beginning assembly.
2

BEFORE YOU BEGIN
Thank you for selecting the versatile WEtDEF_ PRO
9645 Home Gym System. ,'ThePRO 96.+5 o,'fe,-sa
selection of weight stations designed to develop every
major muscle group of the body. Whether your goal is
to tone your body, build dramatic muscle size and
strength, or improve your cardiovascular system, the
PRO 9645 will help you to achieve the specific results
you want.
For your benefit, read this manual carefully before
using the WEIDEFP' PRO 9645 Home Gym System,
tf you have additional questions, please call our toll-
free HELPLINE at 1-800-736-6879, Monday through
5aturaay, 7 a.m. un_ii 7p.m. Central Time (excluding
holidays). To help us assist you, please note the prod-
uct model number and serial number before calling.
The modet number is 831.159380. The serial number
can be found on a decal attached to the WEIOEPP
PRO 9645 (see the front cover of this manual).
Before reading further, please review the drawing
below and familiadze yourself with the parts that are
labeled.
l.at Bar ASSEMBLED
DIMENSIONS:
Height: 78 in.
Width: 86 in.
Length: 66 in.
High Pulley Station
Pull-up Handles Butterfly Arms
Dip Handles Press Arm
_, Backrests
- Leg Press
Plate
Assist Arm "Press Arm
Leg Lever
Weight Stacks
Station
J
Weight Pin Foot Plate
3

ASSEMBLY
Before beginning assembly, carefully read the
following information and Instructions:
•Place all parts of the PRO 9645 in a cleared area
and remove the packing matadals; do not dis-
pose of the packing materials until assembly is
completed.
• The assembly is broken into four stages: 1) frame
assembly, 2) arm assembly, 3) cable and pulley
assembly, and 4) seat and backrest assembly.
The hardware for each stage is packaged sepa-
rately.
•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 pre-
attached for shipping. If apart is not in the parts
bag, check to see if it has been pre-attached.
•As you assemble the PRO 9645 be sure that all
parts are oriented as shown in the drawings.
•Tighten all parts as you assemble them, unless
instructed to do otherwise.
THE FOLLOWING TOOLS (NOT INCLUDED) ARE
REQUIRED FOR ASSEMBLY:
• Two (2) adjustable wrenches
•One (1) standard screwdriver
•One (1) phillips screwdriver
•One (1) rubber mallet
•Lubricant, such as grease or petroleum jelly,
and soapy water will also be needed.
Assembly will be more convenient ifyou have the
following tools: A socket set, a set of open-end or
closed-end wrenches, or a set of ratchet wrenches.
ffl_!?
I
1. Before beginning assembly, be sure that
you have read and understand the Infor-
mation in the box above.
Locate and open the parts bag labeled
"FRAME ASSEMBLY."
Press two 2" Square Outer Caps (51) onto
Cap (27) into the Base (4).
Insert six 5/16" x 2 1/2" Carriage Bolts (1) up
through the Stabilizer (5). Insert two 5/16" x
2 1/2" Carriage Bolts up through the Base
(4).
Attach the Base (4) to the Stabilizer (5) with
two 5/16" x 23/4" Bolts (11), two 5/16" Flat
Washers (8), and two 5/16" Nylon Locknuts
(3). Do not tighten the Nylon Locknuts
yet.
51 11
4
27
4

{TfDi_
_< i<'>7 +
< •
2_ Slide the Assist Upright (74) and the Leg
Press Upright (56) onto the indicated 5/16" x
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) onio the Carriage 8oils.
Do not tighten the Nylon Loeknuts yet.
Press two 2" Square Inner Caps (27) into the
Leg Press Upright (56). Press a 2" Square
Inner Cap into the Assist Upright (74).
Afl_ch _he Rubber Bumper (91) to the Leg
Press lJpdght (56) with the #8 x 1/2" Self-tap-
ping Screw (87).
3. Slide the Front Upright (42) onto the 5/16" x
2 1/2" Cardage 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.
Front Upright (42).
2
74
.,_--_ 27
n Sides
of _rackets
5

.
.
.
Press a 2" Square Inner Cap (27) into the end
of the Top Frame (55). Press a 13/4" Square
Inner Cap (44) into each end of the crossbar
on the Top Frame. Press two 1" Round Inner
Caps (49) into the top of the crossbar.
Attach the Top Frame (55) to the Assist
Updght (74) and the Leg Press Upright (56)
with two 5/16" x 2 3/4" Bolts (11) and two
5/16" Nylon Lock,nuts (3).
Attach the Top Frame (55) to the Front
Updght (42) with two 5/16" x 2 3/4" Bolts (11),
two 5/16" Flat Washers (8), and two 5/16"
Nylon Locknuts (3).
Slide the Rear Seat Frame (100) onto the
indicated 5/16" x21/2" Carriage Bolts (1) in
the Stabilizer (5). Hand-tighten two 5/16"
Nylon Locknuts (3) onto the Carriage Bolts.
Do not tighten the Nylon Locknuts yet.
Attach the other end of the Rear Seat Frame
(100) to the Leg Press Upright (56) with two
5/16" x 23/4" 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 21/2" Carriage
Botts (1) and two 5/16" Nylon Locknuts (3).
Tighten all Nylon Locknuts used in steps
1-5.
Set two Weight Bumpers (19) on the bracket
on the Base (4) as shown. Set two Weight
Bumpers (19) on the bracket on the Stabilizer
(5).
Stack ten Weights (25) onto the bracket on
the Stabilizer (5). Stack eight Weights onto
the bracket on the Base (4). Be sure that the
pin grooves are all on the same side of
each stack of Weights.
Be careful not to tip either stack of
Weights (25) until step 8 is complete.
4
27
55 11 49
44
Crossbar
5
56------
8
100
_/_23-_-_,.., ":
6Pin _//_"-,I /_
I25,o"!!
1o
5---Bracket_
4--Bracket _
6

Press a Weight Tube Bumper (64) into the
end of the Short Weight Tube (I08). Insertthe
Weight Tube into the front stack of Weights
!25). Be sur_ that the pin on the Weight
Tube i;sslt_lng in the pin grooves in the top
Weight.
Lubricate the inside of the holes in aTop
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.
,Press a Weight Tube Bumper (64) into the
end of the Long Wei_si_:- _e (63). Insertthe
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 I._5"_.Set the Top Weiqht onto the
rear stack of Weights (25). Insert bo_h Short
Weight Guides (73) into the stack of Weights.
Be sure that the holes in the Weight
Guides are at the top, as shown.
8
25
Holes
_73
!,
I
Lubricate
7

g* Attach the upper ends of the Short Weight
Guides (73) to the Top Frame (55) with a 5/16"
x 6" Bolt (60), two 1/2" x 3/4" Spacers (61), and
a 5/16" Nylon Locknut (3).
Attach the upper ends of the Long Weight
Guides (62) to the Top Frame (55) in the same
manner.
10. Locate and open the parts beg 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" x3 1/4" Bolt (67). Attach the
Leg Press Ann (96) to the Stabilizer (5) with the
Bolt and a 3/8" Nylon Locknut (21). Do not over-
tighten the Nylon LocknuL 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 a1" 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.
Lubricate the 3/8" x 8" Bolt (59). Attach the
Press Frame (17) to the Base (4) with the Bolt
and a3/8" Nylon Locknut (21).
9
60
61 3 61
< !
lO
Tube
97
27
%/67--Lubricate
11
_this side
t_59--Lubricate
21"_-_"_'_Welded Spacers
90
8

" _ !2. Press a 1" Round Inner Cap (49) into one of
....= ,_:_ss Arms, -6;. Press a 1 3/4" Square
!nner Cap (44) into the Press Arm.
Attach the Pre_ _.rm (46) to one side o_the
Press Frame (i ,') with two 5/16" x 2 1/2" Bolts
(22) and two 5/16" Nylon Locknuts (3).
Assemble the other Press Arm (46) in :ha
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. Lubdc-_ta 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
Indtc_t_.d bracket on the Top Frame (55).
Tap two 1" Retainers (69) and a 1" Rounc;
Cover Cap (70) onto the axle. Be sure tE :-
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 a1(7 Pad (45) onto the
lower end of each Arm.
13 86.._--_ 31
Welded /L :7
48--
14
I"
48
Axle1
9

15. See the inset drawing. Attach the Military
Press Arm (84) to the Pivot Arm (101) with
two 5/16" x 2 1/4" Bolts (33) and two 5/16"
Nylon Locknuts (3).
Press two 1 1/2" Square Inner Caps (32) into
the Military Press Arm (84). Press two 1"
• Round Inner Caps (49) into the Military Press
Arm. Slide two 5" Plastic Handgdps (83) onto
the Military Press Arm.
Attach the Pivot Arm (101) to the Assist
Upright (74) with a 3/8" x 3 1/4" Bott (67) and
a 3/8" Nylon Locknut (21).
16. Press two 1" x 2" Inner Caps (107) into the
Assist Arm (105).
Attach the Assist Arm (105) to the Leg Press
Upright (56) with a 3/8" x 6" Bolt (106), two
3/8" Flat Washers (9), and a 3/8" Nylon
Locknut (21). See the inset drawing, The
Assist Arm must be attached to the lowest
hole In the Ls9 P_ess Upright (5_). T?I_
Assist Arm must also be below the welded
bracket on the Assist Upright (74).
15
16
9
•.32
67 . _--56
Bracket
/, 105
""74 56"_ i
_"" ./56
,, lil i,000i
10

L-
]i
ii !' _"_i _i_
_ _L_i _ _#_
• _ _ i _II_!
,_ <
17. Attach the Le_ F_ .Jp Arm :75) and the Fl!ghl
Pull-up Arm (77) to me Assis_ Upright (74)
with two 5/16" x 2 3/4" Bolts (!1) and two
5/16" ;',_y!on!.cc=',nu_s(3).
Attach the Left Dip Arm (78) and the Right Dip
Arm (79) to the Assist Upright (74) with two
_16"x 2 3/4" Bolts (11) and two 5116" Nylon
Locknuts (3).
Wet the end of the Left Pull-up Arm (75) with
soapy water. Slide a Long Handgrip (80) onto
the Left Pull-up Arm.
Slide a Long Handgdp (80) onto the Right
Pull-up Arm (77), onto the Left Dip Arm (78),
and onto the Right Dip Arm (79) in the same
manner.
Press two 1 1/4" Round Inner Caps (109) into
the Left Pull-up Arm (75) and into the Right
Pull-up Arm (?'7).
Press a1 1/4" Round Inner Cap (109) into the
Left Dip Arm (78), and into the Right Dip Arm
(79).
18. Locate and open the parts bags labeled
"CABLE ASSEMBLY" and "PULLEYS."
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
approximate length of each Cable is listed (in
inches) after the key number in the drawing.
IMPORTANT: While assembling the cables,
.... •.",-b_r, ",.hebolts _n_ nuts
a_a_hl_It.i_;;_'.;_uiieys, The pulleys must be
able iO i.ur_'l _i'a_iy.
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
33/4" Bolt (88) and a31'8"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.
18
75 74
80 \ \
88
11

_ i_
20. Wrap the High Cable (58) around a"V"-Pulley
(50). Attach the "V"-Pulley and aLong Cable
Trap (31) to the indicated bracket on the Front
Upright (42) with a 3/8" x 2 1/2" Bolt (86) and
e3/8" Nylon Locknut (21). Be sure that the
Long Cable Trap Is positioned to hold the
Cable in place.
21. Route the High Cable (58) around the "V"-
Pulley (50) on the LeftArm (47). Be sure that
the Cable is In the groove of the Pulley
and that the Long Cable Trap (31) Is posE-
tioned to hold the Cable in place. 13ghten
the 3/8" x 2 1/2" Bolt (86) and the 3/8" Nylon
Locknut (not shown).
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 2 112"Bolt (86) and the 3/8" Nylon
Locknut (not shown).
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.
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.
12
2O
86_ 31
21 86 31
5O
58
47
22 31 86 50
23

:_ (15) and a Cable Trap (66) to the upper hole ;n
_ 24. See the inset drawing. Attach _-3 ij2" Pulley
a Long "U"-Bracket (57) with a _8" x 2" Bolt
(12) and a 318" Nylon Locknut (21). Be sure
that the Cable Trap is inside the Long "U"-
Bracket• Note: This may come pro-assem-
bled.
?:c
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,
25. Wrap the High Cable (58) around a 31/2"
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.
26. Note: This assembly step shows how to
complete the assembly of several pre-
attached parts.
The 5/8" x 9116" Spacer (7) has been pro-
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
*_ ,'_._:'..,,_._',:e ,?.,:{t•;':_o Bolt has been
shown removed for pa_ identification.
Reattach _e 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/q!) y_.. Be s:_r_ that the
3/8" x 3 3/4" Bolt (88), the 3/8" Flat _,',_sher
(9), the 5/8" x 9/16" Spacer (7), the 3 ;/2"
Low Pulley (102), and the 3/8" Nylon
Locknut (21) are oriented as shown.
24
25
26
Bracket 58 •j12
13

ii
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).
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, "Rghten the 3/8" Nylon Locknut (21)
and the 3/8" x 3 3/4" Bolt (88).
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. _ghten the 3/8" Nylon
Locknut (21) and the 3/8" x 3 1/2" Bolt (not
shown).
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).
<
23
17102
23
_Ball
--17
88--
6
42--
Inset shows view
from other side
J
23
--66
--17
J
6
Inset shows view
from other side
14

31. Attach the end of the Low Cable (23) to the
Long "U"-Bracket (57) with a 1/4" Nylon
Locknut (2) and a1/4" 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.
32. Attach the High Cable (58) to a Small "U"-
Bracket (71) with a114"Nylon Locknut (2) and
a1/4" 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 Short
Weight Tube (108) with a 5/16" x 1 3/4" Bolt
(24) and a5/16" Nylon Locknut (3).
3. 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 a1/4" Rat 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 Long
Weight Tube (63) with a 5/16" x1 3/4" Bolt
(24) and a 5/16" Nylon Locknut (3).
15

34. Wrap the Military Press Cable (72) arour, :
%t"-Pulley (50). Attach the %'-Pulley to ::he
Top Frame (55) with a 3/8" x 2 1/2" Bolt (86)
and a 3/8" Nylon Locknut (21).
Wrap the Military Press Cable (72) around a 3
1/2" Pulley (15). Attach the Pulley to the indt-
catad bmckat on the Assist .,_rm !'.0,m 'v!th 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.
35. Wrap the Military Press Cable (72) around a
"V"-Putley (50). Attach the _/"-Pulley and a
Long Cable Trap (31) to the Assist Upright
(74) with a 3/8" x 4 112" 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,
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.
34
35
Bracket
105
105
21
16 "

36. Slide a 5/16" Flat Washer (8) onto a 5116"x
23/4" 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 Boil
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.
36
37. See inset drawing A. Attach a31/2" Pulley
(15) and a Cable Trap (66) to the upper hole
in a Long "U"-Bracket (57) with a 318" 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 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 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.
37
\72
93\
17

38. Locate the Leg Press Ca_, _(99). Attach the
end of the Leg Press Cable :athe Long "U"-
Bracket (57) with a 1/4" Nylon Locknut (2) and
a 1/4" Ftat Washer (10). Do not completely
tighten the Nylon L_cknut, !_shcdd be
threaded onto the end of : '; CaL;ie only a
couple of turns, as shown Jnthe inset
drawing.
Wrap the Leg Press Cable (99) around a
3 1/2" Pu!tey (15). Attach the Pulley to the Leg
Press Updght (56) with the 3/8" x 3 3/4" Bolt
(88), a3/8" FIaLWasher (9), and a3/8" 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.
39. Attach the Press Bracket (94) to the Leg
Press Arm (96) with a5/16" x3" Bolt (111)
and a 5/16" Nylon Locknut (3).
!;_":_,}',:b" '._,,':_'" '"" C,2_':':"_':_t:':: :d _-3 1/2"
Pulley (15). Attach the Pulley to the Press
Bracket (94) with the 3/8" x2" Bolt (12) and a
3/6" Nylon Locknut (21).
Slide a 5/16" Flat Washer (8) onto a 5/16" x
23/4" Bolt (11). Insert the Bolt through the
lowest hole in the Rear Seat Frame (100)
from the indicated side. (Note: The three
5/16" Nyion 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.
38
€
Bail
Rod
99_ 57
39
96
12
93

40. Locate and open the parts bag labeled
"SEAT ASSEMBLY,"
fnsert 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 I/2" Screws (18).
Insert the !/4" x 2 1/2" Carriage Bolt (92)
through the indicated hole in the Leg Press
Upright (56). Tighten a1/4" 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 Updght with a 1/4" x 2 1/2"
Screw (43) and a 1/4" Flat Washer (10).
41. Attach one end of aSeat (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 a1/4" Flat Washer (10)
and a 1/4" x 2 1/2" Screw (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).
40
85
37 92
41
42
11
4.3
19

4
=s__
i_
i_i_ ,?_
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 Wsshers (10). The Backrest
must be oriented as shown.
44.
45.
Press a1 1/2" Square ' " "- "^
=n,,er ,_ _ _,_2)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) thro_:gh
the indicated hole in the Front Seat Frame
(36). "Nghtena 1/4" Nylon Locknut (2) with a
1/4" Flat Washer (!0) ontothe 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).
Press a11/2" Square inner Cap (32) into the
•,_] 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 Eyeboit.
46. Res_ the Front Seat Frame (38) cn _:_ _n_ic_t-
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).
4.3
f
44
45
f -
_ Thick
End
36
10 2
_36
Lubdcate--33,_.,-!
0_