Gold's Gym GGSY49230 Owner's Manual

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. GGSY49230 Serial No.

Write the serial number in the space above for reference.

CAUTION

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

USER'S MANUAL

Serial Number Decal (Under Seat)

TABLE OF CONTENTS

IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

WEIGHT RESISTANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . .24

TROUBLESHOOTING AND MAINTENANCE . . . . . . . . . . . . . . . .25

CABLE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

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

LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

Note: APART IDENTIFICATION CHART and a PART LIST/ EXPLODED DRAWING are attached in the center of this manual.

1. Read all instructions in this manual and in the accompanying literature before using the weight system.

2. It is the responsibility of the owner to ensure that all users of the weight system are adequately informed of all precautions.

3. The weight system is intended for home use only. Do not use the weight system in any commercial, rental, or institutional setting.

4. Use the weight system only on a level surface. Cover the floor beneath the weight system to protect the floor.

5. Make sure all parts are properly tightened each time the weight system is used. Replace any worn parts immediately.

6. Keep children under 12 and pets away from the weight system at all times.

7. Keep hands and feet away from moving parts.

8. Always wear athletic shoes for foot protection.

9. The weight system is designed to support a a maximum user weight of 300 pounds.

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

11. Always disconnect the lat bar from the

weight system when performing an exercise that does not use the lat bar.

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. Never release the press arm, butterfly arms, military press arm, leg lever, leg press plate, lat bar or nylon strap when weights are raised. The weights will fall with great force.

14. Keep your hands away from the assist upright when the assist arm is being used. Your hand could become pinched between the assist upright and the assist arm.

15. Keep your hands away from the leg press upright when the military press arm is being used. Your hand could become pinched between the leg press upright and the military press arm.

16. Always be sure that your body weight is fully supported by the dip arms or the pull-up arms before kneeling on the assist arm. The assist arm can drop quickly when your body weight is placed on it.

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

18. The decals shown below have been placed

on the weight system in the locations shown on page 3. If a decal is missing or illegible, call our toll-free Customer Hot Line at

1-800-999-3756 and order a free replacement decal. Apply the decal in the location shown.

WARNING:

To reduce the risk of serious injury, read the following important precau-

tions before using the weight 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.

Keep hands and fingers clear of this area.

• Keep clear of this area.

IMPORTANT PRECAUTIONS

Warning Decal 2

Warning Decal 1

Warning Decal 3

BEFORE YOU BEGIN

ASSEMBLED DIMENSIONS: Height: 78 in. Width: 110 in. Length: 92 in.

Foot Plate

High Pulley Station

Lat Bar

Leg Lever

Butterfly Arms

Assist Arm

Press Arm

Weight Stacks

Backrests

Dip Handles

Pull-up Handles

Warning Decal 1

Warning Decal 3

Warning Decal 2

Leg Press

Plate

Thank you for selecting the versatile GOLD’S GYM XR60 weight system. The weight system 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 weight system will help you to achieve the specific results you want.

For your benefit, read this manual carefully before using the weight system. If you have additional

questions, please 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 note the product model number and serial number before calling. The model number is GGSY49230. The serial number can be found on a decal attached to the weight system (see the front cover of this manual).

Before reading further, please review the drawing below and familiarize yourself with the labeled parts.

Weight Pin

Low Pulley

Station

Military Press Arm

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 50mm Square Outer Caps (51) onto the Stabilizer (5). Press a 50mm Square Inner Cap (27) into the Base (4).

Insert six M8 x 65mm Carriage Bolts (1) up through the Stabilizer (5). Insert two M8 x 65mm Carriage Bolts up through the Base (4).

Attach the Base (4) to the Stabilizer (5) with two M8 x 70mm Bolts (11), two M8 Washers (8), and two M8 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 weight system 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 four stages: 1) frame assembly, 2) arm assembly, 3) cable assembly, and 4) seat and backrest assembly. The hardware for each stage is packaged separately.

•Wait until you begin each assembly stage to open the parts bag 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 weight system be sure that all parts are oriented as shown in the drawings.

• Tighten all parts as you assemble them, unless instructed to do otherwise.

THE FOLLOWING TOOLS (NOT INCLUDED) ARE REQUIRED FOR ASSEMBLY:

•Two (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.

2. Slide the Assist Upright (74) and the Leg Press Upright (56) onto the indicated M8 x 65mm 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 M8

Nylon Locknuts (3) onto the Carriage Bolts.

Do not tighten the Nylon Locknuts yet.

Press two 50mm Square Inner Caps (27) into the Leg Press Upright (56). Press a 50mm Square Inner Cap into the Assist Upright (74).

Attach the Rubber Bumper (91) to the Leg Press Upright (56) with the M4 x 16mm Selftapping Screw (87).

3. Slide the Front Upright (42) onto the M8 x 65mm Carriage Bolts (1) in the Base (4). Hand tighten an M8 Nylon Locknut (3) onto each Carriage Bolt. Do not tighten the

Nylon Locknuts yet.

Press a 25mm Square Inner Cap (6) into the Front Upright (42).

High Sides of Brackets

FRAME ASSEMBLY

4. Press a 50mm Square Inner Cap (27) into the end of the Top Frame (55). Press a 45mm Square Inner Cap (44) into each end of the crossbar on the Top Frame. Press two 25mm Inner Caps (113) into the top of the crossbar.

Attach the Top Frame (55) to the Assist Upright (74) and the Leg Press Upright (56) with two M8 x 70mm Bolts (11) and two M8 Nylon Locknuts (3).

Attach the Top Frame (55) to the Front Upright (42) with two M8 x 70mm Bolts (11), two M8 Washers (8), and two M8 Nylon Locknuts (3).

Do not tighten the M8 Nylon Locknuts (3) yet.

5. Slide the Rear Seat Frame (100) onto the indicated M8 x 65mm Carriage Bolts (1) in the Stabilizer (5). Hand tighten two M8 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 M8 x 70mm Bolts (11), two M8 Washers (8), and two M8 Nylon Locknuts (3).

Attach the Handle (82) to the Rear Seat Frame (100) with two M8 x 65mm Carriage Bolts (1) and two M8 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). Make sure the flat side of the Bumpers

are on the bottom.

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.

113

Crossbar

100

Bracket

4—Bracket

FRAME ASSEMBLY

Grooves

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 groove in the top Weight.

Lubricate the inside of the holes in a Top Weight (65). Set the Top Weight onto the front stack of Weights (25). Insert both Long Weight Guides (62) into the stack of Weights.

Be sure that the holes in the Weight Guides are at the top, as shown.

8. Press a Weight Tube Bumper (64) into the end of the Long Weight Tube (63). Insert the Weight Tube into the rear stack of Weights (25). Be sure that the pin on the Weight

Tube is sitting in the pin groove 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 108

Pin Groove

Holes

Lubricate

Pin Groove

FRAME ASSEMBLY

9. Attach the upper ends of the Short Weight Guides (73) to the Top Frame (55) with an M8 x 150mm Bolt (60), two 19.5mm Spacers (61), and an M8 Nylon Locknut (3).

Attach the upper ends of the Long Weight Guides (62) to the Top Frame (55) in the same manner.

10. Locate and open the parts bag labeled

“ARM ASSEMBLY.”

Make sure there is a Bushing (98) in each side of the Stabilizer (5). Press three 50mm Square Inner Caps (27) into the ends of the Leg Press Arm (96).

Lubricate an M10 x 80mm Bolt (67) with grease. Attach the Leg Press Arm (96) to the Stabilizer (5) with the Bolt and an M10 Nylon Locknut (21). Do not overtighten the Locknut; the Leg

Press Arm must be able to pivot freely.

Align the welded tubes on the Leg Press Plate (95) with a 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 22mm 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 snugly over the ends of the indicated tube in the Base. Make sure that the pulleys are on the side shown.

Lubricate the M10 x 198mm Bolt (59) with grease. Attach the Press Frame (17) to the Base (4) with the Bolt and an M10 Nylon Locknut (21). Do not overtighten the

Locknut; the Press Frame must be able to pivot easily.

Pulleys

must be on

this side

Lubricate

Welded Spacers

Tube

FRAME ASSEMBLYARM ASSEMBLY

Welded

Tube

Lubricate

12. Press a 25mm Round Inner Cap (49) into one of the Press Arms (46). Press a 45mm Square Inner Cap (44) into the Press Arm.

Attach the Press Arm (46) to one side of the Press Frame (17) with two M8 x 63mm Bolts (22) and two M8 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.

Press a 70mm Plastic Bushing (89) into the Right Arm (48). Attach a “V”-Pulley (50) and a Long Cable Trap (31) to the Right Arm with an M10 x 58mm Bolt (86) and an M10 Nylon Locknut (21). Do not tighten the Locknut

yet.

Assemble 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 25mm Retainers (69) and a 25mm 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 two 45mm 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 Large Foam Pad (45) onto the lower end of each Arm.

13 86

Welded

Brackets

ARM ASSEMBLY

Bracket

Lubricate Axle

Axle

15. See the inset drawing. Attach the Military Press Arm (84) to the Pivot Arm (101) with two M8 x 55mm Bolts (33) and two M8 Nylon Locknuts (3).

Press two 38mm Square Inner Caps (32) into the Military Press Arm (84). Press two 25mm Round Inner Caps (49) into the Military Press Arm.

Attach the Pivot Arm (101) to the Assist Upright (74) with an M10 x 80mm Bolt (67) and an M10 Nylon Locknut (21). Do not over-

tighten the Locknut; the Pivot Arm must be able to pivot easily.

16. Press two 25mm x 50mm Inner Caps (107) into the Assist Arm (105).

Attach the Assist Arm (105) to the Leg Press Upright (56) with an M10 x 150mm Bolt (106), two M10 Washers (9), and an M10 Nylon Locknut (21). Do not overtighten the

Locknut; the Assist Arm must be able to pivot easily.

Note: (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).

101

ARM ASSEMBLY

107

106

105

Bracket

+ 23 hidden pages