Gold's Gym GGSY49230 Owner's Manual

Model No. GGSY49230

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. 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

CAUTION

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

USER'S MANUAL

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

IMPORTANT PRECAUTIONS

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

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.

Keep hands and fingers clear of this area.

Warning Decal 2

• Keep clear of this area.

Warning Decal 1

Warning Decal 3

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.

2

BEFORE YOU BEGIN

Thank you for selecting the versatile GOLD’S GYM	questions, please call our Customer Service
XR60 weight system. The weight system offers a	Department toll-free at 1-800-999-3756, Monday
selection of weight stations designed to develop every	through Friday, 6 a.m. until 6 p.m. Mountain Time
major muscle group of the body. Whether your goal is	(excluding holidays). To help us assist you, please note
to tone your body, build dramatic muscle size and	the product model number and serial number before
strength, or improve your cardiovascular system, the	calling. The model number is GGSY49230. The serial
weight system will help you to achieve the specific	number can be found on a decal attached to the
results you want.	weight system (see the front cover of this manual).
For your benefit, read this manual carefully before	Before reading further, please review the drawing
using the weight system. If you have additional	below and familiarize yourself with the labeled parts.

	Lat Bar	ASSEMBLED
		DIMENSIONS:
		Height:	78 in.
		Width:	110 in.
		Length: 92 in.
	Pull-up Handles	High Pulley Station
	Warning Decal 1	Butterfly Arms
		Warning Decal 1
	Dip Handles	Military Press Arm
			Backrests
			Leg Press
			Plate
		Warning Decal 2
	Assist Arm		Press Arm
			Leg Lever
		Warning Decal 3
	Weight Stacks
		Low Pulley
			Station
	Weight Pin		Foot Plate
		3

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: A socket set, a set of open-end or closed-end wrenches, or a set of ratchet wrenches.

FRAME ASSEMBLY

1. Before beginning assembly, be sure that	1
you have read and understand the infor-
mation 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		11
through the Stabilizer (5). Insert two M8 x	51		5
65mm Carriage Bolts up through the Base			8
(4).
Attach the Base (4) to the Stabilizer (5) with	8		1
two M8 x 70mm Bolts (11), two M8 Washers
(8), and two M8 Nylon Locknuts (3). Do not
tighten the Nylon Locknuts yet.			3
		1	4
	51
			1
			27

4

FRAME ASSEMBLY

2. Slide the Assist Upright (74) and the Leg	2
Press Upright (56) onto the indicated M8 x			27
65mm Carriage Bolts (1) in the Stabilizer (5).
The high side of the brackets on the Assist		27
Upright and Leg Press Upright should be
on the side shown. Hand tighten four M8		87
Nylon Locknuts (3) onto the Carriage Bolts.			High Sides
Do not tighten the Nylon Locknuts yet.		91	of Brackets
	74
Press two 50mm Square Inner Caps (27) into
			56
the Leg Press Upright (56). Press a 50mm
Square Inner Cap into the Assist Upright (74).		27
Attach the Rubber Bumper (91) to the Leg
Press Upright (56) with the M4 x 16mm Self-
tapping Screw (87).
			3
		3
		3
			5
	3		1
		1
3. Slide the Front Upright (42) onto the M8 x	3
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).
			42
			6
			3
		4
			1

5

FRAME ASSEMBLY

4. Press a 50mm Square Inner Cap (27) into the	4	11
end of the Top Frame (55). Press a 45mm
			113
		55
Square Inner Cap (44) into each end of the		8
crossbar on the Top Frame. Press two 25mm			44
Inner Caps (113) into the top of the crossbar.	27
		3
Attach the Top Frame (55) to the Assist
			Crossbar
Upright (74) and the Leg Press Upright (56)
with two M8 x 70mm Bolts (11) and two M8			44
Nylon Locknuts (3).
Attach the Top Frame (55) to the Front	11		3
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)		56	42
yet.
		74
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	5	1
tighten the Nylon Locknuts yet.
			100
Attach the other end of the Rear Seat Frame		11
(100) to the Leg Press Upright (56) with two
			3
M8 x 70mm Bolts (11), two M8 Washers (8),		56
and two M8 Nylon Locknuts (3).		8
Attach the Handle (82) to the Rear Seat
Frame (100) with two M8 x 65mm Carriage	3	3
Bolts (1) and two M8 Nylon Locknuts (3).			82
Tighten all Nylon Locknuts used in steps		1	5
1–5.
6. Set two Weight Bumpers (19) on the bracket	6
on the Base (4) as shown. Set two Weight
	Pin
Bumpers (19) on the bracket on the Stabilizer
	Grooves
(5). Make sure the flat side of the Bumpers
are on the bottom.
Stack ten Weights (25) onto the bracket on		25
the Stabilizer (5). Stack eight Weights onto
	25
the bracket on the Base (4). Be sure that the
		5
pin grooves are all on the same side of
each stack of Weights.		19	Pin
		Bracket
Be careful not to tip either stack of			Grooves
Weights (25) until step 8 is complete.		4—Bracket	19
6

FRAME ASSEMBLY

	7. Press a Weight Tube Bumper (64) into the	7
	end of the Short Weight Tube (108). Insert the		Holes
	Weight Tube into the front stack of Weights
	(25). Be sure that the pin on the Weight		62
	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.
			65
			Lubricate
			Pin
			108
			64
			Pin Groove
			25
	8. Press a Weight Tube Bumper (64) into the	8
	end of the Long Weight Tube (63). Insert the		Holes
	Weight Tube into the rear stack of Weights
	(25). Be sure that the pin on the Weight		73
	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.		Lubricate
			65
			Pin
			63
			64
			Pin Groove
			25
	7

FRAME ASSEMBLY

ARM ASSEMBLY

9.	Attach the upper ends of the Short Weight	9	61		61
	Guides (73) to the Top Frame (55) with an M8 x			3
	150mm Bolt (60), two 19.5mm Spacers (61),					3
	and an M8 Nylon Locknut (3).	60				55
	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.”
	Make sure there is a Bushing (98) in each side
	of the Stabilizer (5). Press three 50mm Square	10
	Inner Caps (27) into the ends of the Leg Press					27
					95
	Arm (96).					Welded
	Lubricate an M10 x 80mm Bolt (67) with grease.					Tube
	Attach the Leg Press Arm (96) to the Stabilizer
	(5) with the Bolt and an M10 Nylon Locknut			96		97
	(21). Do not overtighten the Locknut; the Leg
					21	27
	Press Arm must be able to pivot freely.
	Align the welded tubes on the Leg Press Plate					Lubricate
				98
	(95) with a set of holes in the Leg Press Arm
					27
	(96). Attach the Leg Press Plate to the Leg					67
	Press Arm with the Press Pin (97).				98
					5
11.	Press a 22mm Plastic Bushing (90) onto each	11
	welded spacer on the Press Frame (17). Slide					Pulleys
	the Press Frame into place onto the Base (4).				17	must be on
	Note: This will be a tight fit; the Plastic					this side
	Bushings should fit snugly over the ends of
	the indicated tube in the Base. Make sure				Lubricate
	that the pulleys are on the side shown.
	Lubricate the M10 x 198mm Bolt (59) with					59
	grease. Attach the Press Frame (17) to the			21	Welded Spacers
	Base (4) with the Bolt and an M10 Nylon
	Locknut (21). Do not overtighten the	4
	Locknut; the Press Frame must be able to	Tube			90
	pivot easily.

8

ARM ASSEMBLY

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.

9

12			44	49
				46
		22
	46
			3
			17
13	86
	31
	50
	89			47
	21	Welded
		Brackets
	48
14
		55	Bracket
				47
			Lubricate
			Axle
	48
			69
				45
			70
				44
	44
	45		Axle
				69
				70

ARM ASSEMBLY

15. See the inset drawing. Attach the Military	15	32
Press Arm (84) to the Pivot Arm (101) with
two M8 x 55mm Bolts (33) and two M8 Nylon			49
Locknuts (3).			49	32
Press two 38mm Square Inner Caps (32) into
the Military Press Arm (84). Press two 25mm
Round Inner Caps (49) into the Military Press	21
Arm.			84
Attach the Pivot Arm (101) to the Assist	101
	67
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	74	56
be able to pivot easily.
		33
	101
			84
		3
16. Press two 25mm x 50mm Inner Caps (107)	16
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			56
Locknut; the Assist Arm must be able to
pivot easily.
	74	106	107
Note: (See the inset drawing.) The Assist			9	9
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).	105			21
	Bracket
		105
	74	56

10