Healthrider Home Gym HRSY23080 User Manual

¨
Model No. HRSY23080  
Serial No.  
The serial number is found in the  
location shown below. Write the  
serial number in the space above.  
USERÕS MANUAL  
Serial  
Number  
Decal  
QUESTIONS?  
As a manufacturer, we are  
committed to providing complete  
customer satisfaction. If you  
have questions, or if there are  
missing or damaged parts, we  
will guarantee complete satisfac-  
tion through direct assistance  
from our factory.  
TO AVOID UNNECESSARY  
DELAYS, PLEASE CALL DIRECT  
TO OUR TOLL-FREE CUSTOMER  
HOT LINE. The trained techni-  
cians on our customer hot line  
will provide immediate assis-  
tance, free of charge to you.  
CUSTOMER HOT LINE:  
1-800-999-3756  
Mon.ÐFri., 6 a.m.Ð6 p.m. MST  
CAUTION  
Read all precautions and instruc-  
tions in this manual before using  
this equipment. Save this manu-  
al for future reference.  
PATENT PENDING  
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Before You Begin  
Thank you for selecting the innovative and versatile  
HEALTHRIDER¨ 230 Home Gym System. The  
HEALTHRIDER¨ 230 offers a unique selection of  
weight stations designed to develop every major mus-  
cle group of the body. Whether your goal is to tone  
your body, build dramatic muscle size and strength or  
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  
HRSY23080. The serial number can be found on a  
improve your cardiovascular system, the HEALTHRID- decal attached to the HEALTHRIDER¨ 230 Home Gym  
ER¨ 230 makes it easy to achieve the results you want. System (see the front cover of this manual).  
For your benefit, read this manual carefully before  
using the HEALTHRIDER¨ 230 Home Gym System.  
If you have additional questions, please call our  
Please use the drawing below to familiarize your-  
self with the major parts and how they fit together.  
ASSEMBLED  
Lat Bar  
DIMENSIONS:  
Height: 81 in.  
Width: 54 in.  
Length: 67 in.  
High Pulley  
Station  
Press Arm  
Adjustment  
Knob  
Press Arm  
Adjustment  
Cam  
Shroud  
Covering  
Weight Stack  
Press Arms  
Weight Stack  
Adjustment  
Disc  
Leg  
Lever  
Butterfly  
Arm  
Backrest  
Adjustment  
Knob  
Low Pulley  
Station  
Backrest  
Seat  
Foot Plate  
3
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Assembly  
Note: This introduction will save you more  
time than it takes to read it!  
Identifying Parts  
To help you identify the small parts used in assem-  
bly, we have included a PART IDENTIFICATION  
CHART located in the center of this manual. Place  
the chart on the floor or work table and use it to  
quickly identify different parts as you open the pack-  
ages for each step.  
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.  
Making Things Easier for Yourself  
Everything in this manual is designed to ensure  
that the assembly of our products can be complet-  
ed successfully by anyone. However, it is impor-  
tant to recognize that your new equipment is a  
sophisticated product with many small parts. The  
assembly process will take timeÑpossibly several  
hours. Most people find that by setting aside plen-  
ty of time, and by deciding to make the task  
enjoyable, assembly will go smoothly. You may  
want to complete the process over a couple of  
evenings.  
Orienting Parts  
As you assemble this product, be sure that all parts  
are oriented as shown in the drawings.  
Tightening of Parts  
Tighten all parts as you assemble them, unless  
instructed to do otherwise.  
Giving Yourself a Good Start  
Before you begin the assembly process itself, take  
the time to complete the steps outlined here.  
Lining Up the Tools  
Assembly requires the following tools (not included):  
Clearing the Workspace  
Clear a workspace that is large enough to hold all  
parts and allow you to walk all the way around the  
assembled equipment.  
¥ Two (2) adjustable wrenches  
¥ One (1) standard screwdriver  
¥ One (1) phillips screwdriver  
¥ One (1) rubber mallet  
Unpacking the Box  
To make the assembly process as smooth as possi-  
ble, we have broken it into separate stages. All parts  
used in each stage are found in individual packages  
in the shipping box. Place all parts in a cleared area  
and remove the packing materials. Do not dispose of  
the packing materials until assembly is completed.  
¥ Lubricant, such as grease or petroleum jelly,  
and soapy water  
¥ Tape, such as clear tape or masking tape  
Assembly will be more convenient if you have a  
socket set, a set of open-end or closed-end wrenches  
or a set of ratchet wrenches. Some assembly steps  
require two people.  
Important: Wait until you begin each assembly  
stage to open the parts bag labeled for that  
assembly stage.  
The Four Stages of the Assembly Process  
Frame Assembly  
Cable Assembly  
You will begin by assembling the base and the  
upright frames that serve as the skeleton of the  
equipment. The seat and all moving parts will later  
be attached to the frame.  
Completes the cables and pulleys that connect the  
moving arms with each other and with the weights.  
This ties the different parts together and makes the  
equipment function as a unit.  
Seat Assembly  
Completes the seat and backrest that support your  
body while you are exercising.  
Arm Assembly  
Completes the press and butterfly arms that you  
operate while you are exercising.  
4
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1
Frame Assembly  
1. Before beginning, make sure that you have read  
and understood the information on page 4.  
4
Locate and open the parts bag labeled ÒFRAME  
ASSEMBLY.Ó  
45  
Insert four 3/8Ó x 2 3/4Ó Carriage Bolts (45) up  
through the indicated holes in the Stabilizer (4). Insert  
a 3/8Ó x 3 1/2Ó Carriage Bolt (62) up through the hole  
in the sidearm on the Stabilizer. Note: If the Bolts  
tend to fall out, secure them by putting a small  
piece of tape over the head of each Bolt. Place the  
Stabilizer flat on the floor.  
62  
2
45  
2. Place the bracket on the lower end of the Support  
Upright (3) over the indicated 3/8Ó x 2 3/4Ó Carriage  
Bolts (45) in the Stabilizer (4). Hand tighten two 3/8Ó  
Nylon Locknuts (50) onto the Bolts. Do not tighten  
the Nylon Locknuts yet.  
CAUTION: Until step 3 has been performed, the  
unit can easily tip over. Have one person hold the  
Support Upright in position or lean it against a  
wall.  
3
Insert two 3/8Ó x 3Ó Bolts (53) with two 3/8Ó Flat  
Washers (55) through the indicated holes in the  
Stabilizer (4) and the bracket on the Support Upright  
(3).  
50  
55  
53  
50  
3. Press a 2Ó Square Inner Cap (28) into the end of the  
Weight Base (5).  
4
53  
Press a 2Ó Square Inner Cap (28) into the end of the  
riser on the Weight Base (5).  
Bracket  
55  
45  
Press a 2Ó Square Cover Cap (33) onto the sidearm  
on the Weight Base (5).  
Insert two 3/8Ó x 2 3/4Ó Carriage Bolts (45) up through  
the indicated holes in the Weight Base (5) and secure  
the bolt heads with pieces of tape to prevent them  
from falling out.  
3
50  
4
3
33  
Insert a 3/8Ó x 3 1/2Ó Carriage Bolt (62) up through  
the hole in the sidearm on the Weight Base (5) and  
secure the bolt head with tape.  
62  
28  
53  
Place the Weight Base (5) on the floor with the holes  
in the mounting bracket over the 3/8Ó x 3Ó Bolts (53)  
going through the Stabilizer (4) and the bracket on  
the Support Upright (3). Hand tighten two 3/8Ó Nylon  
Locknuts (50) onto the Bolts. Do not tighten the  
Nylon Locknuts yet.  
5
28  
45  
5
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4. Place the bracket on the lower end of the Main  
Upright (1) over the indicated 3/8Ó x 2 3/4Ó Carriage  
Bolts (45) in the Stabilizer (4). Hand tighten two 3/8Ó  
Nylon Locknuts (50) onto the Bolts. Do not tighten  
the Nylon Locknuts yet.  
4
Insert two 3/8Ó x 3Ó Bolts (53) with two 3/8Ó Flat  
Washers (55) through the indicated holes in the  
Stabilizer (4) and the bracket on the Main Upright (1).  
1
50  
53  
50  
55  
53  
4
55  
5. Press a 2Ó Square Inner Cap (28) into the end of the  
Seat Base (6).  
45  
Insert two 3/8Ó x 2 3/4Ó Carriage Bolts (45) up through  
the indicated holes in the Seat Base (6) and secure  
the bolt heads with pieces of tape to prevent them  
from falling out.  
5
1
50  
Insert a 3/8Ó x 3 1/2Ó Bolt (56) up through the welded  
tube on the Seat Base (6) and secure the bolt head  
with tape.  
4
Welded Tube  
53  
Place the Seat Base (6) on the floor with the holes in  
the mounting bracket over the 3/8Ó x 3Ó Bolts (53)  
going through the Stabilizer (4) and the bracket on  
the Main Upright (1). Hand tighten two 3/8Ó Nylon  
Locknuts (50) onto the Bolts. Do not tighten the  
Nylon Locknuts yet.  
6
56  
45  
28  
6. Place the Seat Frame (7) onto the 3/8Ó x 2 3/4Ó  
Carriage Bolts (45) in the Seat Base (6). Hand tighten  
two 3/8Ó Nylon Locknuts (50) onto the Bolts. Do not  
tighten the Nylon Locknuts yet.  
6
1
50  
53  
7
Locate two 3/8Ó x 3Ó Bolts (53) and slide a 3/8Ó Flat  
Washer (55) onto each Bolt. Insert the 3/8Ó x 3Ó Bolts  
through the indicated holes in the Main Upright (1)  
and the bracket on the Seat Frame (7). Hand tighten  
two 3/8Ó Nylon Locknuts (50) onto the Bolts. Do not  
tighten the Nylon Locknuts yet.  
55  
50  
50  
45  
6
6
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7. Locate two 3/8Ó x 4 3/4Ó Bolts (46) and slide a 3/8Ó  
Flat Washer (55) onto each of them. Insert the Bolts  
through the indicated holes in the Top Frame (9) and  
then through the holes in the Main Upright (1). Slide a  
3/8Ó Flat Washer onto each Bolt and secure it with a  
3/8Ó Nylon Locknut (50). Do not tighten the Nylon  
Locknut yet.  
7
1
9
50  
55  
8. Slide a 3/8Ó Flat Washer (55) onto a 3/8Ó x 4 3/4Ó Bolt  
(46) and push the Bolt through the Top Frame (9).  
Push the Bolt into the hole in the Support Upright (3)  
until the tip of the Bolt is visible inside the Upright.  
Slide the 1/2Ó x 1 13/16Ó Bushing (84) down into the  
Upright and push the Bolt all the way through the  
Bushing and the Upright. Note: Make sure you donÕt  
drop the Bushing into the Upright!  
55  
46  
8
28  
9
50  
50  
84  
Slide a 3/8Ó Flat Washer (55) onto the Bolt and  
secure it with a 3/8Ó Nylon Locknut (50). Do not  
tighten the Nylon Locknut yet.  
1
55  
55  
Slide a 3/8Ó Flat Washer (55) onto a 3/8Ó x 2 3/4Ó Bolt  
(47) and insert the Bolt through the hole in the  
Support Upright (3) and the bracket on the Top Frame  
(9). Hand tighten a 3/8Ó Nylon Locknut (50) onto the  
Bolt. Do not tighten the Nylon Locknut yet.  
55  
47  
46  
3
9. Place the bracket on the lower end of the Weight  
Upright (2) over the indicated 3/8Ó x 2 3/4Ó Carriage  
Bolts (45) in the Weight Base (5). Hand tighten two  
3/8Ó Nylon Locknuts (50) onto the Bolts. Do not tight-  
en the Nylon Locknuts yet.  
9
Locate two 3/8Ó x 1 3/4Ó Bolts (57) and slide a 3/8Ó  
Flat Washer (55) onto each of them. Insert the Bolts  
through the indicated holes in the Weight Upright (2)  
and then through the bracket on the Support Upright  
(3). Secure the Bolts with two 3/8Ó Nylon Locknuts  
(50).  
50  
Bracket  
3
50  
55  
Go back and fully tighten all Nylon Locknuts used  
in steps 2 through 9.  
57  
2
50  
50  
Bracket  
5
45  
7
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10. Attach two Bumpers (40) to the Weight Base (5) with  
two #8 x 1Ó Screws (78). Insert the two Weight Guides  
(15) through the indicated holes in the Weight Base  
(5).  
77  
10  
21  
15  
See the inset drawing. Press two Weight Inserts (77)  
into the indicated holes in each Weight (21). Make  
sure the large pin groove is pointed downward, as  
shown. Slide all of the included Weights (21) onto  
the two Weight Guides (15). Make sure the Weights  
are oriented correctly. The adjustment holes must  
be turned towards the center of the unit, as  
shown.  
Lubricate  
Large Pin Number  
Groove Decal  
16  
52  
17  
18  
Place Stickers  
on this side  
For packaging purposes, the Top Weight (16) is  
mounted in the upper threaded hole in the Weight  
Tube (17). Unless you have bought the Weight  
Expansion Set with five extra weight plates along with  
your system, the Top Weight must be moved. Use the  
Allen Wrench (100) to loosen the Button Head Screw  
(52) and slide the Top Weight down to the lower of  
the two threaded holes in the Weight Tube, as  
shown. Lubricate the insides of the holes in the Top  
Weight (16). Press the Weight Tube Bumper (18) into  
the indicated end of the Weight Tube (17). Slide the  
Weight Tube (17) with the Top Weight (16) onto the  
Weight Guides (15). Attach the Allen Wrench Holder  
(79) to the indicated location on the Seat Frame (7)  
2
Adjustment  
Holes on this  
side  
78  
7
100  
21  
5
79  
40  
Locate the decal sheet with the stickers showing the  
numbers 1 through 15. Place a sticker on each  
Weight (21) and the Top Weight (16) right next to the  
adjustment holes (see the inset drawing). The Top  
Weight must have the number 1 on it.  
11  
15  
11. Slide a 3/8Ó Flat Washer (55) and a 5/8Ó x 1/2Ó  
Bushing (85) onto a 3/8Ó x 2 3/4Ó Bolt (47). Line up  
the hole in the indicated Weight Guide (15) with the  
hole in the Weight Base (5). Slide the 3/8Ó x 2 3/4Ó  
Bolt through the Weight Guide and the Weight Base.  
Slide a 5/8Ó x 1/2Ó Bushing (85) onto the Bolt. Secure  
the Bolt with a 3/8Ó Flat Washer (55) and a 3/8Ó Nylon  
Locknut (50).  
55  
47  
5
85  
55  
85  
50  
12. Attach the upper ends of the Weight Guides (15) to  
the welded bracket underneath the Weight Upright (2)  
with two 3/8Ó x 1 3/4Ó Bolts (57) and two 3/8Ó Nylon  
Locknuts (50). Tighten, but do not overtighten, the  
Nylon Locknuts.  
12  
2
50  
Welded  
Bracket  
57  
15  
8
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13  
Arm Assembly  
13. Press Arm AssemblyÑLocate and open the parts  
bag labeled ÒARM ASSEMBLY.Ó  
58  
28  
8
Press a 2Ó Square Inner Cap (28) into the open end  
of each press arm on the Press Frame (8). Press a 1Ó  
Round Inner Cap (58) into each of the indicated holes  
on the press arms. Locate the Press Adjustment  
Frame (14).  
28  
14  
14. Tap two 1Ó Retainer Rings (32) and a 1Ó Round Cover  
Cap (81) onto one end of the Press Frame Tube (34).  
Lubricate the Press Frame Tube in its entire length.  
Note: Use the Cover Cap to tap on the Retainer  
Rings. Make sure the teeth on the Retainer Rings  
bend towards the Cover Cap (see inset drawing).  
28  
58  
32  
81  
14  
32  
9
Lubricate  
44  
Have one person lift up the Press Frame (8) while a  
second person slides the indicated end of the Press  
Frame Tube (34) through the bracket on the Top  
Frame (9) and the pre-assembled Large Bushings  
(44) in the Press Frame. Hold up the Press  
34  
8
Adjustment Frame (14) and slide the Press Frame  
Tube through it and the bracket on the Top Frame.  
Secure the Press Frame Tube with two 1Ó Retainer  
Rings (32) and a 1Ó Round Cover Cap (81).  
81  
Teeth  
81  
32  
34  
14  
15. Butterfly Arm Assembly. Identify the Left Adjustment  
Disc (26) and Right Adjustment Disc (27) by looking  
at the three adjustment holes and orienting the Discs  
as shown in the drawing. Make sure a Butterfly  
Bushing (88) has been pre-assembled on each side  
of the Adjustment Discs. Lubricate the indicated rod  
on the crossbar attached to the Main Upright (1).  
Slide the Right Adjustment Disc (27) onto the rod.  
Secure the Adjustment Disc with a 3/4Ó Retainer Ring  
(31) and a 3/4Ó Dome Cap (82). Assemble the Left  
Adjustment Disc (26) in the same manner. Make sure  
the teeth on the Retainer Ring bend towards the  
Dome Cap as shown above.  
15  
26  
Adjustment Holes  
Crossbar  
31  
82  
27  
Adjustment  
Holes  
88  
Lubricate  
16. Press two 2Ó Square Inner Caps (28) into the open  
ends of each Butterfly Arm (10). Wet the end of each  
Arm with soapy water. Slide a Butterfly Foam Pad  
(29) onto the indicated end of each Arm. Make sure a  
Butterfly Bushing (88) has been pre-assembled on  
each side of the Butterfly Arms.  
16  
1
28  
Lubricate the indicated rod on the crossbar attached  
to the Main Upright (1). Orient one Butterfly Arm (10)  
as shown and slide it onto the rod. Secure the  
Butterfly Arm with a 3/4Ó Retainer Ring (31) and a  
3/4Ó Dome Cap (82). Make sure the teeth on the  
Retainer Ring bend towards the Dome Cap as  
shown above. Assemble the other Butterfly Arm (10)  
on the opposite side of the crossbar. Follow the pro-  
cedure described above, but orient the Butterfly Arm  
as shown.  
10  
88  
Lubricate  
10  
82  
31  
29  
28  
9
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17. Leg Lever Assembly. Attach a Bumper (40) to the  
Seat Frame (7) with a #8 x 1Ó Screw (78).  
17  
7
63  
28  
Press a 2Ó Square Inner Cap (28) into the indicated  
end of the Leg Lever (41).  
40  
78  
Lubricate a 3/8Ó x 3Ó Bolt (53). Attach the Leg Lever  
(41) to the Seat Frame (7) with the 3/8Ó x 3Ó Bolt and  
a 3/8Ó Nylon Jamnut (63).  
53  
41  
Lubricate  
18  
Cable Assembly  
18. Locate and open the parts bag labeled ÒCable  
Assembly and Pulleys.Ó For Cable identification  
and routing during steps 18Ñ39, refer to the  
Cable Diagram and Cable ID Chart on page 19.  
Identify the Low Cable (72). It is approximately  
176Ó long and it has a ball on one end and a bolt  
on the other.  
Route the end of the Low Cable (72) with the ball  
through the bracket on the Weight Base (5) as  
shown. Attach the 3 1/2Ó Pulley (24) to the bracket  
with a 3/8Ó x 2Ó Bolt (54) and a 3/8Ó Nylon Locknut  
(50).  
24  
54  
72  
5
50  
Bracket  
19. Wrap the Low Cable (72) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
19  
2
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the welded tube on the Weight Upright (2) with a 3/8Ó  
x 3 3/4Ó Bolt (59) and a 3/8Ó Nylon Locknut (50).  
Make sure the Cable Trap is oriented as shown.  
59  
24  
50  
Welded  
Tube  
25  
72  
10  
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20. Wrap the Low Cable (72) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
20  
14  
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the bracket on the Press Adjustment Frame (14) with  
a 3/8Ó x 3Ó Bolt (53), a 3/8Ó Flat Washer (55), a 5/8Ó x  
1 1/4Ó Bushing (91) and a 3/8Ó Nylon Jamnut (63).  
Make sure the Cable Trap is oriented as shown.  
25  
55  
63  
53  
24  
72  
91  
21. Route the Low Cable (72) through the indicated slot  
in the Support Upright (3) from above.  
21  
Route Cable  
Through Slot  
From Above  
Locate the Small Pulley Frame (22) and remove both  
of the pre-assembled 3 1/2Ó Pulleys (24).  
24  
Wrap the Low Cable (72) around a 3 1/2Ó Pulley (24)  
in the direction shown. Attach the 3 1/2Ó Pulley (24) to  
the top half of the Small Pulley Frame (22) with a 3/8Ó  
x 2Ó Bolt (54) and a 3/8Ó Nylon Locknut (50). Note:  
The Pulley Frame must be oriented as shown.  
72  
Route Cable  
Through Slot  
From Below  
3
54  
50  
22  
Route the Low Cable (72) through the indicated slot  
in the Support Upright (3) from below.  
22. Feed the bolt at the end of the Low Cable (72)  
through the indicated slot in the Weight Upright (2)  
from below.  
22  
85  
55  
47  
Welded Rod  
Attach a 3 1/2Ó Pulley (24) inside the slot in the  
Weight Upright (2). To do this, slide a 3/8Ó Flat  
Washer (55) and a 5/8Ó x 1/2Ó Bushing (85) onto a  
3/8Ó x 2 3/4Ó Bolt (47). Insert the Pulley into the slot in  
the Upright and hold it in position while pushing the  
Bolt through the hole in the Upright and the Pulley.  
Slide a 5/8Ó x 1/2Ó Bushing (85) and a 3/8Ó Flat  
Washer (55) onto the Bolt and secure it with a 3/8Ó  
Nylon Locknut (50). Make sure the Low Cable (72)  
is wrapped around the Pulley in the direction  
shown, and that it is between the welded rod  
inside the Upright and the Pulley.  
85  
55  
24  
72  
50  
2
Bolt  
23  
85  
55  
23. Feed the end of the Low Cable (72) through the indi-  
cated slot in the Weight Upright (2) from above.  
47  
85  
55  
50  
Wrap the Low Cable (72) around a 3 1/2Ó Pulley (24).  
Attach the 3 1/2Ó Pulley inside the slot in the Weight  
Upright (2) with a 3/8Ó x 2 3/4Ó Bolt (47), two 3/8Ó Flat  
Washers (55), two 5/8Ó x 1/2Ó Bushings (85) and a  
3/8Ó Nylon Locknut (50). Make sure the Low Cable  
is wrapped around the Pulley in the direction  
shown, and that it is between the welded rod  
inside the Upright and the Pulley.  
24  
2
Welded Rod  
72  
Bolt  
11  
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24. Thread the bolt at the end of the Low Cable (72) a  
couple of turns into the Weight Tube (17).  
24  
25  
26  
72  
Bolt  
17  
25. Identify the High Cable (73). It is approximately  
340Ó long and it has a ball on one end and a loop  
on the other.  
Slot  
55  
59  
86  
55  
Route the end of the High Cable (73) with the loop  
through the slot in the Main Upright (1).  
50  
1
24  
Wrap the end of the High Cable (73) with the ball  
around a 3 1/2Ó Pulley (24) as shown.  
73  
Attach the 3 1/2Ó Pulley (24) inside the slot in the  
Main Upright (1) with a 3/8Ó x 3 3/4Ó Bolt (59), two  
3/8Ó Flat Washers (55), two 5/8Ó x 1Ó Bushings (86)  
and a 3/8Ó Nylon Locknut (50).  
86  
26. Route the end of the High Cable (73) with the loop  
through the bracket on the Main Upright (1) from  
above. Route the High Cable over a 3 1/2Ó Pulley (24)  
in the direction shown.  
73  
24  
1
Slide the 3 1/2Ó Pulley (24) into the bracket on the  
Main Upright (1). Slide a 3/8Ó x 3Ó Bolt (53) through  
the bracket and the Pulley, but do not mount a  
Locknut yet.  
Bracket  
53  
27. Locate the Adjustable Pulley Frame (23) and remove  
the 3 1/2Ó Pulleys (24) and Cable Traps (25).  
27  
Bracket  
Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown. Attach the 3 1/2Ó Pulley and a  
Cable Trap (25) to the top half of the Adjustable  
Pulley Frame (23) with a 3/8Ó x 2Ó Bolt (54) and a 3/8Ó  
Nylon Locknut (50). Note: The Pulley must be  
attached to the upper of the three adjustment  
holes. Make sure the Cable Trap is oriented as  
shown.  
1
24  
73  
25  
54  
23  
50  
Route the end of the High Cable (73) with the loop  
through the bracket on the Main Upright (1) from  
below.  
12  
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28. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown and route it back down through  
the bracket on the Main Upright (1).  
Top View  
28  
Second Pulley  
24  
1
50  
Attach the 3 1/2Ó Pulley (24) inside the bracket on the  
Main Upright (1) with the 3/8Ó x 3Ó Bolt (53) that was  
inserted in step 26. Secure the Bolt with a 3/8Ó Nylon  
Locknut (50). Make sure the Pulley you are attach-  
ing in this step is on the correct side of the Pulley  
attached in step 26 (see the inset drawing).  
1
73  
53  
First Pulley  
29. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
29  
50  
Attach the 3 1/2Ó Pulley (24) to the bracket on the  
Stabilizer (4) with a 3/8Ó x 2Ó Bolt (54) and a 3/8Ó  
Nylon Locknut (50).  
Bracket  
24  
73  
4
54  
30. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
30  
63  
25  
24  
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the sidearm on the Stabilizer (4) with the 3/8Ó x 3 1/2Ó  
Carriage Bolt (62, inserted earlier) and a 3/8Ó Nylon  
Jamnut (63). Make sure the Cable Trap is oriented  
as shown.  
73  
62  
4
31. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
31  
Riser  
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the riser on the Weight Base (5) by sliding a  
3/8Ó x 4 3/4Ó Bolt (46) through the Pulley, Cable Trap  
and riser. Do not use a 3/8Ó Nylon Locknut unless the  
Bolt slides out during the following step.  
73  
25  
24  
46  
5
13  
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32. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
50  
32  
22  
54  
Attach the 3 1/2Ó Pulley (24) to the lower half of the  
Small Pulley Frame (22) with a 3/8Ó x 2Ó Bolt (54) and  
a 3/8Ó Nylon Locknut (50).  
24  
73  
33. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
33A  
B
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the riser on the Weight Base (5) by sliding the Cable  
Trap and Pulley onto the 3/8Ó x 4 3/4Ó Bolt (46)  
attached in step 31. Thread a 3/8Ó Nylon Locknut (50)  
onto the Bolt and tighten it. Make sure the Cable  
Traps for both of the Pulleys attached to the riser  
are oriented as shown in this step and in step 31.  
73  
50  
Mount  
Pulley  
Here  
24  
25  
Riser  
34  
Note: For the sake of clarity, drawing 33A shows  
some parts removed.  
5
46  
34. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
63  
25  
24  
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the sidearm on the Weight Base (5) by sliding the  
Pulley and Cable Trap onto the 3/8Ó x 3 1/2Ó Carriage  
Bolt (62) inserted earlier. Tighten a 3/8Ó Nylon Jamnut  
(63) onto the Bolt. Make sure the Cable Trap is ori-  
ented as shown.  
73  
62  
5
35. Wrap the High Cable (73) around a 3 1/2Ó Pulley (24)  
in the direction shown.  
35A  
B
50  
25  
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the welded tube on the Seat Base (6) by sliding the  
Pulley and Cable Trap onto the 3/8Ó x 3 1/2Ó Bolt (56)  
inserted earlier. Thread a 3/8Ó Nylon Locknut (50)  
onto the Bolt and tighten it. Make sure the Cable  
Trap is oriented as shown.  
73  
Mount  
Pulley  
Here  
24  
Note: For the sake of clarity, drawing 35A shows  
some parts removed.  
Welded  
Tube  
56  
6
14  
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36. Route the High Cable (73) through the slot in the leg  
of the Seat Frame (7).  
36  
37  
38  
41  
7
Attach the closed loop at the end of the High Cable  
(73) to the Leg Lever (41) with a 3/8Ó x 2 3/4Ó Bolt  
(47), two 3/8Ó Flat Washers (55) and a 3/8Ó Nylon  
Locknut (50). Note: Do not overtighten the Nylon  
Locknut.  
47  
Slot  
73  
55  
55  
50  
37. Identify the Butterfly Cable (92). It is approximate-  
ly 61Ó long and it has a loop on both ends.  
26  
92  
Attach one end of the Butterfly Cable (92) to the Left  
Adjustment Disc (26) with a 5/16Ó x 1Ó Bolt (87), a  
3/8Ó Flat Washer (55), a 1/2Ó x 3/8Ó Bushing (83) and  
a 5/16Ó Nylon Locknut (64). Note: The loop on the  
Cable must wrap around the 1/2Ó x 3/8Ó Bushing.  
For the sake of clarity, some parts have been  
removed and the Adjustment Disc is shown  
exploded.  
64  
55  
83  
87  
38. Wrap the Butterfly Cable (92) around a 3 1/2Ó Pulley  
(24) in the direction shown.  
23  
Attach the 3 1/2Ó Pulley (24) and a Cable Trap (25) to  
the lower half of the Adjustable Pulley Frame (23)  
with a 3/8Ó x 2Ó Bolt (54) and a 3/8Ó Nylon Locknut  
(50). The Pulley must be attached to the middle of  
the three adjustment holes.  
50  
24  
54  
25  
92  
39  
Note: For the sake of clarity, some parts have  
been removed from the drawing.  
39. Attach the free end of the Butterfly Cable (92) to the  
Right Adjustment Disc (27) with a 5/16Ó x 1Ó Bolt (87),  
a 3/8Ó Flat Washer (55), a 1/2Ó x 3/8Ó Bushing (83)  
and a 5/16Ó Nylon Locknut (64).  
27  
Note: The loop on the Cable must wrap around  
the 1/2Ó x 3/8Ó Bushing.  
92  
87  
83  
55  
64  
15  
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40. Important: Follow all three Cables from end to  
end and make sure they rest in the grooves of all  
Pulleys and that both the Cables and the Pulleys  
move smoothly. Attach the bolt at the end of the Low  
Cable (72), the 1/2Ó Plain Nut (68), the 1 1/2Ó Flat  
Washer (48) and the Adjustment Tube (89) to the  
Weight Tube (17) in the order shown. Note: The bolt  
at the end of the Low Cable is one of the means  
for tightening the Cables (72, 73 and 92). Thread  
the bolt into the Weight Tube until all Cables are  
tight and rest firmly in the grooves of all Pulleys.  
Then tighten the 1/2Ó Plain Nut (68) onto the 1  
1/2Ó Washer (48).  
40  
72  
68  
48  
89  
17  
19  
21  
Insert the Weight Pin (19) into one of the holes  
between the Weights (21).  
41  
98  
38  
51  
Seat Assembly  
39  
50  
41. Locate and open the parts bag labeled ÒSeat  
Assembly.Ó  
47  
Press a 1 1/4Ó Square Inner Cap (98) into the indicat-  
ed end of the Backrest Center Tube (38). Attach the  
Backrest Center Tube to the bracket on the Seat  
Frame (7) with a 3/8Ó x 2 3/4Ó Bolt (47) and a 3/8Ó  
Nylon Locknut (50). Slide the Backrest Adjustment  
Tube (39) onto the Backrest Center Tube (38). If nec-  
essary, pull out the Short Adjustment Knob (51).  
7
Bracket  
42. Press a 1Ó x 1 1/2Ó Inner Cap (96) into each end of  
both Backrest Frames (37).  
42  
96  
Welded Bushings  
37  
65  
Identify the Right Backrest Frame (101) and the Left  
Backrest Frame (37) by looking at the welded bush-  
ings. Orient the Backrest Frames so the welded bush-  
ings are facing the Seat Frame (7) and are on the  
lower edge of the Backrest Frames. Attach the  
Backrest Frames (37, 101) to the indicated hole in the  
Seat Frame (7) with a 3/8Ó x 6 1/2Ó Bolt (65) and a  
3/8Ó Nylon Locknut (50).  
101  
65  
39  
96  
50  
Attach the Backrest Frames (37) to the indicated hole  
in the Backrest Adjustment Tube (39) with a  
3/8Ó x 6 1/2Ó Bolt (65) and a 3/8Ó Nylon Locknut (50).  
7
43  
12  
37  
43. Attach the Backrest (12) to the Backrest Frames (37)  
with four 1/4Ó x 2Ó Bolts (74) and four 1/4Ó Flat  
Washers (71).  
13  
71  
Attach the Seat (13) to the brackets on the Seat  
Frame (7) with four 1/4 x 3/4Ó Bolts (49).  
71  
7
74  
74  
49  
16  
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44. Press two 3/4Ó Round Inner Caps (43) into each Pad  
Tube (42).  
44  
30  
43  
42  
7
Insert one Pad Tube (42) into the Seat Frame (7).  
Slide a Foam Roller (30) onto each end of the Pad  
Tube.  
43  
41  
Insert the other Pad Tube (42) into the Leg Lever  
(41). Slide a Foam Roller (30) onto each end of the  
Pad Tube.  
30  
30  
42  
43  
30  
43  
45  
Miscellaneous Assembly  
36  
80  
45. Identify the Right Shroud (36) which is the one that  
does not have a slot in it.  
5
Bracket  
Attach the Right Shroud (36) to the indicated brackets  
on the Weight Base (5) with two 1/4Ó x 5/8Ó Bolts (80).  
Do not tighten the Bolts yet.  
80  
46. Attach the Right Shroud (36) to the indicated bracket  
on the Weight Upright (2) with a 1/4Ó x 5/8Ó Bolt (80).  
Do not tighten the Bolt yet.  
46  
Bracket  
80  
2
36  
47. Follow the procedure described in steps 45 and 46 to  
attach the Left Shroud (35) on the opposite side of  
the weight stack.  
47  
Top Bar  
2
80  
Attach both Shrouds (35, 36) to the end of the top bar  
on the Weight Upright (2) with a 1/4Ó x 5/8Ó Bolt (80).  
80  
Tie the Shrouds (35, 36) together with four 1/4Ó x 5/8Ó  
Bolts (80).  
Go back and fully tighten all of the 1/4Ó x 5/8Ó Bolts  
(80) used to attach both Shrouds (35, 36).  
80  
80  
80  
35  
36  
17  
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48. The decal shown below has been attached to the home gym system in the location shown. If the decal is  
missing or illegible, please call our customer hotline at the number on the front cover to order a replacement  
decal. Apply the new decal in the appropriate location.  
48  
49. Make sure that all parts have been properly tightened. The use of the remaining parts will be explained in  
ADJUSTMENT, beginning on page 20 of this manual.  
Before using the home gym system, pull each cable a few times to make sure that the cables move smooth-  
ly over the pulleys. If one of the cables does not move smoothly, find and correct the problem. IMPORTANT:  
If the cables are not properly installed, they may be damaged when heavy weight is used. If there is  
any slack in the cables, you will need to remove the slack by tightening the cables. See TROUBLE-  
SHOOTING AND MAINTENANCE on page 23.  
18  
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Cable Diagram  
The Cable Diagrams below show the proper routing of the Butterfly Cable (92), the High Cable (73) and the Low  
Cable (72). The numbers show the correct route for each Cable. Make sure the Cables are routed correctly,  
that the Pulleys move smoothly and that the Cable Traps do not touch or bind the Cables. Incorrect  
cable routing can damage the weight system.  
High Cable (73)  
Low Cable (72)  
5
1
4
6
2
3
3
7
4
8
11  
5
6
10  
2
9
1
7
Butterfly Cable (92)  
12  
Cable ID Chart  
92  
73  
72  
2
3
1
19  
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Adjustment  
The instructions below describe how each part of the home gym system can be adjusted. Refer to the exercise  
guide 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 ab strap, make sure that the attachments are in the correct starting  
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  
21  
To change the setting of the weight stack, insert a Weight  
19  
Pin (19) under the desired Weight (21). Make sure you  
insert the Weight Pin as far as it will go. The weight set-  
ting of the weight stack can be changed from 10 pounds  
to 150 pounds, in increments of 10 pounds. Note: Due to  
the cables and pulleys, the amount of resistance at  
each exercise station may vary from the weight set-  
ting. Use the WEIGHT RESISTANCE CHART on page  
22 to find the approximate amount of resistance at  
each weight station.  
Attaching the Lat Bar, Ankle Strap or Ab  
Strap to the Low Pulley Station  
72  
61  
Attach the Lat Bar (61) to the Low Cable (72) with a  
69  
Cable Clip (69). For some exercises, the Chain (67)  
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 exer-  
cise to be performed.  
67  
69  
The Ankle Strap (99) or Ab Strap (75) can be attached in  
the same manner.  
75  
99  
Attaching the Lat Bar, Ankle Strap or Ab  
Strap to the High Pulley Station  
61  
69  
73  
Attach the Lat Bar (61) to the High Cable (73) with a  
Cable Clip (69). For some exercises, the Chain (67)  
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 exer-  
cise to be performed.  
67  
69  
99  
75  
The Ab Strap (75) or Ankle Strap (99) can be attached in  
the same manner.  
20  
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Adjusting the Press Arms  
Pull out on the Press Frame Knob (11) on the Press  
Frame (8) and pivot the press arms up or down to the  
desired position. Release the Press Frame Knob and let it  
snap into one of the adjustment holes in the cam on the  
Press Arm Adjustment Frame (14).  
8
14  
Cam  
Note: Make sure the Butterfly Arms are in the storage  
position, as described on the next page, when you  
are using the press arms.  
Adjustment  
Holes  
11  
Adjusting the Position of the Backrest  
Pull out the Short Adjustment Knob (51) on the Backrest  
Adjustment Tube (39) and pivot the Backrest (12) up or  
down to the desired position. Release the Adjustment  
Knob and let it snap into one of the adjustment holes in  
the Backrest Center Tube (38, not visible).  
12  
Coordinating the Positions of the Backrest  
and Press Frame  
51  
39  
For many exercises, the Press Frame (8) and the  
Backrest (12) must be in the correct positions relative to  
each other. The Press Frame can be set in 12 different  
positions, as indicated by the decal on the cam of the  
Press Arm Adjustment Frame (see drawing A). The  
Backrest can be set to six different positions, as shown  
on drawing B. The positions of the Backrest and Press  
Frame correspond in the following manner:  
A
Storage  
Position  
Cam  
1. Decline, Row, Butterfly, Lat. With the Backrest in this  
position (1. on drawing B), you can use the Butterfly Arms  
or the Lat Bar by setting the Press Frame in the Storage  
Position (see the next page). For row exercises, set the  
Press Frame in one of the three Row positions.  
Row  
Incline  
Shoulder  
Decline  
Press  
2. Decline. With the Backrest raised to this position, the  
Press Frame should be in one of the three Decline posi-  
tions.  
3. Decline/Incline Combo. With the Backrest in this posi-  
tion, the Press Frame should be in the third Decline posi-  
tion or one of the three Press positions.  
B
4. Press/Incline. With the Backrest in this position, the  
Press Frame should be in the third Press position or one  
of the three Incline positions.  
5. Incline/Shoulder. With the Backrest in this position,  
the Press Frame should be in the third Incline position or  
one of the three Shoulder positions.  
2. Decline  
12  
1. Decline, Row, Butterfly/Lat  
38  
6. Shoulder. With the Backrest in this position, the Press  
Frame should be in one of the three Shoulder positions.  
Adjustment Knob (51)  
21  
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Adjusting the Butterfly Arms  
26  
Make sure the Backrest (12) is in the horizontal position  
as described on the previous page. Pull out the  
10  
Adjustment Knob (66) on one of the Adjustment Discs  
(26, 27) and pivot the Butterfly Arm (10 or 11) up or down  
to the desired position. Release the Adjustment Knob and  
let it snap into one of the adjustment holes in the Disc.  
27  
66  
12  
Note: The Adjustment Discs (26, 27) each have three  
adjustment holes for use during regular exercises.  
Each Disc also has one hole for use when the  
Butterfly Arms are stored in a vertical position, point-  
ing towards the floor.  
11  
Weight Resistance Chart  
The chart below shows the approximate weight resistance at each exercise station. ÒTopÓ refers to the 10 lb. top  
weight; the other numbers refer to the 10 lb. weight plates. Note: The actual resistance at each station may  
vary due to differences in individual weight plates as well as friction between the cables, pulleys, and  
weight guides. This chart shows the resistance for the five extra weight plates included with the Weight  
Expansion Set (see No. 16-20 below). The set is available as a separate purchase; ask for Model No.  
HRSA15080.  
Press  
Arm  
(lbs.)  
Lower  
Pulley  
(lbs.)  
Upper  
Pulley  
(lbs.)  
Butterfly  
(one side)  
(lbs.)  
Leg  
Lever  
(lbs.)  
Weight  
Plates  
TopÑ1  
2
15  
24  
18  
31  
16  
26  
9
15  
19  
25  
28  
32  
37  
43  
50  
56  
63  
65  
72  
80  
81  
87  
93  
97  
102  
109  
15  
27  
3
35  
40  
38  
37  
4
46  
54  
49  
49  
5
56  
64  
57  
59  
6
67  
76  
69  
71  
7
77  
87  
80  
84  
8
87  
99  
94  
94  
9
99  
110  
122  
133  
145  
159  
172  
183  
199  
213  
223  
228  
240  
104  
116  
128  
142  
151  
164  
174  
183  
196  
209  
219  
229  
107  
114  
128  
139  
149  
162  
173  
154  
198  
206  
220  
234  
10  
11  
12  
13  
14  
15  
*16  
*17  
*18  
*19  
*20  
110  
119  
129  
139  
150  
163  
169  
182  
194  
202  
211  
22  
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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  
1
Woven cable, the type of cable used on the home gym  
system, can stretch slightly when it is first used. If there is  
23  
slack in the Cables before resistance is felt, the Cables  
should be tightened.  
Adjustment Holes  
Slack can be removed by moving one or both of the  
3 1/2Ó Pulleys (24) attached to the Adjustable Pulley  
Frame (23).  
50  
54  
To move one Pulley, unscrew the 3/8Ó Nylon Locknut (50)  
and the 3/8Ó x 2Ó Bolt (54). Remove the Cable Trap (25)  
and Pulley (24) from the Adjustable Pulley Frame (23).  
Re-attach the Pulley and Cable Trap to the appropriate  
adjustment hole in the Pulley Frame.  
24  
25  
Note: Begin by moving one Pulley to the second  
adjustment hole. If the Cables are still too loose,  
move the same Pulley to the third hole. If additional  
adjustment is needed, move the second Pulley until  
the Cables are tight.  
36  
72  
The Cables can also be tightened by adjusting the bolt at  
the end of the Low Cable (72). To do this, the Shrouds  
(35, 36, not shown) must be removed. Follow assembly  
steps 45 to 47 in the opposite order to remove the  
Shrouds.  
Bolt  
When the Shrouds have been removed, insert the Weight  
Pin (19, not shown) between the third and the fourth  
Weight (21), counting from the top. See ÒChanging the  
Weight SettingÓ on page 20 for instructions on moving the  
Weight Pin.  
68  
17  
Loosen the 1/2Ó Plain Nut (68) securing the bolt at the  
end of the Low Cable (72). Tighten the bolt a couple of  
turns into the Weight Tube (17) until the Cables feel  
tighter. Tighten the Plain Nut to prevent the bolt from turn-  
ing.  
Note: If a Cable tends to slip off the Pulleys often, the  
Cable may have become twisted. Remove the Cable  
and re-install it.  
21  
If the Cables need to be replaced, see ORDERING  
REPLACEMENT PARTS on the back cover of this manual.  
23  
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5/8Ó x 1/2Ó Bushing (85)  
3/4" Round Inner Cap (43)  
3/4Ó Retainer Ring (31)  
5/8Ó x 1Ó Bushing (86)  
1" Round Inner Cap (58)  
1Ó Retainer Ring (32)  
5/8Ó x 1 1/4Ó Bushing (91)  
1/2Ó x 3/8Ó Bushing (83)  
1" Round Cover Cap (81)  
3/4Ó Dome Cap (82)  
1/2Ó x 3/4Ó Bushing (76)  
1 1/4" Square Inner Cap (98)  
1/2Ó x 1 13/16Ó Bushing (84)  
1Ó x 1 1/2" Inner Cap (96)  
1 1/2" x 2Ó Inner Cap (97)  
2" Square Inner Cap (28)  
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Part Identification Chart - Model No. HRSY23080  
1/4" Flat Washer (71)  
3/8" Flat Washer (55)  
1 1/2" Flat Washer (48)  
1/4" Nylon Jamnut (94)  
5/16" Nylon Locknut (64)  
1/2" Plain Nut (68)  
3/8" Nylon Locknut (50)  
3/8" Nylon Jamnut (63)  
#8 x 1Ó Screw (78)  
1/4" x 3/4" Bolt (49)  
5/16" x 1" Bolt (87)  
1/4" x 5/8" Bolt (80)  
1/4" x 1 1/2" Bolt (95)  
1/4" x 2" Bolt (74)  
3/8" x 1 1/2" Button Head Screw (52)  
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3/8" x 1 3/4" Bolt (57)  
3/8" x 2" Bolt (54)  
3/8" x 2 3/4" Bolt (47)  
3/8" x 2 3/4" Carriage Bolt (45)  
3/8" x 3" Bolt (53)  
3/8" x 3 1/2" Bolt (56)  
3/8" x 3 1/2" Carriage Bolt (62)  
3/8" x 3 3/4" Bolt (59)  
3/8" x 4 3/4" Bolt (46)  
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R0199A  
Part List - Model No. HRSY23080  
Key No. Qty.  
Description  
Key No. Qty.  
Description  
1
2
3
4
5
6
7
8
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
14  
1
1
18  
9
1
1
12  
2
4
4
4
5
1
1
1
1
1
1
3
1
2
4
4
8
4
6
1
4
40  
1
1
Main Upright  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
#
9
6
28  
1
4
4
2
1
1
2
4
2
2
2
1
1
2
2
4
1
1
4
1
1
28  
3
1
11  
2
4
2
1
6
2
2
8
1
2
1
1
1
4
4
4
2
1
1
1
1
1
1
1
3/8Ó x 3Ó Bolt  
3/8Ó x 2Ó Bolt  
Weight Upright  
Support Upright  
Stabilizer  
Weight Base  
Seat Base  
Seat Frame  
Press frame  
Top Frame  
Butterfly Arm  
Press Frame Knob  
Backrest  
Seat  
Press Arm Adjustment Frame  
Weight Guide  
Top Weight  
3/8Ó Flat Washer  
3/8Ó x 3 1/2Ó Bolt  
3/8Ó x 1 3/4Ó Bolt  
1Ó Round Inner Cap  
3/8Ó x 3 3/4Ó Bolt  
2Ó Leg Lever Cap  
Lat Bar  
3/8Ó x 3 1/2Ó Carriage Bolt  
3/8Ó Nylon Jamnut  
5/16Ó Nylon Locknut  
3/8Ó x 6 1/2Ó Bolt  
Adjustment Knob  
16Ó Chain  
1/2Ó Plain Nut  
Cable Clip  
Small Grip  
1/4Ó Flat Washer  
Low Cable  
High Cable  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
Weight Tube  
Weight Tube Bumper  
Weight Pin  
Weight Cover  
Weight  
Small Pulley Frame  
Adjustable Pulley Frame  
3 1/2Ó Pulley  
1/4Ó x 2Ó Bolt  
Ab Strap  
1/2Ó x 3/4Ó Bushing  
Weight Insert  
#8 x 1Ó Screw  
Cable Trap  
Left Adjustment Disc  
Right Adjustment Disc  
2Ó Square Inner Cap  
Butterfly Foam Pad  
Foam Roller  
3/4Ó Retainer Ring  
1ÓRetainer Ring  
2Ó Square Cover Cap  
Press Frame Tube  
Left Shroud  
Allen Wrench Holder  
1/4Ó x 5/8Ó Bolt  
1Ó Round Cover Cap  
3/4Ó Dome Cap  
1/2Ó x 3/8Ó Bushing  
1/2Ó x 1 13/16Ó Bushing  
5/8Ó x 1/2Ó Bushing  
5/8Ó x 1Ó Bushing  
5/16Ó x 1Ó Bolt  
Butterfly Bushing  
Adjustment Tube  
Leg Lever Bushing  
5/8Ó x 1 1/4Ó Bushing  
Butterfly Cable  
Weight Support Plate  
1/4Ó Nylon Jamnut  
1/4Ó x 1 1/2Ó Bolt  
1Ó x 1 1/2Ó Inner Cap  
1 1/2Ó x 2Ó Inner Cap  
1 1/4Ó Inner Cap  
Ankle Strap  
Allen Wrench  
Right Backrest Frame  
UserÕs Manual  
Right Shroud  
Left Backrest Frame  
Backrest Center Tube  
Backrest Adjustment Tube  
Bumper  
Leg Lever  
Pad Tube  
3/4Ó Round inner Cap  
Large Bushing  
3/8Ó x 2 3/4Ó Carriage Bolt  
3/8Ó x 4 3/4Ó Bolt  
3/8Ó x 2 3/4Ó Bolt  
1/2Ó Flat washer  
1/4Ó x 3/4Ó Bolt  
3/8Ó Nylon Locknut  
Small Adjustment Knob  
3/8Ó x 1 1/2Ó Button Head Screw  
#
#
Exercise Guide  
Decal Sheet  
Note: Ò#Ó indicates a non-illustrated part. Specifications are subject to change without notice.  
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Exploded DrawingÑ  
Model No. HRSY23080  
R0199A  
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Ordering Replacement Parts  
To order replacement parts, simply call our Customer Service Department toll-free at 1-800-999-3756, Monday  
through Friday, 6 a.m. until 6 p.m. Mountain Time (excluding holidays). To help us assist you, please be pre-  
pared to give the following information:  
1. The MODEL NUMBER of the product (HRSY23080).  
2. The NAME of the product (HEALTHRIDER¨ 230 Home Gym System).  
3. The SERIAL NUMBER of the product (see the front cover of this manual).  
4. The KEY NUMBER and DESCRIPTION of the part(s) (see the PART LIST and EXPLODED DRAWING  
attached at the center of this manual).  
Limited Warranty  
ICON Health & Fitness, Inc. (ICON), warrants this product to be free from defects in workmanship and mate-  
rial, under normal use and service conditions, for a period of ninety (90) days from the date of purchase. This  
warranty extends only to the original purchaser. ICON's obligation under this warranty is limited to replacing  
or repairing, at ICON's option, the product at one of its authorized service centers. All products for which war-  
ranty claim is made must be received by ICON at one of its authorized service centers with all freight and other  
transportation charges prepaid, accompanied by sufficient proof of purchase. All returns must be pre-autho-  
rized by ICON. This warranty does not extend to any product or damage to a product caused by or attribut-  
able to freight damage, abuse, misuse, improper or abnormal usage or repairs not provided by an ICON  
authorized service center, products used for commercial or rental purposes, or products used as store display  
models. No other warranty beyond that specifically set forth above is authorized by ICON.  
ICON is not responsible or liable for indirect, special or consequential damages arising out of or in connection  
with the use or performance of the product or damages with respect to any economic loss, loss of property,  
loss of revenues or profits, loss of enjoyment or use, costs of removal, installation or other consequential dam-  
ages of whatsoever nature. Some states do not allow the exclusion or limitation of incidental or consequen-  
tial damages. Accordingly, the above limitation may not apply to you.  
The warranty extended hereunder is in lieu of any and all other warranties and any implied warranties of mer-  
chantability or fitness for a particular purpose is limited in its scope and duration to the terms set forth herein.  
Some states do not allow limitations on how long an implied warranty lasts. Accordingly, the above limitation  
may not apply to you.  
This warranty gives you specific legal rights. You may also have other rights which vary from state to state.  
ICON HEALTH & FITNESS, INC., 1500 S. 1000 W., LOGAN, UT 84321-9813  
HEALTHRIDER¨ is a registered trademark of ICON Health & Fitness, Inc.  
Part No. 152596 H04547-C R0199A  
Printed in Canada © 1999 ICON Health & Fitness, Inc.  
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