CalGym CG-7503 User manual

OWNER’S MANUAL
Maintenance & Assembly Instructions
CG-7503
Multi-Press
CG-7503_Rev0
Revision Date 7-25-2012
BY TUFFSTUFF FITNESS
IMPORTANT: KEEP THIS MANUAL FOR FUTURE REFERENCE
NOTICE
It is the Purchaser’s/Owner’s obligation:
1. To disclose and post all Rules & Regulations, Danger, Warning and Caution
labels axed on the machine to their customers/users.
2. Equipment to be installed by TuStu Authorized Dealer or a service
company approved by TuStu.
3. Provide trained personnel, supervision and correct usage of the equipment.
4. Provide scheduled inspection, maintenance & repairs and must be performed
by TuStu Authorized Dealer or a service company approved by TuStu.
5. Must use only genuine TuStu replacement parts.
6. Machine must be anchored to a solid and level surface.

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
TuStu Fitness Equipment Inc. continually engages in research related to product improvements. Please take the time to carefully read through this manual thoroughly. Instructions contained in
this manual are not intended to cover all details or variations possible with CALGYM equipment, or to cover every contingency that may be met in conjunction with assembly, installation, operation,
maintenance or troubleshooting of the equipment. Eventhough we have prepared this manual with extreme care, neither the manufacturer nor the author can accept responsibility for any errors in,
or omission from, the information given. Should additional information be required, or should situations arise that are not covered by this manual, the matter should be directed to Customer Service
atTuStu Fitness Equipment Inc. in Chino, California.
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DANGER, WARNING, & CAUTION LABELS INFORMATION ...............Page 3-5
ANCHORING UNIT .............................................................................................Page 6
IMPORTANT SAFETY INSTRUCTIONS..........................................................Page 7
REGISTRATION, SERVICE & ASSEMBLY........................................................Page 8
INSPECTION/MAINTENANCE.........................................................................Page 9
CABLE INSPECTION........................................................................................ Page 10
STEP 1 ................................................................................................................. Page 11
STEP 2 ................................................................................................................. Page 12
STEP 3 ................................................................................................................. Page 13
STEP 4 CABLE ROUTING ............................................................................... Page 14
STEP 5 ................................................................................................................. Page 15
STEP 6 ................................................................................................................. Page 16
STEP 7 ................................................................................................................. Page 17
STEP 8 CABLE ROUTING ............................................................................... Page 18
STEP 9 ................................................................................................................. Page 19
STEP 10............................................................................................................... Page 20
BASIC EXERCISE GUIDE................................................................................. Page 21
PARTS LIST......................................................................................................... Page 22
EXPLODED VIEW ............................................................................................. Page 23
WARRANTY ....................................................................................................... Page 24
Table of Contents
L 72” X W 55” X H 59”

CG-7503 Multi-Press
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Carefully read ALL Danger, Warning & Caution labels posted on the machine

CG-7503 Multi-Press
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Carefully read ALL Danger, Warning & Caution labels posted on the machine
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CG-7503 Multi-Press
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BE ALERT!
THE FITNESS EQUIPMENT IN THIS
FACILITY PRESENTS HAZARDS
WHICH, IF NOT AVOIDED, COULD
CAUSE SERIOUS INJURY OR DEATH.
Prior to using the equipment, READ the
warning labels and instruction placards
affixed to each machine.
If you are unsure on how to use a machine,
seek the assistance of our floor personnel.
We will be happy to instruct you on how to
use the equipment properly.
Immediately report any piece of equipment
that is not functioning properly to our floor
personnel so that it may be evaluated and
service promptly.
DO NOT ATTEMPT to use or fix any piece of
equipment that is not functioning properly.
TUFFSTUFF FITNESS EQUIPMENT INC. CHINO, CA 91710ASTM F1749-96
It is extremely important that the Facility Sign shown to the left
be installed in plain view of the unit.
You should have received it along with this Owners Manual. If
you did not receive this Facility Sign with your order, you can
obtain one at no cost to you from TuStu Fitness by contacting
our service department at:
1 [phone]
service@tustu.net
service1@tustu.net
Carefully read ALL Danger, Warning & Caution labels posted on the machine
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BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
ANCHORING UNIT
6
7/16” DIAMETER
HOLE
Holes on shoe plates are provided for anchoring the unit to the oor. (See anchoring hole locations below)

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Important Safety Instructions
7
It is the responsibility of the facility owner and/or owner of the equipment to review the Owner’s Manual with their facility personnel and
understand all Danger, Warning and Caution labels axed on the machine. It is the responsibility of the oor personnel to instruct users
on proper operation of the equipment and review all danger, warning and caution labels.
SERIOUS INJURY OR DEATH CAN OCCUR
IF THESE SAFETY PRECAUTIONS ARE NOT OBSERVED:
1. Obtain a medical exam before beginning any exercise program.
2. Read and understand Owner’s Manual and all Danger, Warning
and Caution labels before using this equipment. If you still need
help, seek assistance from oor personnel.
3. Inspect the equipment before each use for wear and tear, loose
ttings, worn or frayed cables and frame welds. DO NOT USE if it
appears to be inoperable or damaged.
4. Stop exercising if you feel faint or dizzy. Consult a physician if you
are experiencing pain.
5. Use this equipment only for the intended use and for
exercise(s) shown on page 17.
6. Keep body, clothing and hair clear from all moving parts. Do not
attempt to free any jammed parts by yourself.
7. Always warm-up before and cool-down after weight training.
Warm-up for 10-15 minutes with stretching and cardiovascular
exercises. Cool-down should include light stretching exercises for
5-15 minutes.
8. Never hold your breath – will limit the ow of oxygen to your brain
and may cause dizziness. The most often used breathing pattern is
inhaling during least resistance and exhaling during maximum
resistance.
9. Do not use accessories or accessory attachments that are not
recommended by TuStu.
10. Make sure selector pin is completely inserted. Use only the selector
pin provided by the manufacturer.
11. Never pin the weights in an elevated position. Do not use the
machine if found in this condition.
Facility Safety Guidelines and Practices
1. Read and understand the Owner’s Manual before assembling,
servicing or using the equipment.
2. Equipment to be installed by TuStu Authorized Dealer or
Professional Service Company approved by TuStu.
3. Make sure each machine is set up and operated on a solid level
surface. Do not install equipment on an uneven surface.
4. Anchoring of equipment must be completed at time of
installation and inspected prior to use. Failure to anchor the
machine to the oor could cause the machine to tip or fall over
due to incorrect usage and misuse, and could result in serious
injury or death.
DANGER: indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING: indicates a potentially hazardous situation which, if not
avoided, will result in death or serious injury.
CAUTION: indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
5. Provide an adequate safety perimeter between the machine,
walls and other equipment to ensure that the facility has proper
clearance for usage and training.
6. Post and disclose all safety, rules and regulations on a bulletin
board easily accessible to users.
7. Perform regular maintenance (see Inspection Label). Pay special
attention to areas most susceptible to wear and tear, including but
not limited to cables, pulleys and rubber grips.
8. Do not lean against or pull on the framework, weight stack or
any component at all times.
9. Children must not be allowed near the equipment. Teenager must
be supervised.
10. Replace immediately all parts at rst sign of wear or damage. If
unable to replace worn or damaged components/parts, remove
machine from service until the repair is made.
11. Use only genuineTuStu replacement parts. Failure to do so will
void warranty and could result in serious injury or death to the users.
12. Do not remove any decals axed to the machine. Replace if
damaged.
13. Do not alter or modify the original manufacturer’s 200 lbs. weight
stack with any add-on incremental weights, weight plates or
dumbbells except those with standard factory installed option.
14. Maintain a service contract with a TuStu Authorized Dealer or a
Professional Service Company approved by TuStu. Keep a service
log of all maintenance and repair activities. NOTICE: It is the sole
responsiblity of the owner or facility operator to ensure that regular
maintenance is performed.

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Registration, Service & Assembly
Thank you for purchasing the CALGYM CG-7503 Multi-Press. This machine is part of the TuStu line of quality strength training
equipment. To maximize your use of the equipment, please study the Owner’s Manual thoroughly.
Required Tools
The basic tools that you will need to assemble the CG-7503 but are not
limited to:
• 9/16”, 3/4”, 1/2”combination wrenches
• Adjustable wrench
• Ratchet wrench with 9/16”, 3/4”, 1/2”sockets
• Rubber mallet, measuring tape & utility knife
• Super Lube® spray lubricant and grease
• Windex or household glass cleaner
Assembly Requirements
Follow these installation requirements when assemblying the CG-7503.
Use the overhead view on the Content Page to layout your oor plan
before assemblying.
Set up the CG-7503 on a clean, solid, at surface. A smooth, at surface
under the machine helps keep it level.
Allow ample space around the machine for safe unrestricted use an-
deasier access.
Insert all bolts in the same direction. For aesthetic appearance, insert all
bolts in the same direction unless specied (in text or illustration) to do
otherwise.
Leave room for adjustments. Do not fully tighten fasteners until in-
structed in the assembly steps to do so (to prevent any diculty with
alignment of parts during the assembly process). When not instructed,
tighten fasteners such as bolts, nuts and screws so the unit is stable, but
leave room for adjustments.
Assembly Tips
Read all“Notes”on each page before beginning each step.
While you may be able to assemble the CG-7503 using the illustrations
only, IMPORTANT safety notes and other tips are included in the text.
Some pieces may have extra holes that you will not use. Use only those
holes indicated in the instructions and illustration.
NOTE: With so many assembled parts, proper alignment and
adjustment is critical.While tightening the nuts and bolts,
be sure to leave room for nal adjustments.
CAUTION: Obtain assistance fromTuStu if you have diculty
assemblying the CG-7503. Please do not attempt to complete
the assembly as this could result in equipment failure and
serious injuries to the users.
Symbols & Description
Registration
To avoid unnecessary delays on warranty parts and to insure that a
permanent record of your purchase is on le with our company, be
sure to register online at www.tustutness.com within 10 days
of purchase.
Obtaining Service
Please use this Owner’s Manual as your guide to all parts included in
your shipment. When ordering parts, you must specify the part number
and description from this manual. Use only genuine TuStu
replacement parts when servicing the equipment. Failure to do
so will void warranty and could result in serious injury or death.
For information about product operation or service:
Phone: [phone] Toll Free 888-884-8275
Fax: [phone]
E-mail: service@tustu.net or service1@tustu.net
Hours: M–F 8:00 – 4:30 PST
Or write to: TuStu Fitness Equipment Inc.
Customer Service
13971 Norton Avenue, Chino, CA 91710
Retain this Owner’s Manual for future reference when ordering
service or parts. To assist you better, please be prepared to
provide the following information:
1. Model Number 2. Place of Purchase
3. Serial Number 4. Part # and Description
Loosely Fasten
Finger tighten all hardware in this step. DO NOT wrench tighten.
Some component(s) may need pre-assembly and alignment during
the assembly process.
Fully Fasten
Wrench tighten all hardware in this step.
8

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Perform regular maintenance (see Inspection Label). Pay special attention to areas most susceptible to wear and tear, including but
not limited to cables, pulleys and rubber grip. TuStu recommends you maintain a service contract with a TuStu Authorized Dealer
or a Professional Service Company approved by TuStu. Keep a service log of all maintenance and repair activities. Extra copies can be
downloaded from our website.
DATE REPLACEMENT REPAIRS INSPECTED BY
INSPECTION/MAINTENANCE RECORD
WARRANTY REPAIRS
Inspection/Maintenance
9

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Cable Inspection
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WARNING:
THE FOLLOWING CONDITIONS MAY INDICATE A WORN CABLE. REPLACE IMMEDIATELY.
IMPORTANT NOTE:
DAMAGED OR WORNED CABLE (AS SHOWN ABOVE) MAY DAMAGE THE PULLEY(S). YOU MUST INSPECT
THE PULLEYS AT THIS TIME FOR WEAR AND TEAR. REPLACE IF NEEDED.
“NECKING”, STRECHED CABLE COVERING
A TEAR IN THE CABLE COVER
CABLE END SLIPPING OUT
A CRACK IN THE CABLE COVER
A BREAK ON THE CABLE

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 1
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WARNING IT IS RECOMENDED TO HAVE ANOTHER PERSON ASSIST YOU WITH THE INSTALLATION ON THIS UNIT.
)
FULLY FASTEN

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 2
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)
FULLY FASTEN

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 3
)
FULLY FASTEN
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BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 4
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)
FULLY FASTEN

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 5
NOTE: SOME PARTS NOT SHOWN FOR CLARITY.
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)
FULLY FASTEN

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 6
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FULLY FASTEN

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 7
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FULLY FASTEN

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 8 Cable Routing
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WARNING: CABLE BOLT (#79) MUST BE THREADED A MINIMUM OF 5/8”WITH REGULAR NUT AND SPLIT WASHER TIGHTEN SECURELY TO ENSURE PROPER CONNECTION SEE FIGURES B AND C.
)
FULLY FASTEN
NOTE: 1. SOME PARTS CUT OUT/NOT SHOWN FOR CLARITY. 2. REMOVE ANY PULLEYS NECESSARY TO
INSTALL CABLE. 3. MAKE SURE THE CABLE RUNS BETWEEN THE PULLEYS AS SHOWN.
FIG. B FIG. D
FIG. A
FIG. C

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Step 9
19
Weight stack label and lubrication instructions: 1. Wipe front surface of weight stack with rubbing alcohol and wipe dry. 2. Peel o back sheet (adhesive side) from label and make sure that the label remains attached to the application tape. 3. Line up left edge of label sheet with outside edge of weight holes. 4. Line up the rst label to hole on top plate. 5. Make sure label is straight and slowly press into place. 6. Gently remove application tape and rub each label rmly against the weight stack. 7. Allow labels to stand for 2 days to allow adhesive to cure fully. 8. Open the lube package provided and apply a thin lm of lubricant around the rst 3 inches of the guide rods above the top plate. 9. After the cables are installed, do a set of reps to spread the lubricant thoroughly. Cable Adjustment 1. Adjustments can be made in the area pointed out (FIGURE B) to set the correct tension on the cable. 2. Upon completion of assembly, the TOP PLATE (#21) does not sit on top of the rst WEIGHT PLATE (#20), push the TOP PLATE (#21) down, insert the SELECTOR PIN (#16) and perform several repetitions. This will self-adjust and re-align the cable system. 3. After completing the previous step, the TOP PLATE (#21) still does not sit on top of the rst WEIGHT PLATE (#20) or if there is excess slack in the cable system, loosen regular nut (#41) and adjust split hex tap bolt (#79) in/out to give the cable proper tension (taut). Once achieving the proper tension, re-tighten regular nut (#41).
Assembly List
Item # Description Qty. Item # Description Qty.
5 GUIDE ROD 3/4 RD X 48 1/4 2 41 FINISHED HEX NUT Z/P 1/2 -13 1
7 MULTI-PRESS CABLE 1 64 NYLON INSERT LOCK NUT Z/P 5/16-18 1
11 PRESS BAR PIVOTARM 1 76 SHOULDER BOLT ALLOY 3/8 X 3/4 1
16 SELECTOR PIN W/COIL3/8 X 4 GOLD KNOB 1 79 SPLIT HEX TAP BOLT GR-8 Z/P 1/2 -13 X 3 1/2 (RND CUT) 1 20 10 LB STEEL WEIGHT PLATE BLACK 19 80 SPLIT LOCK WASHER Z/P 1/2 1 21 10 LB TOP PLATE W/ADJUSTABLE SELECTOR BAR 1 85 BRONZE BUSHING 3/8 X 1/2 X 5/16 1 32 LABEL-WEIGHT NUMBERS 1-20 DOTS Ø11/16 1

BY TUFFSTUFF FITNESS
CG-7503 Multi-Press
Important Safety InstructionsStep 10
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)
FULLY FASTEN THESE AND ANY LOOSELY FASTEN HARDWARE