TFI CHL-305WS User manual

CHL-305WS
High/Low Pulley w/200 Lbs.
Weight Stack for CPR-265
CHL-305WS Rev0
Revision Date 9-2-2014
OWNER’S MANUAL
OWNER’S MANUAL
Maintenance & Assembly Instructions
IMPORTANT: KEEPTHIS MANUAL FOR FUTURE REFERENCE
TUFFSTUFF FITNESS INTERNATIONAL
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 TFI Authorized Dealer or a service
company approved byTFI.
3. Provide trained personnel, supervision and correct usage of the equipment.
4. Provide scheduled inspection, maintenance & repairs and must be performed
by TFI Authorized Dealer or a service company approved byTFI.
5. Must use only genuine TFI replacement parts.
6. Machine must be anchored to a solid and level surface.

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com2
Table of Contents
TuStu Fitness International Inc. continually engages in research related to product improvements. Please take the time to carefully read through
this owner’s manual thoroughly. Instructions contained in this owner’s manual are not intended to cover all details or variations possible with
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 owner’s 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 owner’s manual, the matter should be directed to Customer Service at TuStu Fitness International Inc. in Chino, California.
Overhead Specications.................................................................................Page 3
Danger, Warning, & Caution Labels Information ...............................Page 4-7
Anchoring Unit...................................................................................................Page 8
Important Safety Instructions.......................................................................Page 9
Registration, Service & Assembly ............................................................. Page 10
Inspection/Maintenance ............................................................................. Page 11
Cable Inspection............................................................................................. Page 12
Step 1.................................................................................................................. Page 13
Step 2.................................................................................................................. Page 14
Step 3.................................................................................................................. Page 15
Step 4.................................................................................................................. Page 16
Step 5.................................................................................................................. Page 17
Step 6.................................................................................................................. Page 18
Step 7 Cable Routing .................................................................................... Page 19
Step 8.................................................................................................................. Page 20
Parts List............................................................................................................. Page 21
Pre-Assembled Components ...............................................................Page 22-26
Notes................................................................................................................... Page 27
Warranty ............................................................................................................ Page 28

www.tustutness.comCHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265 3
Overhead Specications
L 60” X W 51” X H 84”
PRODUCT WEIGHT 275 lbs
MAX-LOAD WEIGHT LIMIT - 200 lbs

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com
Carefully read ALL Danger, Warning & Caution labels posted on the machine
4
35
42
43
45
37
36
38
Keep body, hands
and fingers clear of
all moving parts.
BNH2926
WARNING

www.tustutness.comCHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265
Carefully read ALL Danger, Warning & Caution labels posted on the machine
5
44
40
41
39

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com6
Carefully read ALL Danger, Warning & Caution labels posted on the machine
35
4245
37
36
38
Keep body, hands
and fingers clear of
all moving parts.
BNH2926
WARNING

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39
41
43
46
Carefully read ALL Danger, Warning & Caution labels posted on the machine
7
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 Owner’s 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

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com
ANCHORING HOLES
Anchoring Unit
8
THIS OPTIONAL ATTACHMENT MUST BE ASSEMBLED ONTO A FULLY ANCHORED CPR-265 UNIT.

www.tustutness.comCHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265
Important Safety Instructions
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.
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 TFI.
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 TFI Authorized Dealer or
Professional Service Company approved byTFI.
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 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 TFI Authorized Dealer or a
Professional Service Company approved byTFI. Keep a service
log of all maintenance and repair activities. NOTICE: It is the sole
responsibility of the owner or facility operator to ensure that regular
maintenance is performed.
9

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com
Thank you for purchasing the CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265. 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 CHL-305WS 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
• External retaining ring pliers
• Rubber mallet, measuring tape & utility knife
• Super Lube® spray lubricant and grease
• Windex or household glass cleaner
Assembly Requirements
Follow these installation requirements when assembling the
CHL-305WS. Use the overhead view on the Content Page to layout your
oor plan before assembling.
Set up the CHL-305WS 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 and
easier 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
instructed 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 CHL-305WS 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 fromTFI if you have diculty
assembling the CHL-305WS. 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 http://www.tustutness.com or mail to
address shown below 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 owner’s 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 International 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
Registration, Service & Assembly
10
Loosely Tighten
70%
100%
Fully Tighten
Loosely Tighten
Loosely tighten all hardware in this step. DO NOT Fully
Tighten. Some component(s) may need pre-assembly
and or alignment during the assembly process.
Fully Tighten
Wrench tighten all hardware in this step.

www.tustutness.comCHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265
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. TFI recommends you maintain a service contract with a TFI Authorized Dealer or a
Professional Service Company approved by TFI. Keep a service log of all maintenance and repair activities. Extra copies can be downloaded
from our website www.tustutness.com
Inspection/Maintenance
INSPECTION / MAINTENANCE RECORDS
DATE REPLACEMENT REPAIRS INSPECTED BY
WARRANTY REPAIRS
DATE REPLACEMENT REPAIRS INSPECTED BY
11

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com
Cable Inspection
WARNING:
THE FOLLOWING CONDITIONS MAY INDICATE A WORN CABLE. REPLACE IMMEDIATELY.
IMPORTANT NOTE:
DAMAGED OR WORN 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
12

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Step 1 Assembly List
Item # Description Qty.
*1 ADJUSTABLE FOOT SUPPORT 1
*3 BOTTOM ASSEMBLY HOLDER 1
8 BLACK NYLON PULLEY 3/8 X 1 X 3 1/2 2
10 LEVELER M12 X 1.5 1
21 NYLON INSERT JAM LOCK NUT 3/8-16 4
22 FLAT WASHER SAE 3/8” 8
23 HEX HEAD CAP SCREW 3/8-16 X 1 3/4 2
24 HEX HEAD CAP SCREW 3/8-16 X 5 2
Step 1
13
NOTE:
1. SOME PARTS ON CPR-265 UNIT NOT SHOWN FOR CLARITY.
100%
Fully Tighten
Fully Tighten
Wrench tighten all hardware in this step.

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Step 2 Assembly List
Item # Description Qty.
*34 10 LB TOP PLATE W/22” SLTR BAR 1
*64 10 LB STEEL WEIGHT PLATE 19
12 GUIDE ROD 3/4 X 71 31/32 2
17 RUBBER DONUT 3/4 X 2 1/2 2
20 SELECTOR PIN W/COIL 3/8 X 4 1
Step 2
14

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Step 3
15
100%
Fully Tighten
Fully Tighten
Wrench tighten all hardware in this step.
Step 3 Assembly List
Item # Description Qty.
*2 TOP ASSEMBLY 1
*11 LAT BAR HOLDER 1
21 NYLON INSERT JAM LOCK NUT 3/8-16 2
22 FLAT WASHER SAE 3/8” 5
26 HEX HEAD CAP SCREW 3/8-16 X 3 2
27 HEX HEAD CAP SCREW 3/8-16 X 1 1
31 SPLIT LOCK WASHER 3/8” 1

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Step 4
16
Step 4 Assembly List
Item # Description Qty.
21 NYLON INSERT JAM LOCK NUT 3/8-16 2
22 FLAT WASHER SAE 3/8” 4
25 HEX HEAD CAP SCREW 3/8-16 X 2 1/2 2
NOTE:
1. LIFT GUIDE RODSAND
INSERT SCREWS AS
SHOWN.
100%
Fully Tighten
Fully Tighten
Wrench tighten all hardware in this step.

www.tustutness.comCHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265
Step 5
17
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 (#43) 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.
NOTE:
1. TOP PLATE LABEL GOES ON HOLE OFF CENTER AS
SHOWN. LABEL WILL COVER HOLE ON CENTER.
43

CHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265www.tustutness.com
3
66
100%
Fully Tighten
Fully Tighten
Wrench tighten all hardware in this step.
10
NOTE:
ONCE GUIDE RODS AND TOPASSEMBLYARE FULLY SECURED, MAKE ANY NECESSARY
ADJUSTMENTS ON LEVELER (#10) SO IT TOUCHES THE FLOOR. THEN TIGHTEN HEX FINISH
JAM NUT #66AGAINST THE BOTTOM ASSEMBLY HOLDER (#3) TO LOCK LEVELER IN PLACE.
Step 6
18
Step 7 Assembly List
Item # Description Qty.
*4 LOW ROW BAR 20” 1
*5 LAT BAR 48” 1
6 ADJ PULLEY PLATE 1/8 X 2 X 9 1
*6 ADJ PULLEY PLATE 1/8 X 2 X 9 1
8 BLK NYLON PULLEY WIDE GROOVE 3/8 X 1 X 4 1/2 5
9 BLK NYLON PULLEY WIDEGROOVE 3/8 X 1 X 3 1/2 2
13 LAT CABLE 1
14 LOW ROW CABLE 1
18 SNAP LINK Z/P 8MM X 80MM 3
19 COIL CHAIN Z/P 3/16 X 21 1
20 SELECTOR PIN W/COIL 3/8 X 4 1
21 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 5
22 FLAT WASHER SAE Z/P 3/8” 10
23 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 1 3/4 5
28 SPLIT BOLT GR-8 Z/P 1/2-13 X 1 1
29 SPLIT LOCK WASHER Z/P 1/2” 2
34 10 LB TOP PLATE W/22” SLTR BAR 19 BLK WTS 1
56 CABLE STOPPER SHELL Ø1.5 X .75 2
57 OVAL HEAD PHILLIPS MACHINE SCREW Z/P #10-32 X 1 1/8 2
58 7/8 RD X 1 5/8 LINK (3/16 CABLE) 2
59 SPLIT HEX TAP BOLT GR-5 B/O 1/2-13 X 3 1/2 1
60 FINISHED HEX NUT B/O 1/2-13 1

www.tustutness.comCHL-305WS High/Low Pulley w/200 Lbs. Weight Stack for CPR-265
FIG. A
FIG. B
18
56
57
58
28
13
29
13
20
20
9
FIG. C
29
14
60
59
19
18
63
4
22 23
22
21
21 22
823
6
23
22
2221
22
21
14
9
8
22
22
8
8
23
5
63 13
100%
Fully Tighten
Fully Tighten
Wrench tighten all hardware in this step.
Step 7 Cable Routing
19
*6
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Step 8 Assembly List
Item # Description Qty.
7 HOLD DOWN BAR 1
15 FOAM FOOT ROLL 1 X 4 X 16 W/VINYL 1
16 FOAM ROLL 1” NYLINER BUSHING 2
30 HITCH PIN 210 WW 1
31 SPLIT LOCK WASHER Z/P 3/8” 1
32 BUTTON HEAD SOCKET CAP SCREW Z/P 3/8-16 X 1 1
33 ALUMINUM WASHER .390 ID X 1.500 OD X .150 THK 1
Step 8
20
100%
Fully Tighten
Fully Tighten
Wrench tighten all hardware in this step.