Tuff stuff Apollo Standard User manual

ASSEMBLY INSTRUCTIONS
America’s Premier Exercise Equipment
Inner Outer Thigh Station Rev0
Revision Date 08-23-05
Apollo Modular Gym System
Inner Outer Thigh Station
Standard
Deluxe

About the Inner Outer Thigh Station
Congratulations on your new purchase of the Inner Outer Thigh
Station. We hope you are completely satisfied with this product
and wish you many years of enjoyment.
Tuff Stuff Equipment
This Tuffstuff product has been built to precise quality standards
and has been carefully packaged to ensure that damage will
not occur during shipment. The TuffStuff Warranty and signature
indicating final inspection has been conducted by our line foreman,
is an expression of our confidence in the completeness, the
materials, and workmanship of this product.
Warranty
SEE ACOPY OF WARRANTY ON BACK PAGE.
Registration Card
To avoid unnecessary delays in warranty service and to insure that
a permanent record of your purchase is on file with our factory,
be sure to complete the warranty registration card and send it to
TuffStuff Fitness Equipment today.
Prior to the Assembly of the Inner Outer Thigh Station
1. We advise you to consult your local Tuff Stuff retailer if you
should have a question or problem regarding the proper
assembly of this unit.
2. Neatly organize and identify all parts according to the Parts List
and the Exploded View Diagram.
Tool Requirements
1.One 7/8” combination wrench
2.One 3/4” combination wrench
3.One 9/16” combination wrench
4.One 1/2” combination wrench
5.One ratchet
6.One 9/16” socket
7.One rubber mallet
8.External retaining-ring pliers
9.Measuring tape
10.Utility knife
1
Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.
Specifications
1. Maximum Wt. Capacity - 200 lbs.
2. Total Machine Weight - 90 lbs.
Inner Outer Thigh Station
Step 1 Main Frame Assembly
Assembly List
Item # Description Qty. Item # Description Qty.
3 ADJUSTABLE PULLEY BRACKET 1 32 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 3
11 MAIN FRAME 1 34 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 2
19 SMALL COVER PLATE 3 1/2” PULLEY 1 39 NYLON INSERT JAM LOCK NUT B/O 3/8-16 2
22 PULLEY 3/8” X 3 1/2” 1 40 NYLON INSERT LOCK NUT B/O 3/8-16 2
23 PULLEY 3/8” X 4 1/2” 2 42 PLASTIC END CAP 2 X 3 1
28 FINISHED HEX NUT B/O 1/2-13 2 60 SPLIT LOCK WASHER B/O 3/8” 1
30 FLAT WASHER SAE B/O 3/8” 9 61 SPLIT LOCK WASHER Z/P 1/2” 2
AAssemble the Adjustable Pulley Bracket (#3) to the Weight Stack Frame using hardware shown.
BAttach a Pulley 3/8 X 4 1/2 (#23) to the Weight Stack Frame using hardware shown.
CUsing a rubber mallet, insert a Plastic End Cap 2 X 3 (#42) onto the tube-end of the Main Frame (#11). Next, affix the
Main Frame (#11) to the Weight Stack Frame using hardware shown.
DAttach a Pulley 3/8 X 3 1/2 (#22) and a Small Cover Plate 3 1/2 Pulley (#19) to the Main Frame (#11) using hardware
shown.

39
28
61
61
28
30
23 32
3
30
32
39
30
23
30
40
30
30
30
34
40
30
32
60
30
19
22
42
11
34
2
Inner Outer Thigh Station
Note: Some parts have
been cut away for clarity.
A
B
C
Weight Stack
Frame
Weight Stack
Frame
D

33
2
16
22
30
405
30
19
14
14
8
11
A
C
Step 2 Attach Pivot Legs to Main Frame
3Inner Outer Thigh Station
Assembly List
Item # Description Qty.
2 ADJUSTABLE CAM PLATE 1
5 CAM SUPPORT TUBE 1
8 LEFT PIVOT LEG 1
14 PIVOT AXLE 1 X 10 13/16 2
16 RIGHT PIVOT LEG 1
19 SMALL COVER PLATE 3 1/2” PULLEY 1
22 PULLEY 3/8” X 3 1/2” 1
30 FLAT WASHER SAE B/O 3/8” 2
33 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1
40 NYLON INSERT LOCK NUT B/O 3/8-16 1 Note: Some parts have
been cut away for clarity.
B
AAttach a Pulley 3/8 X 3 1/2 (#22) and a Small Cover Plate 3 1/2 Pulley (#19) to the Cam
Support Tube (#5) using hardware shown.
BInsert the Pivot Axles (#14) into the receptacles of the Main Frame (#11). Next, attach the
Cam Support Tube (#5) and the Adjustable Cam Plate (#2) to the right side Pivot Axle
(#14).
CAttach the Pivot Legs (#8, 16) to the Pivot Axles (#14).

13
5730
30 57
15
30
30
40
30
40
57
40
34
4
Inner Outer Thigh Station
Step 3 Connect Pivot Legs
AManeuver the two Pivot Axles (#14) into the holes on the bottom side of the Pivot Axle Support Tube (#15). Next,
loosely fasten the Pivot Axle Support Tube (#15) along with the two captive Pivot Axles (#14) to the Main Frame (#11)
using hardware shown.
BAttach the Pivot Actuator Plate (#13) to the Pivot Legs (#8, 16) receptacles
and secure it into place using hardware shown.
CTightly fasten the Pivot Axle Support Tube (#15) to the Main Frame (#11).
Then, thread the four Socket Set Screws 3/8-16 X 1/2 (#57) to align the Pivot
Legs (#8, 16).
Assembly List
Item # Description Qty.
13 PIVOT ACTUATOR PLATE 1
15 PIVOT AXLE SUPPORT TUBE 1
30 FLAT WASHER SAE B/O 3/8” 6
34 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 2
40 NYLON INSERT LOCK NUT B/O 3/8-16 4
57 SOCKET SET SCREW ALLOY 3/8-16 X 1/2 4
Note: Some parts have
been cut away for clarity.
B
A
14
14 30
C
8
16

Step 4 Handles and Leg Pad Pivot Brackets Assembly
AAttach the Handles (#6, #7) to the Main Frame (#11) using hardware shown.
BInsert the Leg Pad Pivot Brackets (#10) into the receptacles of the Pivot Legs (#8, 16). Next, secure the Leg Pad
Brackets (#10) using the two Retaining Snap Rings (#49). If possible, use special snap ring pliers for this job. If tool is
not available, carefully work each Retaining Snap Ring (#49) into the grooves of the Leg Pad Pivot Brackets (#10) then
push up alternately with a screw driver working the Retaining Snap Ring into the groove.
CAttach the Leg Pads (#9) to the Leg Pad Pivot Brackets (#10) using hardware shown.
5Inner Outer Thigh Station
Assembly List
Item # Description Qty. Item # Description Qty.
6 HANDLE (LT) 1 32 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 1
7 HANDLE (RT) 1 34 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 2
9 LEG PAD 2 40 NYLON INSERT LOCK NUT B/O 3/8-16 2
10 LEG PAD PIVOT BRACKET 2 49 RETAINING SNAP RING EXT. PLAIN .925 X 1 X .042 2
26 BUTTON HEAD SOC CAP SCREW B/O 3/8-16 X 1 1/4 3 50 RUBBER BUMPER W/WASHER 3/8 X 1 1/2 1
30 FLAT WASHER SAE B/O 3/8” 7

8
9
10
50
32
26
30
6
49
49
30
40
7
30
40
9
30
26
26
30
10
16
11
34
30
A
C
6
Inner Outer Thigh Station
Note: Some parts have
been cut away for clarity.
B

Step 5 Seat Pad and Back Pad Assembly
AAttach the Seat Pad (#17) to the Main Frame (#11) using hardware shown.
BAttach the Back Pad (#4) to the Adjustable Back Pad Tube (#1) using hardware shown. Next, insert the Adjustable
Back Pad Tube (#1) into the receptacle of the Main Frame (#11).
CAttach a Pulley 3/8 X 4 1/2 (#23) to the Floating Pulley Bracket (#12) using hardware shown.
7Inner Outer Thigh Station
Assembly List
Item # Description Qty. Item # Description Qty.
1 ADJUSTABLE BACK PAD TUBE 1 30 FLAT WASHER SAE B/O 3/8” 6
4 BACK PAD 1 31 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 1/4 4
12 FLOATING PULLEY BRACKET 1 32 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 1
17 SEAT PAD 1 39 NYLON INSERT JAM LOCK NUT B/O 3/8-16 1
23 PULLEY 3/8” X 4 1/2” 1

39
30
12
30
32
23
4
30 31
31
30
1
17
11
30
31
30
31
A
B
C
8
Inner Outer Thigh Station
Note: Some parts have
been cut away for clarity.

Step 6 Cable Routing
A. Connect the Weight Stack Cable (#20) to the Top Plate Selector Bar using hardware shown. See FIG. A.
B. Next, route the Weight Stack Cable (#20) up and over the Pulley 3/8 X 4 1/2 (#23-Labeled G1 ), then route down and under
the Pulley 3/8 X 4 1/2 (#23-Labeled G2 ).
C. Connect the Weight Stack Cable (#20) to the Weight Stack Frame using hardware shown. See FIG. B.
D. Secure the looped end of the Short Cable (#18) to the Floating Pulley Bracket (#12) using one Shoulder Bolt 3/8 X 3/4
(#54) and one Nylon Insert Lock Nut 5/16-18 (#41). See FIG. C.
E. Route the Short Cable (#18) down and under the Pulley 3/8 X 4 1/2 (#23-Labeled G3 ).
F. Next, route the cable under the Weight Stack. Then, route the cable around the Pulleys 3/8” X 3 1/2” (#22-Labeled G4 &
G5 ) passing the cable between the pulleys and the Cover Plates.
G. Attach the Short Cable (#18) to the Adjustable Cam Plate (#2) and secure it into place using the Socket Head Cap Screw
1/4-20 X 3/4 (#55). See FIG. D.
Assembly List
Item # Description Qty. Item # Description Qty.
18 SHORT CABLE 1 55 SOCKET HEAD CAP SCREW B/O 1/4-20 X 3/4 1
20 WEIGHT STACK CABLE 1 58 SPLIT BOLT Z/P 1/2-13 X 1 1
28 FINISHED HEX NUT B/O 1/2-13 1 59 SPLIT HEX TAP BOLT GR-5 B/O 1/2-13 X 3 1/2 1
41 NYLON INSERT LOCK NUT B/O 5/16-18 1 61 SPLIT LOCK WASHER Z/P 1/2” 2
54 SHOULDER BOLT ALLOY 3/8 X 3/4 1
9Inner Outer Thigh Station