Tuff stuff CalGym CG-5519 User manual

AMERICA’SPREMIER EXERCISE EQUIPMENT
CG-5519
CalGym - Ab Crunch #150
ASSEMBLY INSTRUCTIONS
CG-5519 Rev1
Revision Date 07-01-2008
TuffStuff Fitness Equipment, Inc.
1325 E. Franklin Ave., Pomona, CA91766
Ph: 909-629-1600 Fax: [phone]
E-mail: [e-mail]
www.tuffstuffitness.com
L 64" W 28" H 59"
DO NOT DISCARD THIS MANUAL
TUFFSTUFF LIMITED WARRANTY
TuffStuff warrants to the original purchaser that TuffStuff equipment will be free from defects in material and
workmanship. All warranty periods begin to run from the date of delivery to the original purchaser. The warranty
and remedies set forth herein are conditioned upon proper storage, installation, use and maintenance and confor-
mance with any recommendations of TuffStuff. This warranty does not cover products not manufactured by
TuffStuff or products which are altered without the express written consent of TuffStuff. This warranty as speci-
fied:
WARRANTY: a) Frames, welds, cams and weight plates -- Lifetime, b) Pivot bearings, pulleys, bushings, gas
shocks and guide rods -- Five (5) years, c) Belts, linear bearings and pull-pin components -- One (1) year, and
d) Upholstery, cables, finish and rubber grips -- Six (6) months, and all other parts not mentioned elsewhere in
this warranty will expire one (1) year from the date of delivery to the original purchaser. The obligation of
TuffStuff under this warranty is limited to repairing or replacing warranted defective parts, as TuffStuff may
elect, at TuffStuff’s facility in Pomona, California, without charge to purchaser for either parts or labor. Pur-
chaser is responsible for installation of repaired or replaced parts, and all transportation and insurance costs on
returned or replaced equipment to and from TuffStuff’s facility in Pomona.
THE FOREGOING SHALL CONSTITUTE THE SOLE REMEDY OF THE PURCHASER AND THE
SOLE LIABILITY OF TUFFSTUFF WITH REGARD TO WARRANTY. NO IMPLIED STATUTORY
WARRANTY OR IMPLIED STATUTORY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE SHALL APPLY. IN NO EVENT, WHETHER AS A RESULT OF
BREACH OF CONTRACT, WARRANTY, NEGLIGENCE OR OTHERWISE, SHALL TUFFSTUFF BE
LIABLE FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT
LIMITED TO, LOSS OF PROFITS OR REVENUE, LOSS OF USE OF EQUIPMENT, COST OF CAPI-
TAL, COST OF SUBSTITUTION EQUIPMENT, DOWNTIME COST, OR CLAIMS OF CUSTOMERS
OR PURCHASER FROM SUCH DAMAGE.
This written warranty is the final, complete and exclusive agreement of the parties with respect to the quality or
performance of the equipment and no action for breach of this written warranty or any implied warranty shall be
commenced more than one (1) year after the accrual of the cause of action. No modification of this warranty or
waiver of its terms shall be binding on either party unless approved in writing by an authorized representative of
the party. Contact TuffStuff Fitness Equipment, Inc. at 1325 E. Franklin Avenue, Pomona, California 91766,
before returning any defective equipment.
TuffStuff Fitness Equipment, Inc.
1325 E. Franklin Avenue
Pomona, CA 91766, USA
Ph: 909-629-1600 Fax: [phone]
E-mail: [email protected] Net: www.tuffstuff.net

2CG-5519 CalGym - Ab Crunch #150
Introduction
About the CG-5519 CalGym - Ab Crunch #150
Congratulations on your new purchase of the CalGym -Ab Crunch
#150. We hope you are completely satisfied with this product and
wish you many years of enjoyment.
TuffStuff Equipment
ThisTuffstuffproducthasbeenbuilttoprecise quality standardsand
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 A COPY 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 CalGym - Ab Crunch #150
We advise you to consult your local TuffStuff retailer if you should
have a question or problem regarding the proper assembly of this
unit.
Tool Requirements
One 7/8” combination wrench1.One 3/4” combination wrench2.One 9/16” combination wrench3.One 1/2” combination wrench4.One 7/16” combination wrench5.One adjustable wrench6.One ratchet7.One 3/4” socket8.One 9/16” socket9.Rubber Mallet10. Windex or household glass cleaner11. Measuring tape12. Utility knife13.
Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.
Specifications
1. Maximum Wt. Capacity - 150 lbs. fixed
2. Total Machine Weight - 365 lbs.
3. Footprint (LWH) - See Front Cover.
SCREWWIDTH
WASHERDIAMETER
NUTDIAMETER
SCREWLENGTH
Hardware Measurement Diagram
TuffStuff Basic Strength Equipment Safety and General Maintenance
All TUFFSTUFF strength equipment is designed and manufactured to offer maximum, long-life service with minimal
maintenance. However, safety inspection and routine maintenance in your facility should be the upmost importance
in your daily operation. Information presented in these pages will serve as a basic guideline to design your own
inspection procedures.
Part One: General Inspection and Cleaning
Equipment should be wiped down with a damp cloth and dried on a daily basis. The powder coat finish should be
polished with a good car wax on a monthly basis. A daily wipe down of the upholstery with a lanolin based hand
cleaner or Naugahyde Cleaner. Do not use cleaners such as Lysol or Windex as they will dry out and crack the
vinyl. Lanolin hand cleaner dissolves the sweat and lubricates the vinyl, maintaining its natural flexibility. Sweat
is corrosive and when left on the frame and components will eventually cause corrosion or rust. When performing
these cleaning sessions, it is the perfect time to inspect the equipment and note any problems for the maintenance
personnel to correct.
1. Check equipment if it is operating properly.
2. Check the cable for loose fittings or frayed cable and is seating properly on the pulleys and cams.
3. Make sure that the proper weight stack selector pin is with each machine and that the pin functions prop-
erly.
4. If something appears loose be sure to have it tightened immediately.
5. If a piece of equipment appears damaged or not operation properly, place the piece out-of-service imme-
diately.
Maintenance
7CG-5519 CalGym - Ab Crunch #150
CG-5519 Parts List
REV1
Item No. Description Rev. Part No. Qty. Item No. Description Part No. Qty.
1ADJUSTABLESEATTUBE 0UP6092 1 34 HEXHEADCAPSCREWGR‐5B/O3/8‐16X1 BNH0275 2
2ABDOMINALCRUNCHCABLE 0UP6094 1 35 HEXHEADCAPSCREWGR‐5B/O3/8‐16X11/4BNH0273 2
3BACKPAD 0UP6093 1 36 HEXHEADCAPSCREWGR‐5B/O3/8‐16X13/4 BNH0274 3
4FOAMROLL1X4X
7
0 UP5927 2 37 HEXHEADCAPSCREWGR‐5B/O3/8‐16X21/2 BNH0276 2
5FOOTROLLTUBE1X181/2 0 UP2944 1 38 HEXKEYLONGARMALLOY1/8ʺBNH0767 1
6FOOTROLLTUBE1X181/2(2XNUTS) 0 UP5953 139 HEXHEADCAPSCREWGR‐5B/O3/8‐16X3 BNH0282 2
7FRONTFRAME 0UP6095 1 40 HEXHEADCAPSCREWGR‐5B/O3/8‐16X5 BNH0320 4
8GUIDEROD3/4RDX481/4 0 UP5261 2 41 HEXKEYLONGARMALLOY3/16ʺ BNH0371 1
9MAINFRAME 0UP6096 1 42 NYLONBALLW/THREADEDSOCKET13/4X5/16 BNH0022 1
10 SEATPAD 0UP6097 1 43 NYLONINSERTJAMLOCKNUT3/8‐16 BNH0365 11
11 SELECTORPINW/COIL3/8X4GOLDKNOB 0 UP3035 1 44 NYLONINSERTLOCKNUTB/O5/16‐18 BNH0215 1
12 WEIGHTSHIELDSUPPORTBRACKET 0 UP5268 2 45 NYLONPULLEY3/8X1X41/2BLACK BNH0506 1
13 WEIGHTSTACKFRAME 1UP6098 1 46 PLASTICFOOTROLLHOLDER BNH1807 4
14 BNH1650 14 47 PLASTICINSERTCAP1ʺRD10‐12GA BNH0002 2
15 BNH1097 1 48 PLASTICINSERTELLIPTICALGUIDE BNH1760 1
16 BNH0235 1 49 PLASTICSHROUDLID BNH2097 1
17 BNH0553 2 50 PULLPIN1/2X31/2LIGHTSPRING(YELLOWKNOB) BNH0603 1
18 BNH2193 1 51 REARPLASTICWEIGHTSHIELDBNH2133 1
19 BNH2194 2 52 RUBBERDONUT3/4X21/2 BNH0068 2
20 BNH2149 153 RUBBERFOOTFOR6X41/4PLATE BNH1647 4
21 BNH2201 1 54 RUBBERGRIP1IDX.125X71/2 BNH0965 2
22 BNH0126 1 55 RUBBERGROMMET3/4ʺID BNH0401 2
23 BNH2224 1 56 SHOULDERBOLTALLOY3/8X3/4BNH0718 1
24 BNH1893 1 57 SOCKETSETSCREWALLOY1/4‐20X1/4 BNH0790 2
25 BNH1894 258 SOCKETSETSCREWALLOY3/8‐16X3/4 BNH0476 1
26 BNH2226 1 59 SPLITHEXTAPBOLTGR‐5B/O1/2‐13X31/2(RNDCUT) BNH1814 1
27 BNH2225 1 60 SPLITLOCKWASHERB/O1/2ʺBNH0653 1
28 BNH0201 161 SPLITLOCKWASHERB/O3/8ʺBNH0658 2
29 BNH1717 6 62 STRAPBRACKET20#SF20STAINLESSSTEEL BNH0562 1
30 BNH0233 10 63 SUPERLUBETEFLONLUBRICANT82340 BNH0704 2
31 BNH0239 20 64 U‐STYLETAPPEDHOLENUT1/4‐20 BNH0708 10
32 BNH2132 1 65 U‐SHAPEWASHER3/8IDX11/2ODX3/16THICK BNH2245 2
33 BNH0890 10 66 SNAPLINKZ/P8MMX80MM BNH0065 1
DECAL‐IMPORTANTFORBESTPERFORMANCE...(REV0)
CG-5519
Parts List
10LBSTEELWEIGHTPLATEBLACK
10LBTOPPLATEW/ADJ.SLTRBAR14WTS(EA)
ABDOMINALCRUNCHHARNESS
BLACKNYLONPULLEY3/8X1X31/2
DECALCALGYM3/CDOMED15/16X125/8
DECALWARRANTYFULLCOMMERCIAL6X1.6
DECALCALGYM2/CONCHROME111/16X71/2
DECALWEIGHTNUMBERS11/16Ø1‐20CALGYM
DECAL‐CAUTIONWEIGHTTRAININGSAFETY...(REV1)
DECAL‐EXERCISEABCRUNCH
DECAL‐IMPORTANTADJUSTCABLEHERE
DECAL‐MAINTENANANCE
DECAL‐WEIGHTSHIELDNUMBERS9X26(150LB)
FINISHEDHEXNUTB/O1/2‐13
FLATWASHER3/8IDX11/2ODX3/16THICK
FLATWASHERSAEB/O1/4ʺ
FLATWASHERSAEB/O3/8ʺ
FRONTPLASTICWEIGHTSHIELD
HEXHEADCAPSCREWGR‐5B/O1/4‐20X3/4
COLOR CHART
GRAY= SUB-ASSEMBLY PARTS
BLACK= HARDWARE

2
16
2
16
56
62
2
58
42
44
16
66
56
62
2
58
42
44
16
66
2
59
28
60
11
2
59
28
60
11
NOTES: 1. SOME PARTS CUT OUT/NOT SHOWN FOR CLARITY
FIG. B FIG. A
3CG-5519 CalGym - Ab Crunch #150
Part Two: Maintenance
In this paragraph, we will discuss the inspection of the cables, pulleys and their associated components. If there ex-
ists the potential for injury to occur on a machine, it will most likely lie in the cable system. It is important to inspect
the cables frequently and let it be known to all users that it is their responsibility to report any worn-out cable to pre-
vent a sudden failure that can result in an injury. Cables are moving parts, meaning cable-wear will occur regardless
of the type or size used. In the advent of the 3/16” mill-spec cable this wear takes longer to become apparent and
this is why frequent inspections are so important.
1. Check the cable termination at the weight stack. To perform any cable tension adjustment, loosen the hex
jam nut and thread the hex tap bolt in or out to give cable the proper tension. Re-tightened the hex jam
nut when adjustment is complete and make sure the hex tap bolt is threaded 1/2” into the socket of the
selector bar top plate.
2. Check the cable as it terminates at the cam. Check the end fitting for any signs of fraying in this area.
Inspect the bolt and nut and/or screw holding the fitting and be sure that it is tight.
3. Check the cables as it passes over all pulley wheels. Visually inspect the cables and pulleys. Acable that
is wearing will exhibit a ballooned surface that passes over the pulley. This is and early warning sign to
replace the cable.
Part Three: Lubrication
Bearing and linear bearings systems have advanced over the years but they must be maintained on a regular basis
if you expect them to last and perform efficiently. TuffStuff uses only the highest quality bearings and linear motion
components that are virtually trouble-free but requires the regular preventive maintenance to insure long-lasting
performance.
1. Bronze and nylon bushings, we recommend on a monthly basis to spray a teflon-base lubricant (silicone-
free) directly onto the shaft as it passes through these bushings. Spray a small amount onto the shaft and
rotate it through its complete movement and wipe off any excess.
2. Weight stack guide rods and bushings, again use teflon spray lubricant and this time spray onto a rag and
wipe the guide rods down with this rag on a weekly basis. Do not use WD-40 or other lubricants as they
attract dirt and will crate a mess between the weight plates and bushings.
3. Sealed bearings pivot points, as the name implies are protected from the outside environment and require
no lubrication. During the machine wipe down, wipe the external bearing surfaces with the damp rag and
dried to prevent the build up of dust and sweat.
4. Linear bearing systems are precision, high load components that require regular maintenance. Dirt and
corrosion are the major culprits in linear bearing failure. The hardened shafts must be wiped down weekly
and lubricated with a light layer of teflon grease. We recommend a teflon-base (silicone-free) gel/grease
for this purpose. Lack of care and maintenance will result in corrosion of the linear shaft causing the bear-
ings to clogged and jammed.
If you religiously perform the maintenance procedures, you will increase the life of the machine and ultimately lower
your maintenance costs with fewer replaced components and downtime.
Any doubts, equipment with mechanical problems should be placed “Out-of-Service” until all problems are corrected.
If replacement parts are required or maintenance questions, please contact TuffStuff Service Department:
Phone: [phone] Fax: [phone] e-mail: [e-mail]
CG-5519 Cable Mapping Diagram
6CG-5519 CalGym - Ab Crunch #150

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15 33
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30 61 29 46
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446 29 61
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4CG-5519 CalGym - Ab Crunch #150
CG-5519 Exploded View Diagram
5CG-5519 CalGym - Ab Crunch #150