Tuff stuff THL-78WS User manual

ASSEMBLY INSTRUCTIONS
TABLE OF CONTENTS:
Introduction
Pg. 1
Safety Precautions
Pg. 1
Assembly Instructions
Pg. 2 - Pg. 8
Cable Mapping Diagrams
Pg. 9 / Pg. 10
Parts Lists
Pg. 11 / Pg. 13
Exploded View Diagrams
Pg. 12 / Pg. 14
Warranty
Back Page
High/Low Pulley System
(Smith-Half Cage Option)
Includes Assembly for:
THL-78WS
High/Low Pulley w/200 Lbs. Weight Stack
THL-78
High/Low Pulley (Free Weight)
America’s Premium Exercise Equipment
Revision Date 03-27-03THL-78 Pictured above attach to the Smith-Half Cage
76"
68 3/4"
L 76" W 68 3/4" H 83 1/2"

H
igh/Low Pulley System 2
IG. 3 Place the Bottom Assembly Holder (#24) under the Smith-
H
alf Cage’s Bottom Cross Brace. Next, locate the Center Upright
#
19) and place it on top of the Smith-Half Cage’s Bottom Cross
B
race, as shown above, then secure this assembly group into place
sing two Hex Head Cap Screws 3/8-16 X 3 1/4 (#86), four Flat Washers
S
AE 3/8” (#71), and two Nylon Insert Lock Nuts 3/8-16 (#99).
FIG. 2 Using a rubber mallet, insert two Plastic insert Caps 2” R
d
(#113) into the tube-ends of Adjustable Foot Support (#25). The
n
insert two Plastic Insert Caps 2 X 3 (#112) into the tube-ends of th
Bottom Assembly Holder (#24).
Next, insert the Adjustable Foot Support (#25) into the receptacle
o
the Bottom Assembly Holder (#24).
Caution: It is strongly recommended to use another perso
n
in assisting with the following assembly.
Assembly steps only for THL-78WS
A
B
25
113
113
118
112
24
112
19
25
24
Smith-Half Cage’s
Bottom Cross Brace
19
24
25
23
123
123
23
24
23
23
24
Assembly Instruction
IG. 1 The High/Low Pulley System is an option for the Smith-Half
Cage Series.
P
icture Ashows the Smith-Half Cage with out the High/Low Pulley.
P
icture Bshows the same unit with the THL-78 attached to it.
If assembling a THL-78 (Free Weight) skip to Fig. 8
FIG. 4 Insert the two Guide Rods (#23) into the receptacles of th
Bottom Assembly Holder (#24). Next, slide the Rubber Donuts (#12
3
onto the Guide Rods (#23).
Note: Lubricate the Guide Rods (#23) with silicone spray or
teflon spray lubricant at this time.

IG. 7 Locate the Selector Pin w/Coil (#34) and slide its ring over the
S
elector Bar (#137), as shown above.
T
o carry on with the Assembly of the THL-78WS skip to Fig. 11
FIG. 8 Insert the two Guide Rods (#23) into the receptacles of th
Bottom Assembly Holder (#24), then slide one Flat Washer 3/4 X
(#69) onto each Guide Rod (#23).
Next, slide the Spacer Tubes (#31) onto the Guide Rods (#23).
A
ssembly steps only for THL-78WS Assembly steps only for THL-78WS
A
ssembly steps only for THL-78WS Assembly steps only for THL-78
High/Low Pulley Syste
m
3
23
51
49
50
123
23
137
51
51
49
50
133 133
137
34
137
34
69
23
24
23
69
69
23
69
31
23
LABEL
FIG. 6 Attach the Decal Weight Numbers (#133) to the Weight Plat
e
(#50, #49, #51) in the corresponding order. Begin with the 15 at the to
p
20 next, and so on.
IG. 5 Carefully begin sliding the Weight Plates (#50, #49, #51) onto
h
eGuide Rods (#23). Begin with the five 15 Lb. Weight Plates (#50)
t the bottom, the nine 10 Lb. Weight Plates (#49) in the middle, and the
v
e 5 Lb. Weight Plates (#51) at the top.
N
ext, slide the Top Plate/Selector Bar (#137) onto the Guide Rods (#23)
llowing it to come to rest on the completed Weight Stack.
Note: Be sure the Label on the Top Plate/Selector Bar (#137)
is facing out, as shown above, before sliding the Top Plate/
Selector Bar (#137) onto the Guide Rods (#23).
31

IG. 9 Slide another set of Flat Washers 3/4 X 2 (#69) onto the
G
uide Rods (#23) to come to rest on top of the Spacer Tubes (#31).
N
ext, slide the Rubber Donuts (#123) onto the Guide Rods (#23) to
o
me to rest on top of the Flat Washers 3/4 X 2 (#69).
Note: Lubricate the Guide Rods (#23) with silicone spray or
teflon spray lubricant at this time.
A
ssembly steps only for THL-78 Assembly step only for THL-78
H
igh/Low Pulley System 4
23
69
31
23
69
31
23
123
31
23
123
69
31
69
23 23
LABEL
30
109
109
123
123
19
20
Smith-Half Cage’s
Top Cross Brace
20
A
21
Assembly Instruction
FIG. 10 Using a rubber mallet, insert two Plastic Insert Caps 1 7/
8
Rd. (#109) into the tube-ends of the Carriage (#30). Next, slide th
Carriage (#30) onto the Guide Rods (#23) allowing it to come to re
s
on top of the Rubber Donuts (#123).
Note: Be sure the Label on the Carriage (#30) is facing out,
as shown above, before sliding the Carriage (#30) onto the
Guide Rods (#23).
IG. 11 Mount the Top Assembly (#20) to the Smith-Half Cage’s
T
op Cross Brace, as-well-as to the Center Upright (#19). Secure
h
eTop Assembly (#20) to the Smith-Half Cage’s Top Cross Brace
sing two Hex Head Cap Screws 3/8-16 X 4 (#87), four Flat Washers
S
AE 3/8” (#71), and two Nylon Insert Lock Nuts 3/8-16 (#99).
Caution: Do not secure the Top Assembly (#20) to the
Center Upright (#19) at this time.
FIG. 12 Insert a Nylon Pulley 4 1/2 Rd. (#105-Labeled A) into th
pulley bracket located on the Top Assembly (#20) and secure it int
place using one Hex Head Cap Screw 3/8-16 X 2 1/2 (#83), two Fl
a
Washers SAE 3/8” (#71), and one Nylon Insert Jam Lock Nut 3/8-1
(#100). Next, attach the Lat Bar Holder (#21) to the Top Assembl
(#20) using one Hex Head Cap Screw 3/8-16 X 2 3/4 (#84), two Fl
a
Washers SAE 3/8” (#71), and one Nylon Insert Jam Lock Nut 3/8-1
(#100).

High/Low Pulley Syste
m
5
20
22
110
23
23
110
27
66 70
D
D
20
27
F
26
C
IG. 13 Using a rubber mallet, insert two Plastic Insert Caps 1 X 2
#
110) into the tube-end of the Top Guide Rod Retainer (#22). Next,
m
aneuver the two Guide Rods (#23) into the bottom holes of the
T
op Guide Rod Retainer (#22). Next, mount the Top Guide Rod
R
etainer (#22) along with the two captive Guide Rods (#23) to the
T
op Assembly (#20) and secure them into place using one Hex Head
C
ap Screw 3/8-16 X 2 3/4 (#84), two Flat Washers SAE 3/8” (#71), and
ne Nylon Insert Lock Nut 3/8-16 (#100).
FIG. 14 Assemble one Nylon Pulley 4 1/2 RD. (#105-Labeled
D
to the Top Cable Adjuster Bracket (#27) using one Hex Head Ca
Screw 3/8-16 X 1 3/4 (#82), two Flat Washers SAE 3/8” (#71), and on
Nylon Insert Jam Lock Nut 3/8-16 (#100). Next, thread one Finishe
Hex Nut 1/2-13 (#66) and insert one Flat Washer SAE 1/2 (#70) to th
threaded bolt of the Top Cable Adjuster Bracket (#27).
FIG. 16 Assemble the two Adjustable Pulley Plates (#26) usin
two Nylon Pulleys 4 1/2” Rd. (#105-Labeled F, C), two Hex Head Ca
Screws 3/8-16 X 1 3/4 (#82), four Flat Washers SAE 3/8” (#71), an
two Nylon Insert Jam Lock Nuts 3/8-16 (#100).
Note: The four holes of the Adjustable Pulley Plates (#8)
are used to adjust the Cable tension once the cable routing
has been completed.
IG. 15 Attach the Top Cable Adjuster Bracket (#27) to the Top
A
ssembly (#20) using one Flat Washer SAE 1/2” (#70), and one
N
ylon Insert Lock Nut 1/2-13 (#101).
Loosely Fasten: Do not completely fasten this hardware
assembly at this time, as it will be completely fastened once
the cable routing has been completed to give the cable
proper tension.