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.

FIG. 18 Insert a Nylon Pulley 4 1/2 Rd. (#105-Labeled B) 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).
Note: Be sure the Lat Cable (#28) is routed properly into the
pulley’s groove.
FIG. 20 Next, locate the assembled Adjustable Pulley Plates (#2
6
and continue to route the Lat Cable (#28) down and under the Nylo
Pulley 4 1/2” Rd. (#105-Labeled C), then up and over the Nylon Pull
e
4 1/2” Rd. (#105-Labeled D).
IG. 17 Begin the routing of the Lat Cable (#28). Route the end of
h
eLat Cable (#28) up and over the Nylon Pulley 4 1/2” Rd. (#105-
abeled A), then through the Top Assembly’s (#20) tube. Next, pull
h
eLat Cable (#28) down through the slot on the bottom side of the
T
op Assembly (#20).
Caution: Do not pull the Lat Cable (#28) all the way through
the Top Assembly (#20) until you have installed the Nylon
Pulley 4 1/2” Rd. (#105-Labeled B), as this will prevent any
damage to the cable.
H
igh/Low Pulley System 6
A
20
28
28
B
20
19
20
28
B
B
28
27
D
C
F
26
Assembly Instruction
IG. 19 Secure the Top Assembly (#20) to the Center Upright
#
19) using one Hex Head Cap Screw 3/8-16 X 2 3/4 (#84), two Flat
W
ashers SAE 3/8” (#71), and one Nylon Insert Jam Lock Nut 3/8-16
#
100).
Caution: To prevent damage to the Lat Cable (#28), it is
important to make sure that the cable is routed over the
top and not under the Hex Head Cap Screw 3/8-16 X 2 3/4
(#84).

IG. 23 Route the Low Row Cable (#29) through the Center
U
pright’s (#19) pulley bracket, then insert one Nylon Pulley 4 1/2”
R
d. (#105-Labeled E) into the Center Upright’s (#19) pulley bracket
nd secure it into place using one Hex Head Cap Screw 3/8-16 X 1
/
4 (#82), two Flat Washers SAE 3/8” (#71), and one Nylon Insert Jam
ock Nut 3/8-16 (#100).
FIG. 22 Attach the Lat Cable (#28) to the Carriage (#30) using on
Split Bolt 1/2-13 X 1 (#130), and one Split Lock Washer 1/2” (#132
)
Refer to Fig. B on page 10 for further illustration of this assembly.
Fully Fasten: Proceed to fully fasten this assembly.
IG. 21 Attach the Lat Cable (#28) to the Top Plate/Selector Bar
#
137) using one Split Bolt 1/2-13 X 1 (#130), and one Split Lock Washer
/
2” (#132). Refer to Fig. B on page 9 for further illustration of this
ssembly.
Fully Fasten: Proceed to fully fasten this assembly.
A
ssembly steps only for THL-78WS Assembly steps only for THL-78
High/Low Pulley Syste
m
7
28
130
132
28
130
137
137
30
132
130
28
30
130
28
E
19
29
F
19
E
29
26
E
29
19
FIG. 24 Continue to route the Low Row Cable (#29) up and over th
Nylon Pulley 4 1/2” (#105-Labeled F). Next, secure the Low Row Cabl
(#29) to the Center Upright (#19), in the position as shown above, usin
one Hex Head Cap Screw 3/8-16 X 3 (#85), two Flat Washers SAE 3/
8
(#71), and one Nylon Insert Lock Nut 3/8-16 (#99)
Note: Refer to Fig. C on page 9 for further illustration of this
assembly.

FIG. 28 Using a rubber mallet, insert two Foot Roll Plastic End Ca
p
1” (#73) into the tube-ends of the Foot Roll Tube (#33).
Next, insert the Leg Hold Down Assembly into the receptacle of th
*TMP-75 (Multi-Angular Bench). Use the L-Locking Pin (#93) to Adju
s
the Leg Hold Down Assembly to the desire height.
*TMP-75 (Multi-Angular Bench) is part of your package only if you
purchased a Smith-Half Cage Ensemble System. If not, the TMP-75
can be purchased separately as an option.
H
igh/Low Pulley System 8
94 127
57
127 29
111
111
111
21
91
28
127
111
108
32 72
72
33
32
73
72
32
72 73
32
93
TMP-75
Multi-Angular Benc
h
Assembly Instruction
IG. 27 Using a rubber mallet, insert one Plastic Insert Cap 1 3/4” Sq.
#
108) into the tube-end of the Leg Hold-Down Tube (#32).
N
ext, insert the Foot Roll Tube (#33) into the receptacle of the Leg Hold-
D
own Tube (#32), then insert two Foam Foot Rolls 7 X 4 X 1 (#72) over the
u
be-ends of the Foot Roll Tube (#33), as shown above.
Note: Use Windex or household glass cleaner for easy insertion of
the Foam Foot Rolls 7 X 4 X 1 (#72).
IG. 25 Using a rubber mallet, insert two Plastic Insert Caps 1” Rd.
#
111) into the tube-ends of the Low Row Bar 20” (#94). Next, attach
h
e Low Row Bar (#94) to the Low Row Cable (#29) using the Coil
C
hain 3/16” X 21 (#57) and two Snap Links (#127), as shown above.
FIG. 26 Using a rubber mallet, insert two Plastic Insert Caps
1
Rd. (#111) into the tube-ends of the Lat Bar Chrome 48” (#91). Nex
mount the Lat Bar Chrome 48” (#91) onto the Lat Bar Holder (#2
1
and affix it to the Lat Cable (#28), in the position as shown abov
e
using one Snap Link (#127), one Shoulder Bolt 3/8 X 3/4 (#126), an
one Nylon Insert Lock Nut 5/16-18 (#102). Use the supplied Hex K
e
3/16” (#88) and a 1/2” combination wrench to fasten this assembl
properly.
Note: Refer to Fig. A on page 9 or page 10 for furth
e
illustration of this assembly.

High/Low Pulley Syste
m
9
28
130
132
137
126
91
127
FIG. A
FIG. B
29
85
FIG. C
102 136
95
28
71
19
71 99
111 91
111
B
D
C
A
111
94 127 57 127 29
111
E
F
THL-78WS CABLE MAPPING DIAGRAM
Note:
Some parts have
been cut away for clarity.

28
130
132
30
126
91
127
FIG. A
FIG. B
29
85
FIG. C
102 136
95
28
71
19
71 99
111 91
111
B
D
C
A
111
94 127 57 127 29
111
E
F
THL-78 CABLE MAPPING DIAGRAM
H
igh/Low Pulley System 10
Note:
Some parts have
been cut away for clarity.