Tuff stuff Apollo Series User manual

ASSEMBLY INSTRUCTIONS
America’s Premier Exercise Equipment
Ab/Back Station Rev0
Apollo Modular Gym System
Ab/Back Station
Standard
Deluxe
Revision Date 08-23-05

About the Ab/Back Station
Congratulations on your new purchase of theAb/Back 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 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 Ab/Back 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.Windex or household glass cleaner
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 - 185 lbs.
Ab/Back Station
Step 1 Side Frame Assembly
Assembly List
Item # Description Qty. Item # Description Qty.
3ADJUSTABLE PULLEY BRACKET 1 38 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 2
16 SIDE FRAME 1 40 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 2
22 PULLEY 3/8” X 4 1/2” 2 45 NYLON INSERT JAM LOCK NUT B/O 3/8-16 2
33 FINISHED HEX NUT B/O 1/2-13 2 46 NYLON INSERT LOCK NUT B/O 3/8-16 2
36 FLAT WASHER SAE B/O 3/8” 8 65 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 (#22) to the Weight Stack Frame using hardware shown.
CAffix the Side Frame (#16) to the Weight Stack Frame using hardware shown.

33
45
46
65
65
33
36 22
36
38
45
36 3
22
36
38
13
36 40
36
40
16
46
36
A
Weight Stack
Frame
Weight Stack
Frame
2
Ab/Back Station
Note: Some parts have
been cut away for clarity.
B
C

Step 2 Main Frame Assembly
AAttach three Pulleys 3/8 X 4 1/2 (#22) to the Side Frame (#16) using hardware shown..
BUsing a rubber mallet, insert the Plastic End Cap W/Groove 2” Sq. (#48) onto the tube-end of the Main Frame (#10).
CAttach the Side Frame (#16) to the Main Frame (#10) using hardware shown.
Assembly List
Item # Description Qty. Item # Description Qty.
10 MAIN FRAME 1 38 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 3
12 PLATE 1/4 X 2 X 5 1 45 NYLON INSERT JAM LOCK NUT B/O 3/8-16 3
13 PLATE 1/4 X 2 X 6 1 40 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 4
14 PULLEY COVER 1 46 NYLON INSERT LOCK NUT B/O 3/8-16 4
48 PLASTIC END CAP W/GROOVE 2” SQ 1 36 FLAT WASHER SAE B/O 3/8” 14
22 PULLEY 3/8” X 4 1/2” 3
3Ab/Back Station

36
14
22
22
22
36
45 46 36 46
36
48
12
36
36
13
10
46 36
46
36
16
36
38
38
40
36
40
45
4
Ab/Back Station
Note: Some parts have
been cut away for clarity.
A
C
B

Step 3 Pivot Arm and Foot Piece Assembly
AInsert a Nylon Washer 1 X 1 1/4 X 1/16 (#44) onto the axle of the Circular Plate (#4) then insert the Pivot Arm (#11) onto
the axle of the Circular Plate (#4). Next, insert the Circular Plate W/Axle (#4) to the bearing housing of the Side Frame
(#16) then secure the Circular Plate (#4) to the Actuator Arm (#1) using the Roll Pin 3/8 X 1 1/2 (#56). Be sure the Roll
Pin (#56) is aligned with the holes of the Circular Plate (#4) and the Actuator Arm (#1) before hammering it into place.
In addition, make sure the Roll Pin (#56), after hammered in, becomes flush on both sides of the Actuator Arm (#1).
BAttach the Foot Roll Tube 1 X 19 7/8 (#8) to the Adjustable Foot Piece (#2). Next, attach the Foam Rolls 1 X 5 1/2 X
7 1/4 (#5) to the Foot Roll Tube (#8) and secure them into place using hardware shown.
Insert the Assembled Adjustable Foot Piece (#2) into the receptacle of the Main Frame (#10).
5Ab/Back Station
Assembly List
Item # Description Qty. Item # Description Qty.
1ACTUATOR ARM 1 28 BUTTON HEAD SOCKET CAP SCREW B/O 3/8-16 X 1 2
2ADJUSTABLE FOOT PIECE 1 30 CHROME WASHER 3/8 X 1 1/2 2
4CIRCULAR PLATE W/AXLE 1 44 NYLON FLAT WASHER 1 X 1 1/4 X 1/16 1
5FOAM ROLL 1 X 5 1/2 X 7 1/4 2 56 ROLL PIN Z/P 3/8 X 1 1/2 1
8FOOT ROLL TUBE 1 X 19 7/8 1 62 SOCKET SET SCREW ALLOY 3/8-16 X 1/2 1
11 PIVOT ARM 1 64 SPLIT LOCK WASHER B/O 3/8” 2

28
64
30
5
2
62
8
66
5
30
64
28
16
4
44
1156 1
10
6
Ab/Back Station
Note: Some parts have
been cut away for clarity.
B
A

Step 4 Swivel Foam Roll Tube and Seat Pad Assembly
AAttach the Swivel Foam Roll Tube (#17) to the Pivot Arm (#11) and secure it into place using hardware shown. Next,
insert the Aluminum Collar 2.031 ID (#19) and the Foam Roll 2 X 5 1/2 X 18 (#6) to the Swivel Foam Roll Tube (#17)
and secure them into place using hardware shown.
BAttach the Seat Pad (#15) to the Main Frame (#13) using hardware shown.
7Ab/Back Station
Assembly List
Item # Description Qty. Item # Description Qty.
6FOAM ROLL 2 X 5 1/2 X 18 1 30 CHROME WASHER 3/8 X 1 1/2 1
15 SEAT PAD 1 36 FLAT WASHER SAE B/O 3/8” 2
17 SWIVEL FOAM ROLL TUBE 22 1/4 1 39 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 2
19 ALUMINUM COLLAR 2.031 ID X 2.584 OD 1 60 SOCKET SET SCREW ALLOY 10-32 X 1/4 2
23 ALUMINUM WASHER 3/8 X 2.584 OD X .15 THK. 1 64 SPLIT LOCK WASHER B/O 3/8” 2
28 BUTTON HEAD SOCKET CAP SCREW B/O 3/8-16 X 1 2

64
23
28
6
19
60
60
15
30 64 28
39
36
13
36
11
39
8
Ab/Back Station
Note: Some parts have
been cut away for clarity.
A
B
17

Step 5 Cable Routing
A. Secure the looped end of the Ab/Back Cable (#9) to the bracket of the Actuator Arm (#1) using one Shoulder Bolt 3/8 X
3/4 (#58) and one Nylon Insert Lock Nut 5/16-18 (#47). See FIG. A.
B. Next, route the Ab/Back Cable (#9) passing between the Pulleys 3/8 X 4 1/2 (#22-Labeled F1 & F2 ), then route under
the Pulley 3/8 X 4 1/2 (#22-Labeled F3 ).
C. Route the Cable (#9) under the Weight Stack and the Pulley 3/8 X 4 1/2 (#22-Labeled F4 ).
D. Next, route the Cable (#9) up and over the Pulley 3/8 X 4 1/2 (#22-Labeled F5 ).
E. Affix the Cable (#9) to the Weight Stack using one Split Hex Tap Bolt 1/2-13 X 3 1/2 (#9), one Finished Hex Nut 1/2-13
(#33), and one Split Lock Washer 1/2” (#65). See FIG. B.
Assembly List
Item # Description Qty. Item # Description Qty.
9AB/BACK CABLE 1 58 SHOULDER BOLT ALLOY 3/8 X 3/4 1
33 FINISHED HEX NUT B/O 1/2-13 1 63 SPLIT HEX TAP BOLT GR-5 B/O 1/2-13 X 3 1/2 1
47 NYLON INSERT LOCK NUT B/O 5/16-18 1 65 SPLIT LOCK WASHER Z/P 1/2” 1
9Ab/Back Station