Tuff stuff Apollo Standard User manual

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

A bout the Single Column Station
Congratulations on your new purchase of the Single Column
Station. We hope you are completely satisfied with this product and
wish you many years of enjoyment.
T uff Stuff Equipment
Every 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.
W arranty
SEE A COPY OF WARRANTY ON BACK PAGE
R egistration 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 Single Column 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 Exploded
View Diagram on Fold-out Pg. 7 and the Parts List on Pg. 8.
Tool Requirements
1. One 7/8” combination wrench
2. One 9/16” combination wrench
3. One 1/2” combination wrench
4. One ratchet
5. One 9/16” socket
6. One rubber mallet
7. Multi-purpose grease
8. Measuring tape
9. Utility knife
Introduction
Specifications
1. Maximum Wt. Capacity - 200 Lbs.
2. Total Machine Weight - 70 Lbs.
Hardware Measurement Diagram
Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.
FIG. 1 Using a rubber mallet, insert four Plastic Insert Caps 1 Rd.
(#138) into the tube-ends of the Low Row Stabilizer (#63) and the In-
sert Tube (#17).
17
138
138
138
63
138
FIG. 2 Connect the Low Row Foot Support (#64) to the Low Row
Stabilizer (#63) using the Insert Tube 1 X 16 (#17). Next, secure the
Insert Tube (#17) to the Low Row Stabilizer (#63) using one Set
Screw 3/8-16 X 1/2 (#170), as shown in caption above.
63
17
64
63
64 170
1 Single Column Station

FIG. 3 Next, insert the assembled Low Row Stabilizer (#63) into
the receptacle of the Bottom Upright Connector (#69).
146
69
63
FIG. 4 Locate the Adjustable Pulley Bracket (#45) and attach one
Pulley 3 1/2 Rd. (#128-Labeled E6) using one Hex Head Cap Screw
3/8-16 X 1 3/4 (#101), two Flat Washers SAE 3/8” (#94), and one Nylon
Insert Jam Lock Nut 3/8-16 (#123). Next, thread one Finished Hex Nut
1/2-13 (#89) and insert one Split Lock Washer 1/2” (#176) onto the
Screw of the Adjustable Pulley Bracket (#45).
89
176
45
E6
FIG. 5 Next, attach the assembled Adjustable Pulley Bracket
(#45) to the receptacle of the Weight Stack Frame (#1) using one Split
Lock Washer 1/2” (#176) and one Finished Hex Nut 1/2-13 (#89).
89
176
45
1
FIG. 6 Using a utility knife, remove the two Plastic Ties (#195) from
the Guide Rod Retainer (#3), as shown in caption above.
Next, affix the Top Upright Connector (#59) to the Guide Rod Re-
tainer (#3) and the Weight Stack Frame (#1) using two Hex Head Cap
Screws 3/8-16 X 3 1/4 (#105), four Flat Washers SAE 3/8” (#94) and
two Nylon Insert Lock Nuts 3/8-16 (#125).
1
59
3
195
3
2Single Column Station
Assembly Instructions

FIG. 8 Attach the Single Column Upright (#61) to the Bottom Up-
right Connector (#69) using two Hex Head Cap Screws 3/8-16 X 3/4
(#97), two Split Lock Washers 3/8” (#174), and two Flat Washers SAE
3/8” (#94). Next, affix the Single Column Upright (#61) to the Top Up-
right Connector (#59) using one Hex Head Cap Screw 3/8-16 X 1 (#98),
one Split Lock Washer 3/8” (#174), and one Flat Washer SAE 3/8” (#94).
Next, using a rubber mallet, insert one Plastic Insert Cap 2” Sq. (#142)
into the tube-end of the Single Column Upright (#61).
69
61
142
59
61
FIG. 7 Attach two Pulleys 4 1/2 Rd (#78-Labeled E4, E8) and two
Cable Retainer Brackets (#26) to the Top Upright Connector (#59)
using one Hex Head Cap Screw 3/8-16 X 4 3/4 (#110), two Flat
Washers SAE 3/8” (#94), and one Nylon Insert Jam Lock Nut 3/8-16
(#123).
Note: Be sure the Cable Retainer Brackets (#26) are posi-
tioned as shown above.
59
26 26
E8
E4
FIG. 9 Next, locate the assembled Single Column Carriage (#67)
and attach four Pulleys 3 1/2” Rd. (#128) to the Double Pulley Brack-
ets (#65, #66) using four Hex Head Cap Screws 3/8-16 X 1 3/4 (#101),
eight Flat Washers SAE 3/8” (#94), and four Nylon Insert Jam Lock
Nuts 3/8-16 (#123).
65
66
128
128
128
128
67
FIG. 10 Insert the assembled Single Column Carriage (#67) onto
the Single Column Upright (#61).
61
67
146
3 Single Column Station

FIG. 12 Route the Single Column Cable (#62) between the Pulleys
3 1/2 Rd. (#128-Labeled E1, E2), and then route up through the tube of
the Double Pulley Bracket (#66).
Note: Refer to the Cable Mapping Diagram on fold-out page 6
for further detailed illustration of the Single Column Cable (#62)
routing.
62
66
E2
E1
FIG. 11 Attach two Pulleys 4 1/2 Rd (#78-Labeled E3, E9) and two Ca-
ble Retainer Brackets (#26) to the Single Column Upright (#61) using
two Hex Head Cap Screws 3/8-16 X 3 1/2 (#106), four Flat Washers SAE
3/8” (#94), and two Nylon Insert Jam Lock Nuts 3/8-16 (#123).
Note: Be sure the Cable Retainer Brackets (#26) are positioned
as shown above.
61
26
61
26
E9
E3
FIG. 13 Route the Cable (#62) up and over the Pulley 4 1/2” Rd.
(#78-Labeled E3), then route to the Pulley 4 1/2” Rd. (#78-Labeled E4).
Continue routing down and under the Pulley 4 1/2” Rd. (#78-Labeled
E5).
Note: Refer to the Cable Mapping Diagram on fold-out page 6
for further detailed illustration of the Single Column Cable (#62)
routing.
E5
E3
E4
62
FIG. 14 Route the Cable (#62) up and over the Pulley 3 1/2” Rd.
(#128-Labeled E6), then route down and under the Pulley 4 1/2” Rd.
(#78-Labeled E7). Continue routing up and over the Pulley 4 1/2” Rd.
(#78-Labeled E8).
Note: Refer to the Cable Mapping Diagram on fold-out page 6
for further detailed illustration of the Single Column Cable (#62)
routing.
62
E6
E7
E8
4Single Column Station
Assembly Instructions

FIG. 16 Attach Snap Links (#167) to both ends of the Cable (#62)
using two Shoulder Bolts 3/8 X 3/4 (#166), and Nylon Insert Lock Nuts
5/16-18 (#126).
167
167
178
178
FIG. 15 Continue routing the Cable (#62) down and under the Pulley
4 1/2” Rd. (#78-Labeled E9), then up and over the Pulley 3 1/2” Rd.
(#128-Labeled E10). Next, attach one Nylon Ball 1 3/4 X 1/4 (#118),
and one Strap Bracket (#178) to the end of the cable.
Note: Refer to the Cable Mapping Diagram on fold-out page 6
for further detailed illustration of the Single Column Cable (#62)
routing.
E9
178
118
62
E10
FIG. 17 Attach the Single Column Handles (#68) to the Top Up-
right Connector (#59) using two Hex Head Cap Screws 3/8-16 X 3
(#113), four Flat Washers SAE 3/8” (#94), and two Nylon Insert Lock
Nuts 3/8-16 (#125).
68
59
5 Single Column Station

Single Column Station 8
ITEM NO. DESCRIPTION PART NO. QTY. ITEM NO. DESCRIPTION PART NO. QTY.
17 INSERT TUBE 1 X 16 UP0053 1 118 NYLON BALL 1 3/4 X 1/4 BNH0047 2
26 CABLE RETAINER BRACKET(L-SHAPED) UP0014 6 121 NYLON D HANDLE (# H834A) BNH1215 2
45 ADJUSTABLE PULLEY BRACKET UP0127 1 123 NYLON INSERT JAM LOCK NUT 3/8-16 BNH0365 10
59 TOP UPRIGHT CONNECTOR UP2003 1 125 NYLON INSERT LOCK NUT 3/8-16 BNH0214 6
60 TOP PLATE DOUBLE PULLEY BRACKET UP1746 1 126 NYLON INSERT LOCK NUT B/O 5/16-18 BNH0215 2
61 SINGLE COLUMN UPRIGHT UP2013 1 128 ALUMINUM PULLEY PULLEY 3/8 X 3 1/2 BNH1266 5
62 SINGLE COLUMN CABLE UP2023 1 129 NYLON SPACER 3/8 X 3/4 X 3/8 BNH0392 2
63 LOW ROW STABILIZER UP0669 1 130 NYLON STEM BUTTON 12.5 mm X 26 mm x 9.5 mm BNH0547 8
64 LOW ROW FOOT SUPPORT UP0670 1 138 PLASTIC INSERT CAP 1" RD. 10-12 GA. BNH0002 4
65 HIGH/LOW DOUBLE PULLEY BKT (SOLID SHANK) UP1022 1 139 WASHER 3/8 X 1 1/2 CHROME BNH1015 1
66 HIGH/LOW DOUBLE PULLEY BKT (HOLLOW SHANK) UP1023 1 142 PLASTIC INSERT CAP 2" SQ. 10-14 GA. BNH0012 1
67 SINGLE COLUMN CARRIAGE UP0999 1 143 PLASTIC TUBE END 1 X 1 1/4 X 3/8 BNH1089 1
68 SINGLE COLUMN HANDLES UP2005 1 146 PULL PIN 1/2 X 2 7/8 (YELLOW KNOB) BNH0641 2
69 BOTTOM UPRIGHT CONNECTOR UP2004 1 150 RETAINING SNAP RING EXT. PLAIN .925 X 1 X .042 BNH0419 1
76 ALUMINUM CAP 1" RD. (CAP-100) BNH0537 2 154 RUBBER CORR MAT 1/8" X 1 1/2 X 5 BNH1226 1
78 ALUMINUM PULLEY 3/8" X 4 1/2" BNH0069 6 156 RUBBER GRIP 1 ID X .125 X 8 BNH09662
81 BRONZE BUSHING 1 X 1 1/4 X 3/4 X 1 1/2 X 1/8 BNH0527 4 160 RUBBER GRIP 1/2 X 4 BNH0530 1
83 BUTTON HEAD SOCKET CAP SCREW B/O 3/8-16 X 1 BNH0115 1 163 SAFETY TAPE ANTI-SLIP 4" X 7 3/4 BNH1227 4
86 COIL CHAIN Z/P 3/16 X 21 BNH1262 1 166 SHOULDER BOLT ALLOY 3/8 X 3/4 BNH0718 2
89 FINISHED HEX NUT B/O 1/2-13 BNH0201 3 167 SNAP LINK Z/P 8MM X 80MM BNH00653
94 FLAT WASHER SAE 3/8" BNH0239 35 169 SOCKET SET SCREW ALLOY 10-32 X 1/8 BNH0473 4
97 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3/4 BNH0283 2 170 SOCKET SET SCREW ALLOY 3/8-16 X 1/2 BNH04741
98 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 BNH0275 1 174 SPLIT LOCK WASHER 3/8" BNH0658 4
101 HEX HEAD CAP SCREW 3/8-16 X 1 3/4 BNH0274 5 176 SPLIT LOCK WASHER Z/P 1/2" BNH0572 3
105 HEX HEAD CAP SCREW 3/8-16 X 3 1/4 BNH0312 5 178 STRAP BRACKET 20 #SF20 STAINLESS STEEL BNH0652 2
106 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/2 BNH0280 2 184 DECAL-DANGER TIGHTEN THIS RET..., 3/4 X 1-1/2 BNH0142 2
107 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 3/4 BNH0281 1 186 DECAL-ADJUST CABLE HERE BNH0789 1
108 URETHANE BUMPER 962 BNH0244 2 191 DECAL-WARNING KEEP HANDS AND FINGERS... BNH0620 1
110 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 4 3/4 BNH0318 1 195 PLASTIC TIES 14 1/2" BNH0703 2
113 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 BNH0282 2 196 DECAL-EXERCISE SINGLE COLUMN STATION BNH1676 1
116 LEATHER ANKLE STRAP BNH1231 1
ITEM NO. DESCRIPTION PART NO. QTY. ITEM NO. DESCRIPTION PART NO. QTY.
78 NYLON PULLEY 3/8 X 4 1/2 BNH0506 6 128 NYLON PULLEY 3/8 X 3 1/2 BNH0553 5
Single Column Station (Deluxe)
All parts same as Single Column Station (Deluxe), except for the parts listed below
Parts List
Single Column Station (Standard)
Parts List
CHART
BOLD FONT = SUB-ASSEMBLY PARTS
REGULAR FONT = HARDWARE

DO NOT DISCARD THIS MANUAL
TUFFSTUFF 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:
FULL COMMERCIAL WARRANTY (more than 5 hours of use per day): 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.
LIGHT COMMERCIAL WARRANTY (less than 5 hours of use per day): a) Frames, welds, cams and weight
plates -- Lifetime, b) Pivot bearings, pulleys, bushings, gas shocks and guide rods -- Five (5) years, c) Linear
bearings, finish and pull-pin components -- One (1) year, and d) Upholstery, cables and rubber grips -- Three
(3) 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 re-
placing warranted defective parts, as TuffStuff may elect, at TuffStuff’s facility in Pomona, California, without
charge to purchaser for either parts or labor. Purchaser 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