Tuff stuff TS-1000 User manual

TS-1000
Home Gym w/Adjustable
High-Low Pulley System
L108” W 48” H 83”
OWNER’S MANUAL
TABLE OF CONTENTS:
Introduction - Pg. 1
Safety Precautions - Pg. 2
Assembly for TS-1000 - Pg. 3 - Pg. 23
Cable Adjustments - Pg. 22
Cable Mapping Diagrams
Pg. 24 - Pg. 29
Parts List - Pg. 31
Exploded View Diagram
Fold-Out Pg. 32
Adjustment Features - Pg. 33 - Pg. 34
Maintenance - Pg. 35
Warranty - Back Page
Revision Date 10-16-01
America’s Premium Exercise Equipment
108”
48”

A
bout the Home Gym (TS-1000)
C
ongratulations on your new purchase of the Home Gym (TS-
000). This gym is capable of a variety of different exercises, as
w
ell as, smooth and user-friendly adjustment features. In addition,
h
is gym has been designed to meet the needs and performance
e
quirements for a suitable home exercise machine. We hope you
a
re completely satisfied with this product and wish you many years
o
f enjoyment.
T
uff Stuff Equipment
T
his Tuffstuff product has been built to precise quality standards
a
nd has been carefully packaged to ensure that damage will not
o
ccur during shipment. The Home Lifetime Warranty and signature
n
dicating final inspection has been conducted by our line foreman,
s
an expression of our confidence in the completeness, the
m
aterials, and workmanship of this product.
W
arranty
S
EE A COPY OF WARRANTY ON BACK PAGE.
R
egistration Card
T
o avoid unnecessary delays in warranty service and to insure that
a
permanent record of your purchase is on file with our factory, be
ure to complete the warranty registration card and send it to Task
n
dustries today.
Assembly Notes
1. Read and follow each step of this Assembly Instruction Manual
i
sequence. Do not skip ahead, as it will result in an improp
e
assembly or in having to disassemble parts later.
2. During the assembly of this unit you will be instructed to lea
v
some Hex Head Cap Screws loosely fastened. Naturally, th
e
will be fully fastened later in the assembly process. This is do
n
to prevent any difficulty with alignment of some parts during th
i
assembly.
Hardware Measurement Diagram
1
About the Icons
The icons displayed in this Owner’s Manual are used to facilitat
e
the correct assembly and safe use of this Product, as-well-as t
o
prevent injury to yourself or anyone else.
I
n
t
ro
d
uc
ti
on
Note: Due to continuing product improvements, specifications and designs are subject to chan
g
without notice.
Even though we have prepared this manual with extreme care, neither the publisher nor the auth
o
can accept responsibility for any errors in, or omission from, the information given.
P
rior to the Assembly of the TS-1000
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 Home Gym.
2
.Consider the complete surface area of the TS-1000. Use the
overhead view on the front page for designing your layout before
assembling. Once the TS-1000 has been fully assembled it will
be heavy and difficult to move, therefore you should assemble
the TS-1000 in the area where it is to be used upon completion.
3
.It is recommended that another person assist you with the
assembly this unit.
4
.Neatly organize and identify all parts according to the Parts List
on page 31 and the Exploded View Diagram on fold-out page 32.
Tool Requirements
1. One 9/16” combination wrench
2. One 3/4” combination wrench
3. One 7/8” combination wrench
4. One 1/2” combination wrench
5. Two 7/16” combination wrenches
6. One ratchet
7. One 9/16” socket
8. One 3/4” socket
9. One rubber mallet
1
0. External retaining-ring pliers
1
1. Windex or household glass cleaner
1
2. One can silicone spray/ teflon spray lubricant
1
3. Multi-purpose grease
1
4. Measuring tape
1
5. Utility knife
S
pecifications
.Maximum Wt. Capacity - 200 Lbs. Fixed
.Total Machine Weight - 475 Lbs.
.Footprint (LWH) - See Front Cover
Note provides information necessary to properl
y
complete a procedure or information which wil
make the procedure easier to understand.
Caution indicates a potentially hazardous situa
-
tion, which, if not avoided, may result in minor o
r
moderate injury. It may also be used to aler
t
against unsafe practices.
Fully Fasten provides a instruction to fully fasten
(ex: completely tighten) a hardware assembly.
TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
m
FULLY FASTE
N
CAUTION
LOOSELY FASTEN
NOTE:
Loosely Fasten provides a instruction to loosel
y
fasten (ex: hand tighten) a hardware assembl
y
only. This instruction is intended for the alignmen
t
of hardware components during the assembl
y
process.

Fig. 2 Caution: Check that the two Push Pull Pins 1/2 X 3-1/2 (#5
6
located on the Press Bar Selector Housing (#23), and the High-Lo
w
Carriage (#14), also the Push Pull Pins 1/2 X 5-5/8 (#58) located on t
h
and the Front Upright (#6) are fully engaged into the selected holes of t
h
Press Bar (#23),High-Low Selectorized Upright (#13), and the Ba
c
Pad Bracket (#7).
S
afety First
R
egardless of how enthusiastic you may be about getting on
y
our equipment and exercising, take the time to ensure that
y
our safety is not jeopardized. A moment’s lack of attention
c
an result in an accident, as can failure to observe certain
s
imple safety precautions.
1
.Read, study and understand the Owner’s Manual and all
the warning labels on this product. Furthermore, it is
recommended to familiarize yourself and others with the
proper operation and workout recommendations for this
Tuff Stuff product prior to use. Some of this information
can be obtained in this Owner’s Manual, as-well-as from
your local Tuff Stuff retailer.
2
.It is imperative that you retain this Owner’s Manual and be
sure all warning labels are legible and intact.
Replacement Owner’s Manuals and labels are available
from your local Tuff Stuff retailer.
3
.Consult with your physician before beginning any exercise
program.
4
.Use proper discretion when children are present.
5. Frayed or worn cables can be dangerous and may caus
e
injury. Periodically check these cables for any indicatio
n
of wear.
6. Keep hands, limbs, loose clothing and long hair well out o
f
the way of moving parts.
7. Do not attempt to lift more weight than you can contr
o
safely.
8. Inspect the Unit for any sign of wear on parts, hardwar
e
becoming loose or cracks on welds. If a problem is foun
d
do not use or allow the machine to be used until th
e
defective part is repaired or replaced.
9. Pay special attention to the Push Pull Pins 1/2 X 3-1/
2
(#56) located on the Press Bar Selector Housing (#23)
and the High-Low Carriage (#14), the Push Pull Pins 1/
2
X5-5/8 (#58) located on the and the Front Upright (#6)
also the Turn/Pull Pin w/Knob (#57) located on the Le
g
Extension Bench Frame (#9).See Fig.1.Be sure the
y
are fully engaged into the selected holes. Refer to Fig. 2
3for further illustration of this instruction.
Safety Precautions
ig. 1 Illustration above depicts the location of the Push Pull Pins 1/2” X
-
1/2 (#56), Push Pull Pins 1/2” X 5-5/8 (#58),and the Turn/Pull Pin w/
K
nob (#57) on this unit.
T
urn/Pull Pin
w
/Knob (#57)
Push Pull Pin
1/2 X 5-5/8 (#58)
Turn/Pull Pin w/Knob
Fully Engaged
Fig. 3 Caution: Check the Turn/Pull Pin w/Knob (#57) to be ful
l
engaged into the selected hole of the Adjustable Seat Frame (#37).
Push Pull Pin
1/2 X 3-1/2
Fully Engaged
P
ush Pull Pin
1
/2 X 3-1/2 (#56)
Push Pull Pin
1/2 X 3-1/2 (#56)
T
S-1000 Home Gym w/Adjustable High-Low Pulley System 2
CAUTION
CAUTION

IG. 4 On a flat surface, lay the Base Frame (#1) down and insert two
P
lastic End Caps w/Groove 2” Sq. (#70) onto the tube-ends of the Base
rame (#1), as shown above.
Note: When positioning the Base Frame (#1) consider the
complete area surface of the TS-1000.Use the overhead view on
the cover page for designing your layout before assembling.
FIG. 5 Next, using a rubber mallet, insert four Plastic Insert Caps
1
Rd. (#75) into the four tube-ends of the Low Row Stabilizer (#2) and th
Foot Roll Tube 1 x 16 (#4).
IG. 6 Next, attach the Low Row Foot Support (#3) to the Low Row
S
tabilizer (#2) and secure it into place using one Foot Roll Tube 1 x 16
#
4). Using the supplied Hex Key 3/16” (#114), secure the Foot Roll
ube (#4) into place using one Set Screw 3/8-16 x 1/2 (#51), as shown in
a
ption above.
Note: Be sure the Foot Roll Tube (#4) is flush on each end after
inserted into the Low Row Foot Support (#3).
FIG. 7 Insert the Low Row Stabilizer (#4) into the receptacle on th
Base Frame (#1), as shown above.
3TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
m
NOTE:
NOTE:

IG. 8 Locate the Rear Upright (#5), and using a rubber mallet insert
w
o Plastic End Caps w/Groove 2 x 3 (#69) onto the tube-ends of stabi-
z
er tube. Next insert a Plastic Insert Cap 2” Sq. (#71), and a Plastic In-
e
rt Cap 2 x 3 (#78) into the tube-ends, as shown above.
FIG. 9 Next, attach the Rear Upright (#5) to the Base Frame (#1) a
n
secure it into place using two Hex Head Cap Screws 3/8-16 x 4 (#98), fo
u
Flat Washers SAE 3/8” (#87), and two Nylon Insert Lock Nuts /38-1
(#92).
Loosely Fasten: Do not completely fasten this hardware asse
m
bly at this time, as it will be completely fastened later in the a
s
sembly process.
IG. 10 Caution: It is recommended to use another person in as-
sisting with this assembly.
A
ttach the Front Upright (#6) to the Base Frame (#1) and secure it into
lace using one Hex Head Cap Screw 3/8-16 x 2 3/4 (#100), two Flat
W
ashers SAE 3/8” (#87), and one Nylon Insert Jam Lock Nut 3/8-16
#
93).
Loosely Fasten: Do not completely fasten this hardware assem-
bly at this time, as it will be completely fastened later in the as-
sembly process.
Note:The black boxed letters pointing to the pulleys are used
throughout this manual as reference to the Cable Mapping
Diagram on pages 21-29.These black boxed letters will be
primarily used for locating certain pulleys during the cable routing
process beginning with Fig. 11.
FIG. 11 Affix a Nylon Pulley 4 1/2 Rd. (#67- Labeled A4) to the pulle
plate located on the Front Upright (#6) and secure it into place using on
Cable Retainer Bracket L-Shaped (#8), one Hex Head Cap Screw 3/
8
16 X 1 3/4 (#102), two Flat Washers SAE 3/8” (#87), and one Nylon Inse
Jam Lock Nut 3/8-16 (#93). Note: Be sure to position the Cable Retain
e
Bracket L-Shaped (#8) as shown above.
Next, attach two Nylon Pulleys 4 1/2 Rd. (#67-Labeled A6, B
3
into the pulley brackets located on the Front Upright (#6) and secu
r
them into place using two Hex Head Cap Screws 3/8-16 X 1 3/4 (#102
four Flat Washers SAE 3/8” (#87), and two Nylon Insert Jam Lock Nu
t
3/8-16 (#93). Next, insert a Nylon Pulley 4 1/2 Rd. (#67-Labeled B1) in
t
the Front Upright (#6) and secure it in place using one Hex Head Ca
Screw 3/8-16 X 2 1/2 (#10), two Flat Washers SAE 3/8” (#87), and on
Nylon Insert Jam Lock Nut 3/8-16 (#93).
T
S-1000 Home Gym w/Adjustable High-Low Pulley System 4
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CAUTION
LOOSELY FASTEN
O
SELY FASTEN
NOTE:

FIG. 13 Locate the Leg Extension Arm (#10), and using a rubber m
a
let, insert one Plastic Insert Cap 1 1/2 Sq. (#72) into the tube-end.
Affix the Leg Extension Arm (#10), in the position as sho
w
above, to the Leg Extension Bench Frame (#9) and secure it into pla
c
by inserting the Leg Extension Axle 1/2 X 2-3/4 (#11) through the Le
Extension Bench Frame (#9) and Leg Extension Arm (#10) until it b
e
comes flush with both sides of the Leg Extension Bench Frame (#9).
Next, secure the Leg Extension Axle 1/2 X 2-3/4 (#11) to th
Leg Extension Bench Frame (#9) using two Set Screws 1/4-20 X 3/
(#52), as shown above. Use the supplied Hex Key 1/8” (#115) f
o
fastening these Set Screws.
IG. 12 Attach the Leg Extension Bench Frame (#9) to the Base
rame (#1) and secure it into place using one Hex Head Cap Screw 3/8-
6
X 4 1/2 (#96), two Flat Washers SAE 3/8” (#87), and one Nylon Insert
a
m Lock Nut 3/8-16 (#93). Next, attach the Leg Extension Bench
rame (#9) to the Front Upright (#6) and secure it into place using one
H
ex Head Cap Screw 3/8-16 X 2 3/4 (#100), two Flat Washers SAE
/
8” (87), and one Nylon Insert Jam Lock Nut 3/8-16 (#93).
Loosely Fasten: Do not completely fasten this hardware
assembly at this time, as it will be completely fastened later in the
assembly process.
N
ext, using a rubber mallet, insert one Plastic Insert Cap 2” Sq. (#71) into
h
e front of the Leg Extension Bench Frame (#9).
IG. 14 Using a rubber mallet, insert a Plastic Insert Cap 2” Sq. (#71)
n
to the tube-end of the High-Low Selectorized Upright (#13). Next, in-
e
rt a Nylon Pulley 4-1/2 Rd. (#67-Labeled C#) into the pulley bracket of
h
eHigh-Low Selectorized Upright (#13) and secure it into place using
ne Hex Head Cap Screw 3/8-16 x 1 3/4 (#102), two Flat Washers SAE
/
8” (#87), and one Nylon Insert Jam Lock Nut 3/8-16 (#93)
FIG. 15 Insert the two Nylon Pulleys 3 1/2 Rd. (#68) into the High-Lo
w
Double Pulley Bracket (#15) and secure them into place using two H
e
Head Cap Screws 3/8-16 x 1 3/4 (#102), four Flat Washers SA
3/8” (#87), and two Nylon Insert Jam Lock Nuts 3/8-16 (#93). Next, a
s
semble two Hex Head Cap Screws 1/4-20 x 1 1/2 (#104), and two Nylo
Insert Lock Nuts 1/4-20 (#95) to the High-Low Double Pulley Brack
e
(#15), in the positions indicated by the black arrows.
5TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
m
O
SELY FASTEN

IG. 16 Slide the High-Low Carriage (#14) onto the High-Low Selec-
o
rized Upright (#13), in the position as shown above. Be sure to release
h
e Push Pull Pin 1/2 x 3 1/2 (#56) to allow the insertion of carriage as-
e
mbly.
FIG. 17 Next, insert the High-Low Sectorized Upright (#13) onto th
tube-connector of the Rear Upright (#5) and secure it into place usin
one Hex Head Cap Screw 3/8-16 x 2 1/2 (#101), two Flat Washers SA
E
3/8” (#87), and one Nylon Insert Jam Lock Nut 3/8-16 (#93).
FIG. 19 Affix the Top Pulley Assembly (#12) to the Front Upright (#
6
using two Hex Head Cap Screws 3/8-16 x 4 1/4 (#97), four Flat Washe
r
SAE 3/8” (#87), and two Nylon Insert Lock Nuts 3/8-16 (#92).
T
S-1000 Home Gym w/Adjustable High-Low Pulley System 6
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IG. 18 Caution: It is recommended to use another person in
assisting with this assembly.
M
ount the Top Pulley Assembly (#12) to the Front Upright (6), and affix
to the Rear Upright (#5) and the High-Low Selectorized Upright (#13)
s
ing two Hex Head Cap Screws 3/8-16 x 4 1/4 (#97), four Flat Washers
S
AE 3/8” (#87), and two Nylon Insert Lock Nuts 3/8-16 (92).
Loosely Fasten: Do not completely fasten this hardware assem-
bly at this time, as it will be completely fastened later in the as-
sembly process.
CAUTION
O
SELY FASTEN

IG. 20 Attach a Nylon Pulley 4 1/2 Rd. (#67-Labeled C4) into the pulley
racket located on the Top Pulley Assembly (#12) and secure it into
lace using one Hex Head Cap Screw 3/8-16 x 2 1/2 (#101), two Flat
W
ashers SAE 3/8” (#67), and one Nylon Insert Jam Lock Nut 3/8-16
#
93). Next, attach a Nylon Pulley 4 1/2 Rd. (#67-Labeled C6) into the
ulley bracket located on the Top Pulley Assembly (#12) and secure it
n
to place using one Hex Head Cap Screw 3/8-16 x 1 3/4 (#102), two Flat
W
ashers SAE 3/8” (#67), and one Nylon Insert Jam Lock Nut 3/8-16
#
93).
FIG. 21 Attach a Nylon Pulley 4 1/2 Rd. (#67-Labeled A1) into the pull
e
bracket located on the Top Pulley Assembly (#12) and secure it in
t
place using one Hex Head Cap Screw 3/8-16 x 2 1/2 (#101), two Fl
a
Washers SAE 3/8” (#67), and one Nylon Insert Jam Lock Nut 3/8-1
(#93). Next, attach the Lat Bar Holder (#26), in the position as sho
w
above, to the Top Pulley Assembly (#12) and secure it into place usin
one Hex Head Cap Screw 3/8-16 x 2 3/4 (#100), two Flat Washers SA
E
3/8” (#67), and one Nylon Insert Jam Lock Nut 3/8-16 (#93).
IG. 22 Attach the Press Bar Selector Housing (#23) to the Top
P
ulley Assembly (#512), as shown above. Using a rubber mallet, insert
Pivot Axle 1 X 8 1/8 (#24) through the holes in the Press Bar Selector
H
ousing (#23) and through the receptacle on the Top Pulley Housing
#
12) until it is flush with both sides of the Press Bar Selector Housing
#
23).
Note:The four Plastic Insert Caps 2” Sq. (#71) located in the tube-
ends of the Press Bar Selector Housing (#23) have been pre-
assembled by the factory.
FIG. 23 Insert two Plastic Insert Caps 2” Sq. (#71) into the tube-end
o
the Press Bar (#25).
Caution: It is recommended to use another person in assisti
n
with this assembly.
Next, insert the Press Bar (#25) up into the Press Bar Selector Housin
g
(#23) and support in into place using the Push Pull Pin (#56). Next, usin
a rubber mallet, insert the Pivot Axle 1 X 8 1/8 (#24) into the Press B
a
Selector Housing (#23) and through the Press Bar (#25) until it is flus
with both sides of the Press Bar Selector Housing (#23).
7TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
m
N
OTE:
CAUTION

IG. 24 Next, secure the Press Bar Selector Housing (#23) to the
P
ivot Axle 1 X 8 1/8 (#24) using two Set Screws 3/8-16 X 1/2 (#51), as
h
own above. Then, secure into place the Press Bar (#25) to the Pivot
A
xle 1 X 8 1/8 (#24) using two Set Screws 3/8-16 X 1/2 (#51). Use the
S
upplied Hex Key 3/16 (#114) for securing the Set Screws 3/8-16 X 1/2
#
51) into the threaded sockets on the Press Bar Selector Housing
#
23).
FIG. 25 Next, attach two Nylon Pulleys 4 1/2 Rd. (#67-Labeled A3, A
5
to the pulley bracket located on the Press Bar Selector Housing (#2
5
and secure them into place using one Hex Head Cap Screw 3/8-16 X
3/4 (#100), two Flat Washers SAE 3/8” (#87), and one Nylon Insert Ja
m
Lock Nut 3/8-16 (#93).
IG. 26 Insert one Rubber Donut 3/4 x 2 1/2 (#64) onto each Guide
R
od 3/4 x 72 (#16). Next, insert the two Guide Rods 3/4 x 72 (#16) into
h
e receptacles on the Base Frame (#1), as shown above.
FIG. 27 Carefully begin sliding the Weight Plates over the Guid
Rods (#16) beginning with the five 15 Lb. Weight Plates (#17) at the b
o
tom, the nine 10 Lb. Weight Plates (#18) in the middle, and the five 5 L
b
Weight Plates (#19) on top of the weight stack.
T
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IG. 28 Slide the Top Plate/Selector Bar (#20) over the Guide Rods
#
16) allowing it to come to rest on the completed weight stack.
Note: Be sure the Label located on the Top Plate/Selector Bar
(#20) is facing toward you before you slide the Top Plate/Selector
Bar (#20) over the Guide Rods 3/4 X 72 (#16).
FIG. 29 Attach the Decal Weight Numbers (#113) to the Weight Plat
e
(#17, #18, #19) in the corresponding order. Begin with the 15 at the to
p
20 next, and so on.
IG. 30 Next, locate the Selector Pin w/Coil (#21) and slide its ring
v
er the Selector Bar (#20) as shown above.
FIG. 31 Maneuver the two Guide Rods 3/4 X 72 (#16) into the hol
e
on the bottom side of the Guide Rod Retainer Housing (#22).Ne
x
mount the Guide Rod Retainer Housing (#22) along with the two capti
v
Guide Rods 3/4 X 72 (#16) to the side of the Top Pulley Assembl
(#12). Secure this assembly using two Hex Head Cap Screws 3/8-16 X
(#112), four Flat Washers SAE 3/8” (#87), and two Nylon Insert Lock Nu
t
3/8-16 (#92).
Loosely Fasten: Do not completely fasten this hardwa
r
assembly at this time, as it will be completely fastened later in t
h
assembly process.
9TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
m
Label
NOTE:
15
20
25
30
35
45
55
65
75
85
95
105
115
125
140
155
170
185
200
LOOSELY FASTEN

IG. 32 First, locate the Adjustable Pulley Bracket (#27) and insert
ne Nylon Pulley 4 1/2 Rd. (#67-Labeled A8). Secure the Nylon Pulley 4
/
2 Rd. (#67-Labeled A8) into place using one Hex Head Cap Screws 3/8-
6
X 1 3/4 (#102), two Flat Washers SAE 3/8” (#87), and one Nylon Insert
a
m Lock Nut 3/8-16 (#93). Next, thread one Regular Hex Nut 1/2-13
#
90), and insert one Split Washer B/O 1/2” (#82) over the bolt on the
A
djustable Pulley Bracket (#27), as shown above. Second, locate the
w
oAdjustable Stoppers (#28, #29) and thread one Regular Hex Nut
/
2-13 (#90), and insert one Split Washer B/O 1/2” (#82) over each bolt,
s
shown above.
IG. 34 Insert the welded bolt of the Adjustable Pulley Bracket (#27)
h
rough the hole located on the Top Pulley Assembly (#12) and secure it
n
to place at the top using one Flat Washer SAE 1/2” (#86), and one Nylon
n
sert Lock Nut 1/2-13 (#91).
Loosely Fasten: Do not completely fasten this hardware assem-
bly at this time, as it will be completely fastened later in the as-
sembly process.
FIG. 35 Insert (from bottom to top) the Long Adjustable Stopp
e
(#28) into the receptacle of the Front Upright (#6) and secure it into pla
c
using one Split Washer B.O. 1/2” (#82), and one Regular Hex Nut 1/2-1
(#90), as shown above. Loosely fasten the Regular Hex Nuts 1/2-1
(#84) to allow adjustment for cables tension later in the assembly proces
s
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FIG. 33 Locate the Closed-End Adj. Double Pulley Bracket (#30), a
n
the Closed-End Double Pulley Bracket (#31). Then, attach four Nylo
Pulleys 4 1/2 Rd. (#67-Labeled D3,B2,D1,A7). Secure them into pla
c
using four Hex Head Cap Screws 3/8-16 X 1 3/4 (#102), eight Fl
a
Washers SAE 3/8” (#87), and four Nylon Insert Jam Lock Nuts 3/8-1
(#93).
Note: The four holes on the Closed-End Adj. Double Pulle
Bracket (#30) are used to adjust the cable tension once the cab
l
routing has been completed.
Next, locate the Floating Double Pulley Bracket (#32),shown above
a
the right, and attach two Nylon Pulleys 4 1/2 Rd. (#67-Labeled C7,C5
)
Secure the pulleys into place using one Hex Head Cap Screw 3/8-16 X
3/4 (#100), two Flat Washers SAE 3/8” (#87) and one Nylon Insert Ja
m
Lock Nut 3/8-16 (#93).
NOTE:
O
SELY FASTEN

IG. 36 Thread the Short Adjustable Stopper (#29) into the threaded
o
cket on the Base Frame (#1), as shown above.
Loosely Fasten: Do not completely fasten this hardware assem-
bly at this time, as it will be completely fastened later in the as-
sembly process.
FIG. 37 Begin routing the Lat Cable (#33) up and over the Nyl
o
Pulley 4 1/2 Rd. (#67-Labeled A1) and into the tube of the Top Pulle
Assembly (#12).Then, pull the Lat Cable (#33) down through the ope
n
ing at the bottom of the Top Pulley Assembly (#12).
Note: Refer to the Cable Mapping Diagram on page 24 for furth
e
detailed illustration of the Lat Cable (#33) routing.
IG. 38 Insert a Nylon Pulley 4 1/2 Rd. (#67-Labeled A1) into the slot
t
the bottom of the Top Pulley assembly (#12) and secure it into place
s
ing one Hex Head Cap Screw 3/8-16 X 2 1/2 (#101), two Flat Washers
S
AE 3/8” (#87), and one Nylon Insert Jam Lock Nut 3/8-16 (#93). Be sure
h
e cable is routed properly into the groove on the Nylon Pulley 4 1/2 Rd.
#
67-Labeled A1).
Note: Refer to the Cable Mapping Diagram on page 24 for further
detailed illustration of the Lat Cable (#33) routing.
FIG. 39 Next, route the Lat Cable (#33) over the Nylon Pulley 4-1/2 R
d
(#67-Labeled A3).
Note: Refer to the Cable Mapping Diagram on page 24 for furth
e
detailed illustration of the Lat Cable (#33) routing.
11 TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
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O
SELY FASTEN
NOTE:
NOTE:
NOTE:

IG. 42 Next, route the Lat Cable (#33) through the Closed-End Adj.
D
ouble Pulley Bracket (#30) and under the Nylon Pulley 4 1/2 Rd. (#67-
a
beled A7), as shown above.
Note: Refer to the Cable Mapping Diagram on page 24 for further
detailed illustration of the Lat Cable (#33) routing.
FIG. 43 Next, route the Lat Cable (#33) through the Adjustable Pull
e
Bracket (#27) and over the Nylon Pulley 4 1/2 Rd. (#67-Labeled A8),
a
shown above.
Note: Refer to the Cable Mapping Diagram on page 24 for furth
e
detailed illustration of the Lat Cable (#33) routing.
IG. 40 Next, route the Lat Cable (#33) up and over the Nylon Pulley
-
1/2 Rd. (#67-Labeled A4).
Note: Refer to the Cable Mapping Diagram on page 24 for further
detailed illustration of the Lat Cable (#33) routing.
FIG. 41 Next, continue to route the Lat Cable (#33) over the Nylo
Pulley 4 1/2 Rd. (#67-Labeled A5), then through the Front Upright (#
6
and over the Nylon Pulley 4 1/2 Rd. (#67-Labeled A6).
Note: Refer to the Cable Mapping Diagram on page 24 for furth
e
detailed illustration of the Lat Cable (#33) routing.
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NOTE:
NOTE:
NOTE: NOTE:

IG. 46 Remove the hardware from one end of the Leg Extension/
A
bdominal Cable (#34). Next, begin routing the Leg Extension/
A
bdominal Cable (#34) through the opening of the Front Upright (#6)
nd over the Nylon Pulley 4 1/2 Rd. (#67-Labeled B1).
Note: Refer to the Cable Mapping Diagram on page 25 for further
detailed illustration of the Leg Extension/Abdominal Cable (#34)
routing.
FIG. 47 Next, route the Leg Extension/Abdominal Cable (#3
4
through the Closed-end Double Pulley Bracket (#31) and under th
Nylon Pulley 4 1/2 Rd. (#67-Labeled B2), as shown above.
Note: Refer to the Cable Mapping Diagram on page 25 for furth
e
detailed illustration of the Leg Extension/Abdominal Cable (#3
4
routing.
IG. 44 Next, attach the Lat Cable (#33) to the Top Plate/ Selector
B
ar (#20) and secure it into place using one Split Bolt 1/2-13 x 1 (#85),
nd one Split Washer Z/P 1/2” (#83). Refer to Fig. B on page 24 for
u
rther illustration of this hardware assembly.
Fully Fasten: Proceed to fully fasten this hardware assembly.
FIG. 45 Before beginning routing the Leg Extension/Abdomin
a
Cable (#34) it is necessary to remove the Adjustabl
Back Pad Bracket (#7) and the Hardware that connec
t
the Leg Extension Bench Frame (#9) to the Front Up Right (#6). Th
i
is done to ensure the Leg Extension/Abdominal Cable (#34) be proper
l
routed. Otherwise the Cable will get tangled between the bolts that hol
these assemblies.
13 TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
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L
LY FASTEN
CAUTION
NOTE:
NOTE:

IG. 50 Route the Leg Extension/Abdominal Cable (#34) up to the
eg Extension Arm (#10). Then, affix a Nylon Ball 1 3/4 x 5/16 (#108),
nd a Strap Bracket #20 (#107) to the cable end. Lock them into place
s
ing a Shoulder Bolt 3/8 x 3/4 (#106), and a Nylon Insert Lock Nut 5/16-
8
(#94).
Next, secure the Leg Extension/Abdominal Cable (#34) to the
eg Extension Arm (#10) using one Hex Head Cap Screw 1/4-20 (#104),
nd one Nylon Insert Lock Nut 1/4-20 (#95). Refer to Fig. C on page 25
o
r further illustration of this hardware assembly.
Note: Refer to the Cable Mapping Diagram on page 25 for further
detailed illustration of the Leg Extension/Abdominal Cable (#34)
routing.
FIG. 51 Press down the Closed-End Double Pulley Bracket (#31) t
apply tension to the Leg Extension/Abdominal Cable (#34). Then, r
e
attach the Leg Extension Bench Frame (#9) to the Front Upright (#
6
using the previously removed Hardware (one Hex Head Cap Screw 3/8-1
x 2 3/4 (#100), two Flat Washers SAE 3/8” (#87), and one Nylon Inse
Jam Lock Nut 3/8-16 (#93).
IG. 48 Continue to route the Leg Extension/Abdominal Cable (#34)
p and over the Nylon Pulley 4 1/2 Rd. (#67-Labeled B3), then down into
h
eFront Upright’s (#6) tube. Next, pull the Leg Extension/Abdominal
C
able (#34) through the opening at the bottom of the Front Upright (#6).
N
ote: Refer to the Cable Mapping Diagram on page 25 for further detailed
l
ustration of the Leg Extension/Abdominal Cable (#34)routing.
FIG. 49 Insert two Nylon Pulleys 4 1/2 Rd. (#67-Labeled B4), one to th
bottom pulley bracket of the Front Upright (#6) and the other to the pull
e
bracket of the Leg Extension Arm (#10). Secure them into place usin
two Hex Head Cap Screws 3/8-16 x 1 3/4 (#102), four Flat Washers SA
E
3/8” (#87), and two Nylon Insert Jam Lock Nuts 3/8-16 (#93).
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IG. 54 Route the High-Low Cable (#35) up and over the Nylon Pulley
1/2 Rd. (#67-Labeled C3)
Note: Refer to the Cable Mapping Diagram on page 26 for further
detailed illustration of the High-Low Cable (#35) routing.
FIG. 55 Route the High-Low Cable (#35) down to the Nylon Pulley
4
1/2 Rd. (#67-Labeled C4) passing through the opening of the Top Pulle
y
Assembly (#12).
Note: Refer to the Cable Mapping Diagram on page 26 for furth
e
detailed illustration of the High-Low Cable (#35) routing.
IG. 52 Press down the Closed-End Double Pulley Bracket (#31) to
pply tension to the Leg Extension/Abdominal Cable (#34). Then, re-
t
tach the Adjustable Back Pad Bracket (#7) to the Front Upright (#6)
s
ing the previously removed Hardware (one Hex Head Cap Screw 3/8-16
3 1/4 (#99), two Flat Washers SAE 3/8” (#87), two Nylon Flat Washer
/
8” (#88), and one Nylon Insert Jam Lock Nut 3/8-16 (#93).
FIG. 53 Route the High-Low Cable (#35) between the two Nylon Pu
leys 3 1/2 Rd. (#68-Labeled C1, C2), then up between the Nylon Pulley
1/2 Rd. (#68-Labeled C2) and the Hex Head Cap Screw 1/4-20 x 1 1
/
(#104). Continue routing the cable up through the tube of the High-Lo
w
Double Pulley Bracket (#15).
Note: Refer to the Cable Mapping Diagram on page 26 for furth
e
detailed illustration of the High-Low Cable (#35) routing.
15 TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
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NOTE:
NOTE:
NOTE:

IG. 58 Next, route the High-Low Cable (#35) down into the tube of
h
eRear Upright (#5). Next, insert a Nylon Pulley 4 1/2 Rd. (#67-Labeled
C
8) into the slot of the Rear Upright (#5) and secure it into place using
ne Hex Head Cap Screw 3/8-16 X 2 1/2 (#101), two Flat Washers SAE
/
8” (#87), and one Nylon Insert Jam Lock Nut 3/8-16 (#93). Be sure the
a
ble is routed properly into the groove on the Nylon Pulley 4 1/2 Rd.
#
67-Labeled C8).
Note: Refer to the Cable Mapping Diagram on page 26 for further
detailed illustration of the High-Low Cable (#35) routing.
FIG. 59 Continue routing the High-Low Cable (#35) down into the tu
b
of the Rear Upright (#5). Next, pull the Cable end through the opening
a
the bottom of the Rear Upright (#5). Then, route the cable around
Nylon Pulley 4 1/2 Rd. (#67-Labeled C9), as shown above. Secure th
Nylon Pulley 4 1/2 Rd. (#67-Labeled C9) to the Rear Upright (#5) usin
one Hex Head Cap Screw 3/8-16 X 2 1/2 (#101), two Flat Washers SA
E
3/8” (#87), and one Nylon Insert Jam Lock Nut 3/8-16 (#93). Be sure th
cable is routed properly into the groove on the Nylon Pulley 4 1/2 R
d
(#67-Labeled C9).
Note: Refer to the Cable Mapping Diagram on page 26 for furth
e
detailed illustration of the High-Low Cable (#35) routing.
IG. 56 Next, locate the Floating Double Pulley Bracket (#32) and
o
ntinue to route the High-Low Cable (#35) down and under the Nylon
P
ulley 4 1/2 Rd. (#67-Labeled C5). Then, up and over the Nylon Pulley 4
/
2” Rd. (#67-Labeled C6).
Note: Refer to the Cable Mapping Diagram on page 26 for further
detailed illustration of the High-Low Cable (#35) routing.
FIG. 57 Next, route the High-Low Cable (#35) down and under the N
y
lon Pulley 4 1/2 Rd. (#67-Labeled C7).
Note: Refer to the Cable Mapping Diagram on page 26 for furth
e
detailed illustration of the High-Low Cable (#35) routing.
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OTE:
NOTE:
NOTE:
NOTE:

IG. 62 Route the Tension Cable (#36) up to the Closed-End Adj.
D
ouble Pulley Bracket (#30) and over the Nylon Pulley 4 1/2 Rd (#67-
a
beled D1), as shown above.
Note: Refer to the Cable Mapping Diagram on page 27 for further
detailed illustration of the Tension Cable (#36) routing.
FIG. 63 Continue routing the Tension Cable (#36) down and under th
Nylon Pulley 4 1/2 Rd (#67-Labeled D2). Then, up and over the Nyl
o
Pulley 4 1/2 Rd (#67-Labeled D3).
Note: Refer to the Cable Mapping Diagram on page 27 for furth
e
detailed illustration of the Tension Cable (#36) routing.
IG. 60 Next, route the High-Low Cable (#35) up to the High-Low Car-
age (#14) and insert the cable to the welded bracket on the side of the
H
igh-Low Carriage (#14), as shown in caption above. Lock the High-
ow Cable (#35) into place using one Shoulder Bolt 3/8 x 3/4 (#106), and
ne Nylon Insert Lock Nut 5/16-18 (#94).
Note: Refer to the Cable Mapping Diagram on page 26 for further
detailed illustration of the High-Low Cable (#35) routing.
FIG. 61 Affix the looped end of the Tension Cable (#36) to the pull
e
bracket located on the Base Frame (#1) using one Hex Head Cap Scre
w
3/8-16 x 1 3/4 (#102), two Flat Washers SAE 3/8” (#87), two Nylon spa
c
ers 3/8 x 3/8 (#109), and one Nylon Insert Jam Lock Nut 3/8-16 (#93).
Note: Refer to Fig F on page 27 for further illustration of this a
s
sembly.
17 TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
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NOTE:
NOTE: NOTE:

IG. 66 Next, using a rubber mallet, insert a Plastic Insert Cap 1 X 2
#
73) into the tube-end of the Adjustable Seat Frame (#37).Next, locate
h
eSeat Pad (#40) and attach it to the Adjustable Seat Frame (#37), as
h
own above, using two Hex Head Cap Screws 3/8-16 X 1 3/4 (#102),
nd two Flat Washers SAE 3/8” (#87).
FIG. 66 Insert the assembled Adjustable Seat Frame (#37) into th
Leg Extension Bench Frame (#9), in the position as shown above. B
sure to release the Turn/Pull Pin w/Knob (#557) as you begin inserting th
assembled Adjustable Seat Frame (#37) into the Leg Extension Benc
Frame (#9).
IG. 64 Route the Tension Cable (#36) into the tube of Base Frame
#
1) then pull it out through the opening at the top of the Base Frame
#
1). Next, insert two Nylon Pulleys 4 1/2 Rd (#67-Labeled D4, D5) to the
ulley brackets located on the Base Frame (#1) and secure them into
lace using two Hex Head Cap Screws 3/8-16 x 1 3/4 (#102), four Flat
W
ashers SAE 3/8” (#87), and two Nylon Insert Jam Lock Nuts 3/8-16
#
93). Be sure the cable is routed properly into the grooves of the Nylon
P
ulleys 4 1/2 Rd. (#67-Labeled D4, D5), as shown above.
Note: Refer to the Cable Mapping Diagram on page 27 for further
detailed illustration of the Tension Cable (#36) routing.
FIG. 65 Conclude the routing of the Tension Cable (#36) by Threa
d
ing a Regular Hex Nut 1/2-13 (#90) and inserting a Split Washer B/
O
1/2” (#82) to the Hex Tap Bolt 1/2-13 x 3 (#84). Then, thread the Hex T
a
Bolt 1/2-13 x 3 (#84) to the threaded socket located on the Floating Do
u
ble Pulley Bracket (#32).
Loosely Fasten: Do not completely fasten this hardware asse
m
bly at this time, as it will be completely fastened later in the a
s
sembly process.
Note: Refer to the Cable Mapping Diagram on page 27 for furth
e
detailed illustration of the Tension Cable (#36) routing.
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LOOSELY FASTEN

IG. 70 Use a measuring tape to center the Foot Roll Tube 1 x 27
#
38) with the Adjustable Back Pad Bracket’s (#7) receptacle. The
m
easurement from one end of the tube to the receptacle, as pictured
bove, should be about 12 1/8”. Secure the Foot Roll Tube 1 X 27 (#38)
o
the Adjustable Back Pad Bracket (#7) using a Set Screw 1/4-20 X 1/4
#
53), as shown above. Use the supplied Hex Key 1/8” (#115) to properly
e
cure the Set Screw 1/4-20 X 1/4 (#53) into place.
FIG. 71 Next, attach one Foam Foot Roll 7 X 4 X 1 (#62) to each en
of the three tubes as shown above. Refer to the Exploded View Diagra
m
on fold out page for further clarification of this assembly.
IG. 68 Next, insert a Foot Roll Tube 1 X 16 (#4) into the receptacle
f
the Adjustable Seat Frame (#37).Then, insert another Foot Roll
ube 1 X 16 (#34) into the receptacle of the Leg Extension Arm (#10).
N
ext, insert the Foot Roll Tube 1 X 27 (#38) into the receptacle of the
A
djustable Back Pad Bracket (#7), as shown above.
FIG. 69 Use a measuring tape to center the Foot Roll tube 1 x 16 (#
4
with the Adjustable Seat Frame’s (#37) receptacle. The measureme
n
from one end of the tube to the receptacle, as picture above, should
b
about 7”. Secure the Foot Roll Tube 1 X 16 (#4) to the Adjustable Se
a
Frame (#37) using a Set Screw 1/4-20 X 1/4 (#53), as shown above. Us
the supplied Hex Key 1/8” (#115) to properly secure the Set Screw 1/4-2
X 1/4 (#53) into place.
19 TS-1000 Home Gym w/Adjustable High-Low Pulley Syste
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