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"

igh/Low Pulley System 2

IG. 3 Place the Bottom Assembly Holder (#24) under the Smith-

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

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

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

(#113) into the tube-ends of Adjustable Foot Support (#25). The

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

the Bottom Assembly Holder (#24).

Caution: It is strongly recommended to use another perso

in assisting with the following assembly.

Assembly steps only for THL-78WS

113

118

112

Smith-Half Cage’s

Bottom Cross Brace

123

Assembly Instruction

IG. 1 The High/Low Pulley System is an option for the Smith-Half

Cage Series.

icture Ashows the Smith-Half Cage with out the High/Low Pulley.

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

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

elector Bar (#137), as shown above.

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).

ssembly steps only for THL-78WS Assembly steps only for THL-78WS

ssembly steps only for THL-78WS Assembly steps only for THL-78

High/Low Pulley Syste

123

137

133 133

137

LABEL

FIG. 6 Attach the Decal Weight Numbers (#133) to the Weight Plat

(#50, #49, #51) in the corresponding order. Begin with the 15 at the to

20 next, and so on.

IG. 5 Carefully begin sliding the Weight Plates (#50, #49, #51) onto

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

e 5 Lb. Weight Plates (#51) at the top.

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).

IG. 9 Slide another set of Flat Washers 3/4 X 2 (#69) onto the

uide Rods (#23) to come to rest on top of the Spacer Tubes (#31).

ext, slide the Rubber Donuts (#123) onto the Guide Rods (#23) to

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.

ssembly steps only for THL-78 Assembly step only for THL-78

igh/Low Pulley System 4

123

23 23

LABEL

109

123

Smith-Half Cage’s

Top Cross Brace

Assembly Instruction

FIG. 10 Using a rubber mallet, insert two Plastic Insert Caps 1 7/

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

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

op Cross Brace, as-well-as to the Center Upright (#19). Secure

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

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

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

Washers SAE 3/8” (#71), and one Nylon Insert Jam Lock Nut 3/8-1

(#100).

High/Low Pulley Syste

110

66 70

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,

aneuver the two Guide Rods (#23) into the bottom holes of the

op Guide Rod Retainer (#22). Next, mount the Top Guide Rod

etainer (#22) along with the two captive Guide Rods (#23) to the

op Assembly (#20) and secure them into place using one Hex Head

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

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

ssembly (#20) using one Flat Washer SAE 1/2” (#70), and one

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

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

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

4 1/2” Rd. (#105-Labeled D).

IG. 17 Begin the routing of the Lat Cable (#28). Route the end of

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

eLat Cable (#28) down through the slot on the bottom side of the

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.

igh/Low Pulley System 6

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

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

pright’s (#19) pulley bracket, then insert one Nylon Pulley 4 1/2”

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.

ssembly steps only for THL-78WS Assembly steps only for THL-78

High/Low Pulley Syste

130

132

130

137

132

130

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/

(#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

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

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.

igh/Low Pulley System 8

94 127

127 29

111

127

111

108

32 72

72 73

TMP-75

Multi-Angular Benc

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).

ext, insert the Foot Roll Tube (#33) into the receptacle of the Leg Hold-

own Tube (#32), then insert two Foam Foot Rolls 7 X 4 X 1 (#72) over the

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

e Low Row Bar (#94) to the Low Row Cable (#29) using the Coil

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

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

and afﬁx it to the Lat Cable (#28), in the position as shown abov

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

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

illustration of this assembly.

High/Low Pulley Syste

130

132

137

126

127

FIG. A

FIG. B

FIG. C

102 136

71 99

111 91

111

94 127 57 127 29

111

THL-78WS CABLE MAPPING DIAGRAM

Note:

Some parts have

been cut away for clarity.

130

132

126

127

FIG. A

FIG. B

FIG. C

102 136

71 99

111 91

111

94 127 57 127 29

111

THL-78 CABLE MAPPING DIAGRAM

igh/Low Pulley System 10

Note:

Some parts have

been cut away for clarity.

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