TuffStuff ACS-100 Assembly Manual
ASSEMBLY MANUAL
TABLE OF CONTENTS:
Introduction
Pg. 1
Assembly
Pg. 2 - Pg. 36
Leg Ext / Ab Cable Routing
Pg. 19 - Pg. 22
Crossover Cables Routing
Pg. 23 - Pg. 26
Tension Cable Routing
Pg. 27 - Pg. 28
Cable Adjustment
Pg. 29 - Pg. 30
Parts List
Pg. 39
Exploded View Diagram
Pg. 40
Basic Exercise Guide
Pg. 42 - Pg. 43
Maintenance
Pg. 44 - Pg. 45
Warranty
Back Page
ACS-100
Free Movement Adjustable
Cable System
Revision Date 05-26-04
68 3/4"
51"
America’s Premier Exercise Equipment
© 2003 TASK INDUSTRIES, INC.
L 68 3/4" W 51" H 84 1/2"
ACS-100 Rev0
About the Free Movement Adjustable Cable System
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Congratulations on your new purchase of the ACS-100. We hope
you are completely satisfi ed with this product and wish you many
years of enjoyment.
Prior to the Assembly of the ACS-100
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.
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 Home Lifetime Warranty and
signature indicating fi nal inspection has been conducted by our line
foreman, is an expression of our confi dence 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 fi le with our factory, be
sure to complete the warranty registration card and send it to Task
Industries today.
Specifi cations
1. Maximum Wt. Capacity - 200 lbs.
2. Total Machine Weight - 450.
3. Footprint (LWH) - See Front Cover.
Note: Due to continuing product improvements, specifi cations and designs are subject to change
without notice.
2. Neatly organize and identify all parts according to the Parts List
and the Exploded View Diagram.
Tool Requirements
1. One 3/4” combination wrench
2. Two 9/16” ratchet box wrenches
3. One ratchet
4. One 3/4” socket
5. One 9/16” socket
6. One 7/16” socket
7. One adjustable wrench
8. One rubber mallet
9. Windex or household glass cleaner
10. Measuring tape
11. Utility knife
Hardware Measurement Diagram
Safety Precautions
Safety First
Regardless of how enthusiastic you may be about getting on
your equipment and exercising, take the time to ensure that your
safety is not jeopardized. A moment’s lack of attention can result
in an accident, as can failure to observe certain simple safety
precautions.
1. Read, study and understand the Assembly 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 Assembly
Manual, as-well-as from your local Tuff Stuff retailer.
2. It is imperative that you retain this Assembly Manual and be
sure all warning labels are legible and intact. Replacement
Assembly Manual and labels are available from your local Tuff
Stuff retailer.
1
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 cause injury.
Periodically check the cable for any indication of wear.
6. Keep hands, limbs, loose clothing and long hair well out of the
way of moving parts.
7. Do not attempt to lift more weight than you can control safely.
8. Inspect the Unit for any sign of wear on parts, hardware
becoming loose or cracks on welds. If a problem is found do
not use or allow the machine to be used until the defective
part is repaired or replaced.
ACS-100 Free Movement Adjustable Cable System
Assembly Manual
Step 1 Base Frame Assembly
A. Using a rubber mallet, insert one Plastic End Cap 2 X 3 (#73) onto the tube-end of the Base Frame (#1).
B. Assemble two Hex Head Cap Screws 3/8-16 X 2 3/4 (#54) to the Base Frame (#1) using four Flat Washers SAE
3/8” (#44), and two Nylon Insert Jam Lock Nuts 3/8-16 (#69).
Note: Use the overhead view on the cover page for designing your layout before assembling.
Assembly List
Item # Description Qty.
1 BASE FRAME 1
44 FLAT WASHER SAE B/O 3/8” 4
54 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 3/4 2
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 2
73 PLASTIC END CAP W/GROOVE 3 X 2 1
73
69 44
44
44
5444
1
ACS-100 Free Movement Adjustable Cable System
2
Step 2 Assembling Rear Frame and Bottom Support Pulley Brkt to Base Frame
A. Using a rubber mallet, insert two Plastic End Caps 2 X 3 (#73) onto the tube-ends of the Rear Frame (#5).
B. Assemble Rear Frame (#5) and Bottom Support Pulley Brkt (#18) to Base Frame (#1) using two Hex Head
Cap Screws 3/8-16 X 3 1/4 (#56), four Flat Washers SAE 3/8” (#44), and two Nylon Insert Lock Nuts 3/8-16
(#66).
C. Assemble fi ve Nylon Pulleys 3 1/2 Rd. (#71) to the pulley brackets of the Rear Frame (#5) using hardware
shown.
Assembly List
Item # Description Qty.
5 REAR FRAME 1
18 BOTTOM SUPPORT PULLEY BRKT 1
44 FLAT WASHER SAE B/O 3/8” 14
50 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 5
56 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 2
66 NYLON INSERT LOCK NUT B/O 3/8-16 2
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 5
71 NYLON PULLEY 3 1/2 RD, WHITE 5
73 PLASTIC END CAP W/GROOVE 3 X 2 GREY 2
76 PLASTIC INSERT CAP 2” SQ 1
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ACS-100 Free Movement Adjustable Cable System
Assembly Manual
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73
44
50
44
71
44
69
50
44
71
44
69
5
69
44
44
69
71
66
44
44
50
18
76
66
44
71
44
50
1
ACS-100 Free Movement Adjustable Cable System
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44
50
69
44
71
44
73
4
Step 3 Assembly of the Adjustable Stoppers and the Floating Pulley Brackets
A. Install the two Adjustable Stoppers (#21) to the Rear Frame (#5) using hardware shown.
B. Assemble the two Closed End Adjustable Pulley Brkts (#24) and the Floating Pulley Bracket (#22) using
hardware shown
Assembly List
Item # Description Qty.
21 ADJUSTABLE STOPPER 2
22 FLOATING PULLEY BRACKET 1
24 CLOSED END ADJUSTABLE PULLEY BRKT 2
41 FINISHED HEX NUT B/O 1/2-13 4
44 FLAT WASHER SAE B/O 3/8” 10
50 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 5
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 5
71 NYLON PULLEY 3 1/2 RD, WHITE 5
92 SPLIT LOCK WASHER B/O 1/2” 4
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ACS-100 Free Movement Adjustable Cable System
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92
92
Assembly Manual
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92
50
44
41
21
44
71 44
24
71
44
69
69
44
44
71
24
44
92
41
21
71
44
50
69
44
71
22
44
50
ACS-100 Free Movement Adjustable Cable System
5
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Step 4 Assembling the Front Frame to the Base Frame
A. Attach the Front Frame (#2) to the Base Frame (#1) using one Hex Head Cap Screw 3/8-16 X 2 3/4 (#54), two
Flat Washers SAE 3/8” (#44), and one Nylon Insert Jam Lock Nut 3/8-16 (#69).
B. Attach one Nylon Pulley 4 1/2 Rd. (#70) to the bottom pulley bracket of the Front Frame (#2) using hardware
shown.
C. Attach four Nylon Pulleys 3 1/2 Rd. (#71) to the pulley brackets of the Front Frame (#2) using hardware
shown.
Assembly List
Item # Description Qty.
2 FRONT FRAME 1
39 BRONZE BUSHING 3/8 X 1/2 X 1/2 X 11/16 X 1/16 2
44 FLAT WASHER SAE B/O 3/8” 12
50 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 2
52 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 1/2 3
54 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 3/4 1
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 6
70 NYLON PULLEY 4 1/2 RD, WHITE 1
71 NYLON PULLEY 3 1/2 RD, WHITE 4
80 PUSH PULL PIN 1/2 X 3 1/2 REGULAR 1
7
ACS-100 Free Movement Adjustable Cable System
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69
69
44
44
71
44
Assembly Manual
50
44
71
44
69
71
44
52
44
69
71
44
39
44
2
80
39
44
52
54
44
70
ACS-100 Free Movement Adjustable Cable System
1
8
Step 5 Assembling the Bench Frame to the Base Frame and Front Frame
A. Attach the Bench Frame (#9) to the Base Frame (#1) using one Hex Head Cap Screw 3/8-16 X 4 1/2 (#57),
two Flat Washers SAE 3/8” (#44), and one Nylon Insert Jam Lock Nut 3/8-16 (#69).
B. Attach the Bench Frame (#9) to the Front Frame (#2) using one Hex Head Cap Screw 3/8-16 X 2 3/4 (#54),
two Flat Washers SAE 3/8” (#44), and one Nylon Insert Jam Lock Nut 3/8-16 (#69).
Assembly List
Item # Description Qty.
9 LEG EXTENSION BENCH FRAME 1
42 FLAT PHILLIPS MACHINE SCREW 8-32 X 1/4 1
44 FLAT WASHER SAE B/O 3/8” 4
54 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 3/4 1
57 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 4 1/2 1
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 2
96 TURN/PULL PIN W/KNOB AND LOCK 1
9
ACS-100 Free Movement Adjustable Cable System
Assembly Manual
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96
44
42
2
69
44
9
44
54
1
44
57
ACS-100 Free Movement Adjustable Cable System
10
Step 6 Assembling the Leg Extension Arm to the Bench Frame
A. Using a rubber mallet, insert two Plastic Insert Caps 1 3/4 Sq. (#74) into the tube-ends of the Leg Extension
Arm (#11).
B. Attach the Leg Extension Arm (#11) to the Bench Frame (#9) using the Sex Bolt Female 1/2 X 2 5/16 (#86)
and the Sex Bolt Male 5/16-20 X 3/4 (#87).
C. Attach a Nylon Pulley 3 1/2 Rd. (#71) to the Leg Extension Arm (#11) using hardware shown.
Assembly List
Item # Description Qty.
11 LEG EXTENSION ARM 1
38 BRONZE BUSHING 1/2 X 5/8 X 1/2 X 7/8 X 1/8 4
44 FLAT WASHER SAE B/O 3/8” 2
53 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 1/4 1
60 L-LOCKING PIN 1
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 1
71 NYLON PULLEY 3 1/2 RD, WHITE 1
74 PLASTIC INSERT CAP 1 3/4” SQ. 10-14 GA. 2
86 SEX BOLT FEMALE 1/2 X 2 5/16 1
87 SEX BOLT MALE 5/16-20 X 3/4 1
97 URETHANE BUMPER 1 3/4 1
11
ACS-100 Free Movement Adjustable Cable System
Assembly Manual
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9
38
11
38
69
44
74
71
87
38
97
38
44
53
74
ACS-100 Free Movement Adjustable Cable System
60
12
Step 7 Weight Stack Assembly
A. Attach a Nylon Pulley 4 1/2 Rd. (#70) to the Top Plate Pulley Bracket (#23) using hardware shown.
B. Attach the Selector Pin W/Coil (#28) to the Selector Bar (#34). Then, affi x the Assembled Top Plate Pulley
Bracket (#23) to the Top Plate Selector Bar (#34) using one Finished Hex Nut 1/2-13 (#41), and one Split Lock
Washer 1/2” (#92).
C. Insert the Guide Rods (#8) into the receptacles of the Base Frame (#1).
D. Slide the Rubber Donuts (#83) onto the Guide Rods (#8).
E. Carefully begin sliding the Weight Plates (#33) over the Guide Rods (#8).
F. Slide the Top Plate Selector Bar (#34) onto the Guide Rods (#8) allowing it to rest on top of the completed
Weight Stack.
G. Adhere the Decal Weight Numbers (#107) to the Weight Plates (#33) in the corresponding order. Begin with the
20 at the top, 30 next, and so on.
Assembly List
Item # Description Qty.
8 CHROME SOLID GUIDE ROD 3/4 X 72 2
23 TOP PLATE PULLEY BRACKET 1
28 SELECTOR PIN W/COIL 3/8 X 3 1/2 GOLD KNOB 1
33 10 LB CAST WEIGHT PLATE GREY 19
34 10 LB TOP PLATE/SELECTOR BAR GREY 19 WTS. 1
41 FINISHED HEX NUT B/O 1/2-13 1
44 FLAT WASHER SAE B/O 3/8” 2
51 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 1
69 NYLON INSERT JAM LOCK NUT B/O 3/8-16 1
70 NYLON PULLEY 4 1/2 RD, WHITE 1
83 RUBBER DONUT 3/4 X 2 1/2 2
92 SPLIT LOCK WASHER B/O 1/2” 1
107 DECAL-NUMBERS 20-200 LBS. SET 1
13
ACS-100 Free Movement Adjustable Cable System
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