TuffStuff AP-250S, AP-250D Owner's Manual

OWNER’S MANUAL
TABLE OF CONTENTS:
Introduction - Pg. 1
Assembly for AP-250S_AP-250D 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. 36
Maintenance - Pg. 37
Optional Stations - Pg. 38 - Pg. 39
Warranty - Back Page
Apollo 2-Stack Gym System
Includes Assembly for:
AP-250S
Apollo 2-Stack Gym System (Standard)
AP-250D
Apollo 2-Stack Gym System (Deluxe)
Revision Date 06-12-03
100”
America’s Premium Exercise Equipment
72”
L 72” W 100” H 83”
Int
roduction
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bout the AP-250S_AP-250D
ongratulations on your new purchase of the AP-250S_AP-250D.
his gym is capable of a variety of different exercises, as well as, mooth and user-friendly adjustment features. In addition, this gym as been designed to meet the needs and performance
quirements for a suitable home exercise machine. We hope you re completely satisfied with this product and wish you many years f enjoyment.
uff Stuff Equipment
his Tuffstuff product has been built to precise quality standards nd has been carefully packaged to ensure that damage will not ccur during shipment. ignature indicating final inspection has been conducted by our line
reman, is an expression of our confidence in the completeness, e materials, and workmanship of this product.
arranty
EE A COPY OF WARRANTY ON BACK PAGE.
pecifications
Maximum Wt. Capacity - 200 Lbs. Each Weight Stack Total Machine Weight - 990 Lbs.
Footprint (LWH) - See Front Cover
The Home Lifetime Warranty and
About the Icons
The icons displayed in this Owner’s Manual are used to facilitat the correct assembly and safe use of this Product, as-well-as t prevent injury to yourself or anyone else.
Note provides information necessary to properl 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 moderate injury. It may also be used to aler against unsafe practices.
Loosely Fasten provides a instruction to loosel fasten (ex: hand tighten) a hardware assembl only. This instruction is intended for the alignmen of hardware components during the assembl process.
Fully Fasten provides a instruction to fully fasten (ex: completely tighten) a hardware assembly.
rior to the Assembly of the AP-250S_AP-250D
. 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.
. Consider the complete surface area of the AP-250S_AP-250D.
Use the overhead view on the front page for designing your layout before assembling. Once the AP-250S_AP-250D has been fully assembled it will be heavy and difficult to move, therefore you should assemble the unit in the area where it is to be used upon completion.
. It is recommended that another person assist you with the
assembly this unit.
. 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 7/16” combination wrench
5.One 1/2” combination wrench
6.One ratchet
7.One 9/16” socket
8.One 3/4” socket
9.One rubber mallet
0.One flat head steel hammer
1.External retaining-ring pliers
2.Windex or household glass cleaner
3. One can silicone spray/ teflon spray lubricant
4.Multi-purpose grease
5.Measuring tape
6.Masking tape
7.Utility knife
Assembly Notes
1. Read and follow each step of this Assembly Instruction Manual sequence. Do not skip ahead, as it will result in an improp assembly or in having to disassemble parts later.
2. During the assembly of this unit you will be instructed to lea some Hex Head Cap Screws loosely fastened. Naturally, th will be fully fastened later in the assembly process. This is do to prevent any difficulty with alignment of some parts during th assembly.
Hardware Measurement Diagram
SCREW LENGHT
WASHER DIAMETER
SCREW WIDTH
Note: Due to continuing product improvements, specifications and designs are subject to chan without notice.
Even though we have prepared this manual with extreme care, neither the publisher nor the auth can accept responsibility for any errors in, or omission from, the information given.
NUT DIAMETER
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afety First
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Safety Precautions
egardless of how enthusiastic you may be about getting on our equipment and exercising, take the time to ensure that our safety is not jeopardized. A moment’s lack of attention an result in an accident, as can failure to observe certain imple safety precautions.
. 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.
. 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.
. 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 injury. Periodically check these cables for any indication o wear.
6. Keep hands, limbs, loose clothing and long hair well out o the way of moving parts.
7. Do not attempt to lift more weight than you can control safely
8. Inspect the AP-250S_AP-250D for any sign of wear on parts hardware becoming loose or cracks on welds. If a problem i found do not use or allow the machine to be used unti defective part is repaired or replaced.
9. Pay special attention to the Push Pull Pins (#73, # 74, #136 #137) and the Turn/Pull Pin w/Knob (#138). Be sure they ar fully engaged into their corresponding holes. Refer to Fig. 1 and Fig. 2 for further illustration..
Push Pull Pin Fully Engaged
Fig. 1 Caution: Check the
Push Pull Pins (#73, # 74, #136, #137) to be fully engaged into their
corresponding holes.
Turn/Pull Pin w/Knob Fully Engaged
Fig. 2 Caution: Check the
Turn/Pull Pins w/Knob (#138) to be fully engaged into their corre­sponding holes
Push-Pull Pin 1/4” X 3 1/2” (#136)
Push-Pull Pin 1/2” X 2 3/4” (#137)
Push-Pull Pin 1/2” X 3 1/2” (#73)
Push-Pull Pin 1/2” X 3 1/2” (#73)
Turn/Pull Pin W/Knob (#138)
Push-Pull Pin 1/2” X 2 7/8” (#74)
Turn/Pull Pin W/Knob (#138)
Fig. 3 Picture above depicts the location of the Push Pull Pins (#73, # 74, #136, #137) and the Turn/Pull Pin w/Knob (#138) on the
unit.
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IG. 4 On a flat surface, lay the Base Frame (#2) down and attach
ree Pulleys 4 1/2 Rd (#68-Labeled D1,E1,E3) to the Base Frame (#2)
ing three Hex Head Cap Screws 3/8-16 X 2 (#109), six Flat Washers AE 3/8” (#91), and three Nylon Insert Jam Lock Nuts 3/8-16 (#101). ext, affix one Hex Head Cap Screw 3/8-16 X 2 (#109), two Flat
ashers SAE 3/8” (#91), and one Nylon Insert Jam Lock Nut 3/8-16
101) to the bracket in front of the Base Frame (#2).
Note: The black boxed letters pointing to the pulleys are used throughout this manual as reference to the Cable Mapping Diagrams on pages 24 - 39. These black boxed letters will be primarily used for locating certain pulleys during the cable routing process.
D2
F2
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FIG. 5 Using a rubber mallet, insert two Plastic Insert Caps 2” S (#85) into the tube-ends of the Base Frame (#2). Next, attach thre Pulleys 4 1/2 Rd (#68-Labeled A3,D2,F2) to the pulley brackets of th
Base Frame (#2) using three Hex Head Cap Screws 3/8-16 X 1 3
(#110), six Flat Washers SAE 3/8” (#91), and three Nylon Insert Ja Lock Nuts 3/8-16 (#101).
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IG. 6 Insert the Low Row Stabilizer (#14) into the receptacle of
e Base Frame (#2). Next, using a rubber mallet, insert two Plastic sert Caps 1” Rd. (#89) into the tube-ends of the Low Row Stabilizer
14).
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FIG. 7 Using a rubber mallet, insert two Plastic Insert Caps 1” R (#89) into the tube-ends of the Foot Roll Tube 1X16 (#31). Next, co nect the Low Row Foot Support (#15) to the Low Row Stabiliz
(#14) using the Foot Roll Tube 1 X 16 (#31). Secure the Foot Ro Tube 1X16 (#31) to the Low Row Stabilizer (#14) using one S
Screw 3/8-16 X 1/2 (#69), as shown in caption above.
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IG. 8 Using a rubber mallet, insert one Plastic Insert Cap w/ Groove
X 3 (#57) onto the tube-end of Rear Upright (#4). Next, attach the
ear Upright (#4) to the Base Frame (#2) using two Hex Head Cap
crews 3/8-16 X 4 (#105), four Flat Washers SAE 3/8” (#91), and two ylon Insert Lock Nuts 3/8-16 (#100).
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FIG. 9 Using a rubber mallet, insert two Plastic Insert Caps Groove 2 X 3 (#57) onto the tube-ends of the Leg Extension Mai
Frame (#9). Next, attach one Pulley 4 1/2 Rd. (#68-Labeled A2) an
one Pulley Cover Plate (#50) to the Leg Extension Main Frame (# threaded socket using one Hex Head Cap Screw 3/8-16 X 1 3/4 (#110 one Split Lock Washer 3/8” (#95), and one Flat Washer SAE 3/8” (#91
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Note: Attach the Leg Extension Main Frame (#9) to the Re
Upright (#4) using ONLY the 1st hole with one Hex Head C
Screw 3/8-16 X 4 1/4 (#104), two Flat Washers SAE 3/8” (#9 and one Nylon Insert Lock Nut 3/8-16 (#100). The other Bolt w be installed in the 2nd hole once the Weight Shrouds (#22) ha been assembled onto the unit. Refer to Fig. 82 on page 23 f further clarification of this assembly.
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IG. 10 Next, attach the Leg Extension Front Frame (#11) to the
g Extension Main Frame (#9) using two Hex Head Cap Screws 3/8-
X 4 1/4 (#104), four Flat Washers SAE 3/8” (#91), and two Nylon
sert Lock Nuts 3/8-16 (#100). Next, attach one Pulley 4 1/2 Rd. (#68-
beled A1) and one Cable Retainer L-Shaped Bracket (#28) to the
g Extension Front Frame (#11) using one Hex Head Cap Screw
8-16 X 4 1/4 (#105), one Flat Washer SAE 3/8” (#91), and one Nylon sert Lock Nut 3/8-16 (#100). Refer to Fig. 86 on page 30 for further
ustration of this hardware assembly.
Note: Be sure the Cable Retainer L-Shaped Bracket (#28) is positioned as shown in caption above.
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FIG. 11 Using a rubber mallet, insert one Plastic Insert Cap 2” S (#85) into the tube-end of the Leg Extension Seat Frame (#12).Ne attach the Leg Extension Seat Frame (#12) to the Leg Extensio
Main Frame (#9) using two Hex Head Cap Screws 3/8-16 X 4 1
(#104), four Flat Washers SAE 3/8” (#91) and two Nylon Insert Lo Nuts 3/8-16 (#100).
Loosely Fasten: Do not completely fasten this hardwa assembly at this time, as it will be completely fastened later i the assembly process.
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IG. 12 Next, attach the Leg Extension Arm Support (#13) to the
g Extension Front Frame (#11) using two Hex Head Cap Screws
8-16 X 4 1/4 (#104), four Flat Washers SAE 3/8” (#91), and two Nylon sert Lock Nuts 3/8-16 (#100). Next, attach the other end of the Leg
xtension Arm Support (#13) to the Leg Extension Seat Frame
12) using two Hex Head Cap Screws 3/8-16 X 3 1/4 (#106), four Flat
ashers SAE 3/8” (#91), and two Nylon Insert Lock Nuts 3/8-16
100).
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FIG. 13 Attach the Leg Extension Right Handle (#45) and the Le
Extension Left Handle (#46) to the Leg Extension Seat Frame (#12
in the position as shown above, using two Hex Head Cap Screws 3/ 16 X 3 1/4 (#106), four Flat Washers SAE 3/8” (#91), and two Nyl Insert Lock Nuts 3/8-16 (#100).
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IG. 14 Using a rubber mallet, insert two Plastic Insert Caps 2” Sq.
85), and one Plastic Insert Cap 1 X 2 (#87) into the tube-ends of the
ivot-Arm (#25). Next, insert one Plastic Insert Cap 2” Rd. (#88) into
e tube-end of the Swivel Foam Roll Tube (#29), and the Top Adj.
g Hold-Down Tube (#32).
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122
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FIG. 15 Insert a Nylon Washer 1 X 1 1/4 (#122) to the Circul
Plate w/ Axle (#16) as shown in caption above.
Note: It is recommended to lubricate the axle on the Circul
Plate w/ Axle (#16) with multi-purpose grease prior
assembling.
Next, attach the Pivot-Arm (#25) to the Circular Plate w/ Axle (#16) Then, insert the Circular Plate w/ Axle (#16) into the Ball Bearin housing of the Leg Extension Front Frame (#11).
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IG. 16 Attach the Actuator Arm (#43) to the axle of the Circular
late (#16). Next, align the hole of the Actuator Arm (#43) with the
le of the axle of the Circular Plate (#16) and, using a hammer, insert
e Roll Pin 3/8 X 1 1/2 (#123). Be sure that the Roll Pin 3/8 X 1 1/2
123) is aligned with the holes before hammering into place. In dition, make sure the Roll Pin 3/8 X 1 1/2 (#123), after hammered in, comes flush on both sides of the Actuator Arm (#43). Next, using a
bber mallet, insert one Plastic Insert Cap 1 X 2 (#87) into the tube-
dof the Actuator Arm (#43).
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FIG. 17 Next, attach the Top Adjustable Leg Holder Tube (#32) the Leg Extension Front Frame (#11) using one Hex Head Cap Scre 3/8-16 X 1 (#113), one Split Lock Washer 3/8” (#95), and one Fend Washer 3/8 X 1 1/2 (#92). Next, attach the Swivel Foam Roll Tub
(#29) to the Pivot- Arm (#25) using one Hex Head Cap Screw 3/8-16
1 (#113), one Split Washer 3/8” (#95), and one Fender W asher 3/8 X 1/2 (#92).
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IG. 18 Caution: It is strongly recommended to use another
ttach the Front Frame (#3) to the Base Frame (#2) using two Hex ead Cap Screws 3/8-16 X 4 1/4 (#104), four Flat Washers SAE
8” (#91) and two Nylon Insert Lock Nuts 3/8-16 (#100). Next, using a
bber mallet, insert one Plastic Insert Cap 2” Sq. (#85) into the tube-
d of the Front Frame (#3).
person in assisting with this assembly.
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FIG. 19 Next, attach one Pulley 4 1/2” Rd. (#68-Labeled C4), an one Cable Retainer L-Shaped Bracket (#28), in the position as sho above, to the plate of the Front Upright (#3) using one Hex Head Ca Screw 3/8-16 X 1 3/4 (#110), two Flat Washers SAE 3/8” (#91), an one Nylon Insert Jam Lock Nut 3/8-16 (#101). Next, attach two Pulle 4 1/2” Rd. (#68-Labeled C6,D7) to the pulley brackets of the Fro
Upright (#3) using two Hex Head Cap Screws 3/8-16 X 2 1/2 (#108
four Flat Washers SAE 3/8” (#91), and two Nylon Insert Jam Lock Nu 3/8-16 (#101).
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IG. 20 Caution: It is strongly recommended to use another
ttach the Top Pulley Assembly (#5) to the Front Upight (#3) using
o Hex Head Cap Screws 3/8-16 X 4 1/4 (#104), four Flat Washers
AE 3/8” (#91), and two Nylon Insert Lock Nuts 3/8-16 (#100).
person in assisting with this assembly.
Loosely Fasten: Do not completely fasten this hardware assembly at this time, as it will be completely fastened later in the assembly process.
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FIG. 21 Next, attach the Top Pulley Assembly (#5) to the Re
Upright (#4) using two Hex Head Cap Screws 3/8-16 X 3 1/4 (#106
four Flat Washers SAE 3/8” (#91) and two Nylon Insert Lock Nuts 3/ 16 (#100).
Fully Fasten: Proceed to align and fully fasten this hardwa assembly and all the previous assemblies that were l loosely fastened.
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IG. 22 Attach four Pulleys 4 1/2 Rd. (#68-Labeled D5, C7, D3, C8)
the pulley brackets of the Top Pulley Assembly (#5) using two Hex
ead Cap Screws 3/8-16 X 2 3/4 (#107), four Flat Washers SAE
8” (#91), and two Nylon Insert Jam Lock Nuts 3/8-16 (#101). Next, tach another Pulley 4 1/2 Rd (#68-Labeled C1) to the Top Pulley As-
mbly (#5) using one Hex Head Cap Screw 3/8-16 X 2 1/2 (#108),
o Flat Washers SAE 3/8” (#91), and one Nylon Insert Jam Lock Nut
8-16 (#101). Next, attach the Lat Bar Holder 2 X 3 (#19) to the Top
ulley Assembly (#5) using one Hex Head Cap Screw 3/8-16 X 2 3/4
107), two Flat Washers SAE 3/8” (#91), and one Nylon Insert Jam ck Nut 3/8-16 (#101).
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FIG. 23 Next, attach one Pulley 4 1/2 Rd. (#68- Labeled A4), an one Cable Retainer L-Shaped Bracket (#28) to the pulley plate of th
Top Pulley Assembly (#5) using one Hex Head Cap Screw 3/8-16 X
3/4 (#110), two Flat Washers SAE 3/8” (#91), and one Nylon Insert Ja Lock Nut 3/8-16 (#101). Be sure to position the Cable Retainer
Shaped Bracket (#28) as shown above.
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IG. 24 Insert the Left Pec Dec Arm (#7) along with the Aluminum
am Plate (#144) into the receptacle of the Front Upright (#3).
epeat the same procedure for the Right Pec Dec Arm (#6).
Note: It is recommended to grease both axles of the Left and
Right Pec Dec Arms (#7,#6) with multi-purpose grease prior to
assembling.
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FIG. 25 Secure the Left Pec Dec Arm (#7) into place using on Hex Head Cap Screw 3/8-16 X 1 (#113), one Split Lock Wash 3/8” (#95), and one Fender Washer 3/8 X 1 1/2 (#92). Repeat th same procedure for the Right Pec Dec Arm (#6).
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IG. 26 Using a rubber mallet, insert a Pec Dec Swivel Handle
8), in the position as shown above, into the Left Pec Dec Arm (#7).
epeat the same procedure for the Right Pec Dec Arm (#6).
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FIG. 27 Next, secure the Pec Dec Swivel Handles (#8) using two R taining Snap Rings (#115). If possible, use Snap Ring Pliers for this jo as shown above. If the tool is not available, carefully work each Retainin Snap Ring (#115) into the groove, then push up alternately with a scre driver working the Retaining Snap Ring (#115) into the groove.
Note: Be careful not to distort the Retaining Snap Rings (#115) bend them.
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IG. 28 Using a rubber mallet, insert one Pivot Axle 1 X 8 1/8 (#18)
rough the holes of the Press Bar Selector Housing (#17) and rough the receptacle of the Top Pulley Housing (#5) until the Pivot
xle 1 X 8 1/8 (#18) is flush with both sides of the Press Bar Selector ousing (#17).
Note: It is recommended to grease the Pivot Axles 1 X 8 1/8
(#18) with multi-purpose grease prior to assembling.
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FIG. 29 Using a rubber mallet, insert two Plastic Insert Caps 2” S (#86) into the tube-ends of the Press Bar (#1). Next, insert the Pres
Bar (#1) up into the Press Bar Selector Housing (#17) and support i
into place using the push-pull pin 1/2 X 3 1/2 (#73). Next, using rubber mallet, insert the Pivot Axle 1 X 8 1/8 (#18) into the Press B
Selector Housing (#17) and through the Press Bar (#1).
Note: Refer to Fig. 83 on page 30 for further clarification of th assembly.
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IG. 30 Secure the two Pivot Axles 1 X 8 1/8 (#18) to the Press
ar Selector Housing (#17) using four Set Screws 3/8-16 X 1/2 (#69).
se the Supplied Hex Key 3/16 (#126) for securing these Set Screws
8-16 X 1/2 (#69) into the threaded sockets on the Press Bar Selector
ousing (#17). Next, clean the ends of the Pivot Axles 1 X 8 1/8
18) and apply four 1” Rd. Silver Mylar Decals (#131–Not shown).
hese decals are used to hide and protect the ends of the axles.
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FIG. 31 Next, attach two Pulleys 4 1/2 Rd. (#68-Labeled C3, C5) t the Press Bar Selector Housing (#17) using one Hex Head C Screw 3/8-16 X 2 3/4 (#107), two Flat Washers SAE 3/8” (#91), an one Nylon Insert Jam Lock Nut 3/8-16 (#101).
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IG. 32 Insert the four Guide Rods 3/4 X 72 (#21) into the
ceptacles of the Base Frame (#2), as shown above. Next, insert four
ubber Donuts 3/4 X 2 1/2 (#81) onto the Guide Rod 3/4 X 72 (#21).
Note: Lubricate the Guide Rods 3/4 X 72 (#21) with a silcone or teflon lubricant at this time.
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134
FIG. 33 Carefully begin sliding the Weight Plates over the Guid
Rods (#21) beginning with the five 15 Lb. Weight Plates (#134) at th
bottom, the nine 10 Lb. Weight Plates (#23) in the middle, and the fi
5 Lb. Weight Plates (#133) on top of the weight stack. Same proce
for both weight stacks.
23
134
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LABEL
24
IG. 34 Slide the Top Plate/Selector Bar (#24) over the Guide
ods (#21) allowing it to come to rest on top of the completed weight
ack. Same process for both weight stacks.
Note: Be sure the Label located on the Top Plate/Selector Bar
(#24) is facing out, as shown above, before sliding the Top Plate/Selector Bar (#24) onto the Guide Rods (#21).
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FIG. 35 Maneuver the two Guide Rods (#21) into the holes on th bottom side of the Guide Rod Retainer Housing (#20). Next, secu the Guide Rod Retainer Housing (#20) along with the two capti
Guide Rods (#21) to the Top Pulley Assembly (#5) using two H
Head Cap Screws 3/8-16 X 2 3/4 (#107), four Flat Washers SA 3/8” (#91), and two Nylon Insert Jam Lock Nuts 3/8-16 (#101). Repe the same procedure for the other Guide Rod Retainer Housing (#20)
Loosely Fasten: Do not completely fasten this hardwa assembly at this time, as it will be completely fastened later the assembly process.
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IG. 36 To attach the Decal-Numbers we recommend using a piece of
asking tape as a guide to vertically align the Decal-Numbers. Attach the
ecal Weight Numbers (#116) to the Weight Plates (#133, #23, #134) in
e corresponding order. Begin with the 15 at the top, 20 next, and so on.
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99
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36
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99
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FIG. 37 Next, attach the Selector Pins w/Coil (#83) to the Select
Bars (#24).
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68
90
99
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IG. 38 Locate the two Adjustable Pulley Brackets (#36) and at-
ch two Pulleys 4 1/2 Rd. (#68) using two Hex Head Cap Screws 3/8-
X 1 3/4 (#110), four Flat Washers SAE 3/8” (#91), and two Nylon
sert Jam Lock Nuts 3/8-16 (#101). Next, thread two Regular Hex
uts 1/2-13 (#99) and insert two Flat Washers SAE 1/2” (#90) over the
lts of the Adjustable Pulley Brackets (#36). Next, locate the two
djustable Stoppers (#33) and thread one Regular Hex Nut 1/2-13
99) and insert one Flat Washer SAE 1/2” (#90) over each of the bolts, shown above.
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FIG. 39 Attach the two Adjustable Pulley Brackets (#36) to th
Top Pulley Assembly (#5) using two Flat Washers SAE 1/2” (#90) an
two Nylon Insert Lock Nuts 1/2-13 (#98).
Loosely Fasten: Do not completely fasten this hardwa assembly at this time, as it will be completely fastened later the assembly process.
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