Tuff stuff AP-2TO Assembly & Instruction Manual

ASSEMBLY INSTRUCTION MANUAL

Start / End

Midpoint

INNER THIGH

OUTER THIGH

Revision Date 11-03-99

AP-2TO

Inner/ Outer Thigh (Option)

America’s Premium Exercise Equipment

100”

126”

L 126” W 100” H 83”

Introduction

About the Inner / Outer (AP-2TO)

Congratulations on your new purchase of the Inner / Outer (AP­2TO). We hope you are completely satisfied with this product and
wish you many years of enjoyment.

Tuff 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.
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.

The Home Lifetime Warranty and

Warranty

SEE WARRANTY REGISTRATION CARD

Registration 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
Task Industries today.

Specifications

1. Maximum Wt. Capacity - 200 Lbs. Fixed on Apollo-250

2. Total Machine Weight - 60 Lbs.

3. Footprint (LWH) - See Front Cover

Maintenance Information

1. Lubrication of the Pivot Axles (#16) is essential to the longevity
and optimal performance of your Inner / Outer (AP-2TO). We
recommend multi-purpose grease for this application.

2. All cables and bushings should be checked regularly for signs of
wear.

3. Periodically check all moving parts, upholstery and grips for
wear. If replacement is necessary, please contact your local Tuff
Stuff retailer or call our Customer Service Department.

4. As needed, upholstery may be cleaned with a mild solution of
soap and water. Regular use of vinyl treatment will add to life
and appearance of your upholstery.

Tool Requirements

1.One 9/16” combination wrench

2.One 7/8” combination wrench

3.One 1/2” combination wrench

4.One ratchet

5.One 9/16” socket

6.One rubber mallet

7.External retaining-ring pliers

8.Multi-purpose grease

9.Measuring tape

10.Utility knife

Prior to the Assembly of the AP-2TO

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 Inner / Outer (AP-2TO).

2. Neatly organize and identify all parts according to the Parts List
on page 7 and the Exploded View Diagram on page 8.

S afety 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 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 of Owner’s
Manual 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.

Safety Precautions

Hardware Measurement Diagram

5. Frayed or worn cables can be dangerous and may cause injury.
Periodically check these cables 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 Inner / Outer (AP-2TO) 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.

9. Pay special attention to the Push Pull Pin 1/2 X 5 1/4 (#37) located
on the Right Leg Arm (#3). Be sure it is fully engaged into the
selectorized holes of the Adjustable Cam (#4).

Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.

Even though we have prepared this manual with extreme care, neither the publisher nor the author
can accept responsibility for any errors in, or omission from, the information given.

1

AP-2TO Inner / Outer (Option)

Owner’s Manual: Assembly Instructions

FIG. 1 Locate the Main Frame (#1) and, using a rubber mallet, insert

two Plastic Caps w/Groove 2 Sq. (#32) onto the tube-ends of the Main

Frame (#1), as labeled above. Next, insert two Plastic Insert Caps 2” Sq.

(#30) and one Plastic Insert Cap 1 X 2 (#31) into the tube-ends of the

Main Frame (#1), as labeled above. Then, thread a Plastic Knob 1/2 -13

X 1 (#26) into the thread socket located on the Main Frame (#1), as pic­tured above.

FIG. 2 Next, install one Nylon Pulley 3” Rd. (#14-Labeled B) and a

Small Cover Plate (#15), in the position shown above, to the Main
Frame (#1) and secure them into place using one Hex Head Cap Screw

3/8-16 X 1 1/2 (#40) and one Flat Washer SAE 3/8” (#46). Next, affix
the Connector Tube (#8) to the Main Frame (#1), as pictured above,
and secure it into place using two Hex Head Cap Screws 3/8-16 X 2 3/4
(#41), four Flat Washers SAE 3/8” (#46) and two Nylon Insert Jam Lock
Nuts 3/8-16 (#47).

Note: The black boxed letters pointing to the pulleys are used
throughout this manual as reference to the Cable Mapping

NOTE

Diagram on page 5. These black boxed letters will be primarily
used for locating certain pulleys during the assembly and the
cable routing process beginning with Fig. 16.

FIG. 3 Locate the Cam Support Tube (#5) and, using a rubber mallet,
insert two Plastic Insert Caps 1 x 2 (#31) into the tube-ends, as labeled
above. Next, install one Nylon Pulley 3” Rd. (#14-Labeled A) and a

Small Cover Plate (#15), in the position as shown above, to the Cam
Support Tube (#5) and secure them into place using one Hex Head

Cap Screws 3/8-16 X 2 3/4 (#41), two Flat Washers SAE 3/8” (#46) and
one Nylon Insert Jam Lock Nut 3/8-16 (#47).

Note: Be sure to position the Small Cover Plate (#15) as
shown in picture above.

NOTE

AP-2TO Inner / Outer (Option)

FIG. 4 Next, insert the two Pivot Axles (#16) into the receptacles on
the Main Frame (#1). Then, insert the Cam Support Tube (#5) and the

Adjustable Cam (#4), in the position as shown above, onto the left side
Pivot Axle (#16).

Note: It is recommended to grease the Pivot Axles (#16) with
multi-purpose grease prior to assembling. In addition, be sure

NOTE

to position the Cam Support Tube (#5) and the Adjustable

Cam (#4), as pictured above.

2

FIG. 5 Next, attach the Left Leg Arm (#2) onto the left side Pivot Axle

(#16), as pictured above.

FIG. 6 Next, attach the Right Leg Arm (#3) onto the right side Pivot

Axle (#16), as pictured above.

FIG. 7 Locate the Pivot Axle Support Tube (#6) and, using a rubber

mallet, insert two Plastic Insert Caps 2 Sq. (#30) into the tube-ends, as
labeled above. Next, maneuver the two Pivot Axles (#16) into the holes
on the bottom side of the Pivot Axle Support Tube (#6). Next, mount
the Pivot Axle Support Tube (#6) along with the two captive Pivot Ax-

les (#16) to the Main Frame (#1) and secure it into place using two Hex

Head Cap Screws 3/8-16 X 3 (#42), four Flat Washers SAE 3/8 (#46)
and two Nylon Insert Jam Lock Nuts 3/8-16 (#47). Then, secure the two

Pivot Axles (#16) to the Pivot Axle Support Tube (#6) using two Set

Screws 3/8-16 X 1/2 (#45). Use the supplied Hex Key 3/16” (#58) to se­cure the two Set Screws 3/8-16 X 1/2 (#45) into the threaded sockets on
the Pivot Axle Support Tube (#6), as shown in caption above.

3

FIG. 8 Connect the Left Leg Arm (#2) and the Right Leg Arm (#3) by
inserting the Pivot Actuator Plate (#7) into the receptacles on the Left

Leg Arm (#2) and the Right Leg Arm (#3), as shown above. Secure

this assembly using two Flat Washers SAE 3/8 (#46) and two Nylon In­sert Lock Nuts 3/8-16 (#48), as shown in caption above.

Note: It is recommended to grease the axles on the Pivot

Actuator Plate (#7) with multi-purpose grease prior to

NOTE

assembling.

AP-2TO Inner / Outer (Option)