TuffStuff Apollo Owner's Manual
OWNER’S MANUAL
TABLE OF CONTENTS:
Introduction - Pg. 1
Safety Precautions - Pg. 2
Assembly Instructions
Pg. 3 - Pg. 28
Parts List - Fold-out Pg. 20
Cable Mapping Diagrams
Vertical Multi-Press Station Pg. 21
Mid Row Station Pg. 23
Leg Developer Station Pg. 25
Exploded View Diagrams
Vertical Multi-Press Station Pg. 22
Mid Row Station Pg. 24
Leg Developer Station Pg. 26
Maintenance - Pg. 29 - Pg. 30
Warranty - Back Page
Apollo Modular Gym System
(Base Unit)
Standard
Deluxe
103"
91 1/2"
TuffStuff Fitness Equipment, Inc.
1325 E. Franklin Avenue
Pomona, CA 91766, USA
Ph: 909-629-1600 Fax: 909-629-4967
E-mail: service@tuffstuff.net Net: www.tuffstuff.net
AMERICA’S PREMIER EXERCISE EQUIPMENT
L 103” W 91 1/2” H 84
Apollo Base Unit Rev1
Revision Date 11-13-2007
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Introduction
T
bout the Apollo Modular Gym System
Congratulations on your new purchase of the Apollo Modular Gym
System. This gym is capable of a variety of different exercises, as
well as, smooth and user-friendly adjustment features. We hope
you are completely satisfied with this product and wish you many
years of enjoyment.
uff 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 Limited Warranty and 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.
arranty
SEE A COPY OF WARRANTY ON BACK PAGE.
egistration 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
TuffStuff Fitness Equipment today.
pecifications
1. Maximum Wt. Capacity - 200 Lbs. Each Weight Stack
2. Total Machine Weight - 1575 Lbs.
3. Footprint (LWH) - See Front Cover
bout the Icons
The icons displayed in this Owner’s Manual are used to facilitate
the correct assembly and safe use of this Product, as-well-as to
prevent injury to yourself or anyone else.
Note provides information necessary to properly
complete a procedure or information which will
make the procedure easier to understand.
Caution indicates a potentially hazardous situation, which, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
Loosely Fasten provides a instruction to loosely
fasten (ex: hand tighten) a hardware assembly
only. This instruction is intended for the alignment
of hardware components during the assembly
process.
Fully Fasten provides a instruction to fully fasten
(ex: completely tighten) a hardware assembly.
rior to the Assembly of the Apollo Modular Gym System
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.
2. Consider the complete surface area of the Apollo Modular Gym
System. Use the overhead view on the front page for designing
your layout before assembling. Once the Apollo Modular Gym
System 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.
3. It is recommended that another person assist you with the
assembly of this unit.
ool Requirements
1. One 7/8” combination wrench
2. One 3/4” combination wrench
3. One 9/16” combination wrench
4. One 1/2” combination wrench
5. One ratchet
6. One 3/4” socket
7. One 9/16” socket
8. One 1/2” socket
9. One rubber mallet
10. One hammer
11. External retaining-ring pliers
12. Windex or household glass cleaner
13. One can silicone spray/ teflon spray lubricant
14. Multi-purpose grease
15. Measuring tape
16. Masking tape
17. Utility knife
1
ssembly Notes
1. Read and follow each step of this Assembly Instruction Manual in
sequence. Do not skip ahead, as it will result in an improper
assembly or in having to disassemble parts later.
2. During the assembly of this unit you will be instructed to leave
some Hex Head Cap Screws loosely fastened. Naturally, they
will be fully fastened later in the assembly process. This is done
to prevent any difficulty with alignment of some parts during the
assembly.
Hardware Measurement Diagram
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Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.
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Apollo Modular Gym System (Base Unit)
S
Safety Precautions
afetyFirst
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.
4. Use proper discretion when children are present.
5. Frayed or worn cables can be dangerous and may cause
injury. Periodically check these cables for any indication
of wear.
1. Read, study and understand the Assembly Instructions
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 Instructions, as-well-as
from your local Tuff Stuff retailer.
2. It is imperative that you retain this Assembly Instructions
and be sure all warning labels are legible and intact.
Replacement Assembly Instructions and labels are
available from your local Tuff Stuff retailer.
3. Consult with your physician before beginning any exercise
program.
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.
2Apollo Modular Gym System (Base Unit)
C3
53
For the Single Column Station
no pulley needed here
53
B3
D6
B5
FIG. 1 Locate the Weight Stack Frame (#53) and attach two
Pulleys 4 1/2 Rd (#67-Labeled C3, D6) using two Hex Head Cap
Screws 3/8-16 X 1 3/4 (#97), four Flat Washers SAE 3/8” (#93), and
two Nylon Insert Jam Lock Nuts 3/8-16 (#118). Next, attach two
Pulleys 3 1/2 Rd (#66-Labeled B3, B5) to the Weight Stack Frame
(#53) brackets using one Hex Head Cap Screw 3/8-16 X 4 (#103), two
Flat Washers SAE 3/8” (#93), and one Nylon Insert Jam Lock Nut 3/816 (#118).
Note: The black boxed letters pointing to the pulleys are used
throughout this manual as reference to the Cable Mapping
Diagrams. These black boxed letters will be primarily used for
locating certain pulleys during the cable routing process.
122
122
122
122
Leg Extension/Curl Station
25
Press Bar Station
7
FIG. 2 Using a rubber mallet, insert one Plastic End Cap 2 X 3
(#122) onto the tube-end of the Bottom Connector Press Bar/Pec Fly
(#7), Next, insert three Plastic End Caps 2 X 3 (#122) onto the tubeends of the Leg Extension Bottom Frame (#25). Secure the Bottom
Connector Press Bar/Pec Fly (#7) and the Leg Extension Bottom
Frame (#25) to the Weight Stack Frame (#53), in the position as
shown above, using four Hex Head Cap Screws 3/8-16 X 3 1/4 (#101),
eight Flat Washers SAE 3/8 (#93), and four Nylon Insert Lock Nuts 3/816 (#119).
53
53
Single Column Station
Leg Press Station
FIG. 3 Attach the Leg Press Bottom Connector and the Bottom
Upright Connector to the Weight Stack Frame (#53), in the position
as shown above, using four Hex Head Cap Screws 3/8-16 X 3 1/4
(#101), eight Flat Washers SAE 3/8 (#93), and four Nylon Insert Lock
Nuts 3/8-16 (#119).
Note: Depending on what optional Stations your system may include, the bottom connectors of these stations (Ab/Back, Inner
Outer Thigh, Multi-Press) can be attach to the Weight Stack
Frame (#53) as described above.
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52
52
52
FIG. 4 Next, affix four Weight Shield Holders (#52) to the Weight
Stack Frame (#53) using eight Hex Head Cap Screws 3/8-16 X 3/4
(#102), and eight Nylon Insert Lock Nuts 3/8-16 (#119).
3 Apollo Modular Gym System (Base Unit)
Assembly Instructions
10
10
136
136
136
136
Press Bar Station
Single Column
Station
92
92
FIG. 5 Insert the eight Guide Rods (#10) into the receptacles of the
Weight Stack Frame (#53). Next, insert two Rubber Donuts (#136)
onto the Guide Rods (#10) located at the side of the Press Bar Station.
Next, on the side of the Single Column Station insert onto the Guide
Rods (#10) the following:
1. Two Flat Washers 3/4 X 2 (#92)
2. Two Rubber Donuts (#136)
Note: Lubricate the Guide Rods (#10) with a silcone or teflon
lubricant at this time.
136
92
54
92
10
136
92
54
10
136
92
10
136
92
Leg Extension
92
Leg Pre
FIG. 6 On the Leg Extension/Curl Station insert onto the Guide
Rods (#10) the following:
1. Two Flat Washers 3/4 X 2 (#92)
2. Two Weight Stack Spacers (#54)
3. Two Flat Washers 3/4 X 2 (#92)
4. Two Rubber Donuts (#136)
On the Leg Press Station insert onto the Guide Rods (#10) the following:
1. Two Flat Washers 3/4 X 2 (#92)
2. Two Rubber Donuts (#136)
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56
10
10
10
10
56
56
FIG. 7 Carefully begin sliding the nineteen (19) 10 Lb. Weight
Plates (#56) over the Guide Rods (#10). Repeat the same process for
the other three stations.
Assembled to be used on
the Single Pulley Station
No Label
58
58
31
58
58
31
To be used on the
Leg Press Station
31
31
FIG. 8 Locate the four Top Plate Selector Bars (#58) and assemble
Magnetic Selector Pins W/Coil 3/8 X 4 (#31) in the position as shown
above.
Apollo Modular Gym System (Base Unit)
4
10
58
58
10
LABEL
58
17
127
127
Single Column Station
127
Lat Cable will route
through this hole
LABEL
31
58
31
FIG. 9 Assemble each Top Plate/Selector Bar (#58) to its corresponding workstation
Note: Be sure the Label and the Selector Pin w/Coil (#31) located on each Top Plate/Selector Bar (#58) are facing out, before sliding the Top Plate/Selector Bars (#58) onto the Guide
Rods (#10).
Leg Extension/Curl Station
53
Leg Press Station
18
53
10
10
Press Bar Station
FIG. 10 On the Single Column Station, maneuver the two Guide
Rods (#10) into the bottom holes of a Guide Rod Retainer (#17).
Next, temporary secure the Guide Rod Retainer (#17) to the Weight
Stack Frame (#53) using two Plastic Ties (#127).
Next, locate the Press Bar Station Guide Rod Retainer (#18) and attach it to the side of the Press Bar Station following the previous procedure.
85
85
43
43
10
10
17
17
10
FIG. 11 On the side of the Leg Extension/Curl Station, maneuver the
two Guide Rods (#10) into the bottom holes of a Guide Rod Retainer
(#17). Next, secure the Guide Rod Retainer (#17) to the Weight
Stack Frame (#53) using one Reinforcement Plate 1/4 X 2 X 8 1/2
(#43), two Hex Head Cap Screws 3/8-16 X 3 1/4 (#101), four Flat
Washers SAE 3/8” (#93), and two Nylon Insert Lock Nuts 3/8-16
(#119).
Next, repeat the same procedure for the Leg Press Station.
5
56
56
85
85
FIG. 12 Attach the Decal Weight Numbers (#85) to the Weight
Plates (#56).
Apollo Modular Gym System (Base Unit)
Assembly of the Press Bar Station Fig. 13 - Fig. 48
Assembly Instructions
16
B2
7
FIG. 13 Attach two Pulleys 4 1/2 Rd. (#67-Labeled B2, B6) to the
Press Bar Station Base Frame (#7) pulley brackets using one Hex
Head Cap Screw 3/8-16 X 4 (#103), two Flat Washers SAE 3/8 (#93),
and one Nylon Insert Jam Lock Nut 3/8-16 (#118).
16
B6
7
FIG. 14 Caution: It is strongly recommended to use another
person in assisting with this assembly.
Attach the Front Upright (#16) to the Bottom Connector Press Bar/
Pec Fly (#7) using two Hex Head Cap Screws 3/8-16 X 4 1/4 (#104),
four Flat Washers SAE 3/8” (#93), and two Nylon Insert Lock Nuts 3/816 (#119).
Loosely Fasten: Do not completely fasten this hardware
assembly until assembling the Top Pulley Assembly (#49) to
the Press Bar Station Guide Rod Retainer (#18) described in
FIG. 18.
8
8
B7
B1
FIG. 15 Attach two Pulleys 4 1/2 Rd (#67-Labeled B1, B7) and two
Cable Retainer Brackets (#8) to the Front Upright (#16) using two
Hex Head Cap Screws 3/8-16 X 2 (#98), four Flat Washers SAE
3/8” (#93), and two Nylon Insert Lock Nuts 3/8-16 (#119).
Note: Be sure the Cable Retainer Brackets (#8) are positioned
as shown above.
A4
16
8
A6
FIG. 16 Next, attach a Pulley 4 1/2 Rd (#67-Labeled A4) and a Cable Retainer Bracket (#8) to the plate of the Front Upright (#16) using
one Hex Head Cap Screw 3/8-16 X 2 (#98), two Flat Washers SAE
3/8” (#93), and one Nylon Insert Lock Nut 3/8-16 (#119).
Note: Be sure the Cable Retainer Bracket (#8) is positioned as
shown above.
Next, attach another Pulley 4 1/2 Rd (#67-Labeled A6) to the Front Upright (#16) using one Hex Head Cap Screw 3/8-16 X 2 1/2 (#99), two
Flat Washers SAE 3/8” (#93), and one Nylon Insert Jam Lock Nut 3/816 (#118).
Apollo Modular Gym System (Base Unit)
6
49
16
FIG. 17 Caution: It is strongly recommended to use another
person in assisting with this assembly.
Attach the Top Pulley Assembly (#49) to the Front Upright (#16)
using two Hex Head Cap Screws 3/8-16 X 4 1/4 (#104), four Flat
Washers SAE 3/8” (#93), and two Nylon Insert Lock Nuts 3/8-16
(#119).
Loosely Fasten: Do not completely fasten this hardware
assembly at this time.
49
53
18
127
18
FIG. 18 Using a utility knife, remove the two Plastic Ties (#127) from
the Press Bar Station Guide Rod Retainer (#18).
Next, affix the Top Pulley Assembly (#49) to the Press Bar Station
Guide Rod Retainer (#18) and the Weight Stack Frame (#53) using
two Hex Head Cap Screws 3/8-16 X 3 1/4 (#101), four Flat Washers
SAE 3/8” (#93) and two Nylon Insert Lock Nuts 3/8-16 (#119).
Fully Fasten: Proceed to align and fully fasten this hardware
assembly and the previous assemblies that were left loosely
fastened. (Assemblies described in FIG. 14 and FIG. 17).
36
60
35
60
16
FIG. 19 Insert the Left Pec Dec Arm (#35) along with the Aluminum Cam Plate (#60) into the receptacle of the Front Upright (#16).
Repeat the same procedure for the Right Pec Dec Arm (#36).
Note: It is recommended to grease both axles of the Left and
Right Pec Dec Arms (#35, #36) with multi-purpose grease prior
to assembling.
15
16
119
8
119
FIG. 20 Secure the Left Pec Dec Arm (#35) into place using one
Button Head Socket Cap Screw 3/8-16 X 1 (#71), one Split Lock
Washer 3/8” (#152), and one Chrome Washer 3/8 X 1 1/2 (#74).
Repeat the same procedure for the Right Pec Dec Arm (#36).
7
Apollo Modular Gym System (Base Unit)
Assembly Instructions
49
21
A1
FIG. 21 Next, attach a Pulley 4 1/2 Rd (#67-Labeled A1) to the Top
Pulley Assembly (#49) using one Hex Head Cap Screw 3/8-16 X 2 1/2
(#99), two Flat Washers SAE 3/8” (#93), and one Nylon Insert Jam
Lock Nut 3/8-16 (#118). Next, attach the Lat Bar Holder 2 X 3 (#21) to
the Top Pulley Assembly (#49) using one Hex Head Cap Screw 3/816 X 2 3/4 (#100), two Flat Washers SAE 3/8” (#93), and one Nylon
Insert Jam Lock Nut 3/8-16 (#118).
39
49
41
FIG. 22 Using a rubber mallet, insert one Pivot Axle 1 X 8 1/8 (#39)
through the holes of the Press Bar Selector Housing (#41) and
through the receptacle of the Top Pulley Assembly (#49) until the
Pivot Axle 1 X 8 1/8 (#39) is flush with both sides of the Press Bar
Selector Housing (#41).
Note: It is recommended to grease the Pivot Axles 1 X 8 1/8
(#39) with multi-purpose grease prior to assembling.
130
39
41
42
126
126
FIG. 23 Using a rubber mallet, insert two Plastic Insert Caps 2” Sq.
(#126) into the tube-ends of the Press Bar (#42). Next, insert the
Press Bar (#42) up into the Press Bar Selector Housing (#41) and
support in into place using the Pull Pin 1/2 X 3 1/2 (#130). Next, using
a rubber mallet, insert the Pivot Axle 1 X 8 1/8 (#39) into the Press
Bar Selector Housing (#41) and through the Press Bar (#42).
150
150
150
39
41
39
150
FIG. 24 Secure the two Pivot Axles 1 X 8 1/8 (#39) to the Press Bar
Selector Housing (#41) using four Set Screws 3/8-16 X 1/2 (#150).
Use the Supplied Hex Key 3/16” (#107) for securing these Set Screws
3/8-16 X 1/2 (#150) into the threaded sockets on the Press Bar
Selector Housing (#41). Next, clean the ends of the Pivot Axles 1 X
8 1/8 (#39) and apply four 1” Rd. Silver Mylar Decals (#77–Not shown).
These decals are used to hide and protect the ends of the axles.
Apollo Modular Gym System (Base Unit)
8
A9
41
A3
A5
FIG. 25 Next, attach two Pulleys 4 1/2 Rd. (#67-Labeled A3, A5) to
the Press Bar Selector Housing (#41) using one Hex Head Cap
Screw 3/8-16 X 2 3/4 (#100), two Flat Washers SAE 3/8” (#93), and
one Nylon Insert Jam Lock Nut 3/8-16 (#118).
12
B4
153
88
30
FIG. 26 Locate the Closed-end Double Pulley Bracket (#12) and
attach two Pulleys 4 1/2 Rd. (#67-Labeled A9, B4) using two Hex Head
Cap Screws 3/8-16 X 1 3/4 (#97), four Flat Washers SAE 3/8” (#93),
and two Nylon Insert Jam Lock Nuts 3/8-16 (#118). Next, thread one
Finished Hex Nut 1/2-13 (#88) and insert one Split Lock Washer
1/2” (#153) onto the Adjustable Stopper (#30).
1
88
153
88
153
53
30
FIG. 27 Next, attach the Adjustable Stopper (#30) to the receptacle
of the Weight Stack Frame (#53) using one Split Lock Washer
1/2” (#153) and one Finished Hex Nut 1/2-13 (#88).
Loosely Fasten: Do not completely fasten this hardware assembly at this time, as it will be completely fasten once the cables have been adjusted.
9
A10
FIG. 28 Next, attach a Pulley 4 1/2 Rd. (#67-Labeled A10) to the
Weight Stack Frame (#53) using one Hex Head Cap Screw 3/8-16 X 1
3/4 (#97), two Flat Washers SAE 3/8” (#93), and one Nylon Insert Jam
Lock Nut 3/8-16 (#118).
Apollo Modular Gym System (Base Unit)
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