TuffStuff BRT-1 Owner's Manual
OWNER’ S MANUAL
TABLE OF CONTENTS:
Introduction - Pg. 1
Safety Precautions - Pg. 2
Assembly for BRT-1 - Pg. 3 - Pg. 17
Cable Adjustments - Pg. 18
Cable Mapping Diagrams
Pg. 19 - Pg. 20
Parts List - Pg. 21
Exploded View Diagram
Fold-Out Pg. 22
Adjustment Features - Pg. 23- Pg. 25
Basic Exercises - Pg. 26
Maintenance - Pg. 27
Warranty - Back Page
BRT-1
“The Brute” Plate Loaded
Home Gym
Revision Date 02-05-02
99”
63”
America’s Premium Exercise Equipment
© 2003 TASK INDUSTRIES, INC.
L 99” W 63” H 83”
-
Introduction
N
About the Plate Loaded Home Gym (BRT-1)
Congratulations on your new purchase of the “The Brute” Plate
Loaded Home Gym (BRT-1). This gym is capable of a variety of
different exercises, as well as, smooth and user-friendly adjustment
features. In addition, this gym has been designed to meet the
needs and performance requirements for a suitable home exercise
machine. We hope you are completely satisfied with this product
and wish you many years of enjoyment.
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.
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 signature
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 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.
2. Total Machine Weight - 350 Lbs.
3. Footprint (LWH) - See Front Cover
About 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
NOTE:
CAUTION
LOOSELY FASTEN
FULLY FASTE
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.
Prior to the Assembly of the BRT-1
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 Home Gym.
2. Consider the complete surface area of the BRT-1. Use the
overhead view on the front page for designing your layout before
assembling. Once the BRT-1 has been fully assembled it will be
heavy and difficult to move, therefore you should assemble the it
in the area where it is to be used upon completion.
3. It is strongly recommended that another person assist you with
the assembly of this unit.
4. Neatly organize and identify all parts according to the Parts List
on page 21 and the Exploded View Diagram on fold-out page 22.
Tool Requirements
1. One 9/16” combination wrench
2. One 3/4” combination wrench
3. One 7/8” combination wrench
4. One 1/2” combination wrench
5. Two 7/16” combination wrenches
6. One ratchet
7. One 9/16” socket
8. One 3/4” socket
9. One 3/8” drive extension
10. One rubber mallet
11. Long-Reach Needle-Nose Pliers
12. Windex or household glass cleaner
13. Multi-purpose grease
14. Measuring tape
15. Utility knife
Assembly 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 this
assembly.
Hardware Measurement Diagram
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
BRT-1 “The Brute” Plate Loaded Home Gym
Safety Precautions
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
simple 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
Owner’s Manuals 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.
Weight Plates
CAUTION
Fig. 1 Caution: Remove weight(s) on the Press Arms (#8, #9) before
releasing Turn/Pull Pin (#42) for any kind of height adjustments. Use the
Ring-Grip Self-Locking Pins (#98) at all times in case of accidental releasing of the Turn/Pull Pins (#42).
Olympic Weight
Plates
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 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.
9. Remove weight(s) on the Press Arms (#8, #9) before releasing Turn/Pull Pin (#42) for any kind of height adjustments. Use the Ring-Grip Self-Locking Pin (#98) at all
times to prevent the Press Arms (#8, #9) from falling beyond this point in case of accidental releasing of the Turn/
Pull Pins (#42). Refer to Fig. 1 for further illustration of this
instruction.
10.Secure the weight plates using collars to prevent the
weight plates from falling off the weight prongs of the Car-
riage (#10). Refer to Fig. 2 for further illustration of this
instruction.
Olympic Weight
Collar
CAUTION
Fig. 2 Caution: Use collars to prevent the weight plates from falling off
the weight prongs of the Carriage (#10)
11.Pay special attention to the Turn/Pull Pins w/Knob (#42)
and the Push Pull Pins (#43). Be sure they are fully
engaged into the selected holes of their corresponding assemblies. Refer to Fig. 3 for further illustration of this instruction.
BRT-1 “The Brute” Plate Loaded Home Gym
Turn/Pull Pin w/Knob
CAUTION
Fig. 3 Caution: Check the Turn/Pull Pins w/Knob (#42) and the
Push Pull Pins (#43) to be fully engaged into the selected holes of their
corresponding assemblies.
Fully Engaged
Push Pull Pin
Fully Engaged
2
FIG. 4 Using a rubber mallet, insert two Plastic Insert Caps w/Groove 3
x 2 (#54) onto the bottom tube-ends of the Base Frame (#1). Next, insert
one Plastic Insert Cap 2 x 3 (#59) into the top tube-end of the Base
Frame (#1).
Note: When positioning the Base Frame (#1) consider the
complete area surface of the BRT-1. Use the overhead view on
NOTE:
the cover page for designing your layout before assembling.
FIG. 5 Affix the Left and Right Triangular Reinforcement Plates (#2,
#113) to the Base Frame (#1), in the position as shown above, and se-
cure them into place using two Hex Head Cap Screws 1/2-13 X 3 1/4
(#69), four Flat Washers SAE 1/2” (#68), and two Nylon Insert Lock Nuts
1/2-13 (#74).
Loosely Fasten: Do not completely fasten this hardware assembly
at this time, as it will be completely fastened later in the assembly
LOOSELY FASTEN
process.
FIG. 6 Insert the Foot Support Tube (#3) half way through the receptacle of the two Triangular Reinforcement Plates (#2, #113), as shown
above.
3
FIG. 7 Locate the two Stabilizers (#4), and using a rubber mallet, insert two Plastic End Caps w/Groove 3 X 2 (#54) onto the bottom tubeends. Next, insert two Plastic Insert Caps 2” Sq. (#58) into the top tubeends of the Stabilizers (#4).
Note: The Press Arm Holders (#6) have been assembled to the
Stabilizers (#4).
NOTE:
BRT-1 “The Brute” Plate Loaded Home Gym
Owner’s Manual: Assembly Instructions
FIG. 8 Affix the two Stabilizers (#4) to the Triangular Reinforcement
Plates (#2, #113) and the Base Frame (#1), in the position as shown
above, and secure them into place using two Hex Head Cap Screws 1/213 X 4 (#71), four Flat Washers SAE 1/2” (#68), and two Nylon Insert Lock
Nuts 1/2-13 (#74).
3 3/8”
FIG. 9 Secure the Foot Support Tube (#3) to the Triangular Rein-
forcement Plates (#2, #113), and the two Stabilizers (#4) using four Hex
Head Cap Screws 3/8-16 X 2 3/4 (#80), eight Flat Washers SAE
3/8” (#84), and four Nylon Insert Jam Lock Nuts 3/8-16 (#85).
FIG. 10 Remove the backing of the two Safety Anti-Slip Tape 4 X 10
(#40) strips. Next, attach the two Safety Anti-Slip Tape 4 X 10 (#40) to the
Foot Support Tube (#3), in the position as shown above.
Note: To facilitate the alignment of the strips across the Foot sup-
port Tube (#3), use a measuring tape. The measurement from the
NOTE:
edge of the Triangular Reinforcement Plate (#2, or #113) to the
inner edge of the Safety Anti-Slip Tape (#40), as picture above,
should be about 3 3/8”
BRT-1 “The Brute” Plate Loaded Home Gym
FIG. 11 Mount the Base Frame Handles (#37) to the Base Frame (#1)
and secure them into place using one Hex Head Cap Screw 3/8-16 X 2
3/4 (#80), two Flat Washers SAE 3/8” (#84), and one Nylon Insert Jam
Lock Nut 3/8-16 (#85).
4
FIG. 12 Caution: It is strongly recommended to use another per-
son in assisting with this assembly.
CAUTION
Insert the Main Frame (#5) between the two Triangular Reinforcement
Plates (#2, #113), in the position as shown above. Next, secure the Main
Frame (#5) to the Triangular Reinforcement Plates (#2, #113) using
three Hex Head Cap Screws 1/2-13 X 3 1/4 (#69), six Flat Washers SAE
1/2” (#68), and three Nylon Insert Lock Nuts 1/2-13 (#74).
FIG. 13 Insert a Nylon Pulley 4 1/2 Rd. (#64-Labeled E) into the pulley
bracket located on the Main Frame (#5) and secure it into place using one
Hex Head Cap Screw 3/8-16 X 3 (#81), two Flat Washers SAE 3/8” (#84),
and one Nylon Insert Lock Nut 3/8-16 (#83).
Note: The black boxed letter pointing to the pulleys are used
throughout this manual as reference to the Cable Mapping Dia-
NOTE:
gram on page 20. These black boxed letters will be primarily used
for locating certain pulleys during the cable routing process beginning with Fig. 13.
FIG. 14 Confine the Arm Holders (#6) within the Stabilizer’s (#4) tubes
using two Hex Head Cap Screws 3/8-16 X 2 1/2 (#79), and two Nylon Insert Jam Lock Nuts 3/8-16 (#85).
5
FIG. 15 Rest the Right Press Arm (#9) on the corresponding Arm
Holder (#6) and affix it to the Main Frame (#5) using one Hex Head Cap
Screw 1/2-13 X 5 1/2 (#73), two Flat Washers SAE 1/2” (#68), and one
Nylon Insert Jam Lock Nut 1/2-13 (#75). Repeat the same procedure for
the Left Press Arm (#8).
BRT-1 “The Brute” Plate Loaded Home Gym
Owner’s Manual: Assembly Instructions
FIG. 16 Using a rubber mallet, insert three Plastic Insert Caps 2” Sq.
(#58) into the tube-ends of the Weight Carriage (#10).
FIG. 17 Using the two supplied Hex Keys 7/32” (#74), remove the Pivot
Axle 1 X 8 1/8 (#7) from the Main Frame (#5).
FIG. 18 Attach the Weight Carriage (#10) to the Main Frame (#5), in
the position as shown above. Next, using a rubber mallet, insert the Pivot
Axle 1 X 8 1/8 (#7) through the holes of the Weight Carriage (#10) and
the receptacle of the Main Frame (#5) until it is flush with both sides of the
Weight Carriage (#10).
BRT-1 “The Brute” Plate Loaded Home Gym
FIG. 19 Secure the Weight Carriage (#10) to the Pivot Axle (#7) using
two Chrome Washers 3/8 X 1 1/2 (#95), two Split Lock Washers
3/8” (#97), and two Button Socket Cap Screws 3/8-16 X 1 (#96). Use the
two supplied Hex Keys 7/32” (#94) to fasten this assembly properly.
6
FIG. 20 Using a rubber mallet, insert three Plastic Insert Caps 1 3/4” Sq.
(#57) into the tube-ends of the Leg Extension Arm (#18). Next, attach
the Rubber Bumper 3/8 X 1 1/2 (#53) to the Leg Extension Arm (#18) using one Hex Head Cap Screw 3/8-16 X 1 1/4 (#76).
Note: The Adjustable Foot Roll Tubes (#20) have been assembled to the Leg Extension Arm (#18).
NOTE:
FIG. 21 Affix the Leg Extension Arm (#18), in the position as shown
above, to the Base Frame (#1) and secure it into place by inserting the
Leg Extension Axle 1/2 X 2 3/4 (#19) through the Base Frame (#1) hole
and the Leg Extension Arm (#18) receptacle until it becomes flush with
both sides of the Base Frame (#19).
FIG. 22 Secure the Leg Extension Axle 1/2 X 2 3/4 (#19) to the Base
Frame (#1) using two Set Screws 1/4-20 X 3/8 (#41). Use the supplied
Hex Key 1/8” (#93) to fasten these Set Screws.
7
FIG. 23 Attach the Lat Bar Holder (#30), in the position as shown
above, to the Main Frame (#5) and secure it into place using one Hex
Head Cap Screw 3/8-16 X 2 3/4 (#80), two Flat Washers SAE 3/8” (#84),
and one Nylon Insert Jam Lock Nut 3/8-16 (#85).
BRT-1 “The Brute” Plate Loaded Home Gym
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