84 1/2"
OWNER’ S MANUAL
123"
RCO-140WS
Crossover Pulley W/2 X 200 Lbs
Steel Weight Stack
AMERICA’S PREMIER EXERCISE EQUIPMENT
38"
RCO-140WS Rev0
Revision Date 5-30-2007
Introduction
About the RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel
Weight Stack
Congratulations on your new purchase of the Crossover Pulley
W/2 X 200 Lbs Steel Weight Stack. We hope you are completely
satisfi ed 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. 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
TuffStuff Fitness Equipment today.
Specifi cations
1. Maximum Wt. Capacity - 2x200 lbs. Weight Stack 50% Ratio
2. Total Machine Weight - 605 lbs.
3. Footprint (LWH) - See Front Cover.
Note: Due to continuing product improvements, specifi cations and designs are subject to change
without notice.
Prior to the Assembly of the Crossover Pulley W/2 X 200 Lbs
Steel Weight Stack
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.
Tool Requirements
One 7/8” combination wrench1.
One 3/4” combination wrench2.
One 9/16” combination wrench3.
One 1/2” combination wrench4.
One ratchet5.
One 9/16” socket6.
One rubber mallet7.
Two stepladders8.
Windex or household glass cleaner9.
Measuring tape10.
Utility knife11.
Hardware Measurement Diagram
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Step 1 Assembly List
Item # Description Qty.
8 STABILIZER 2
46 PLASTIC ELLIPTICAL SHOE 4
8
46
46
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8
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2 RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
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Step 2 Assembly List
Item # Description Qty.
2 CARRIAGE 2
12 UPRIGHT 2
17 BLACK NYLON PULLEY 3/8 X 1 X 4 1/2 2
29 FLAT WASHER SAE 3/8” 8
30 HEX HEAD CAP SCREW 3/8-16 X 1 4
34 HEX HEAD CAP SCREW 3/8-16 X 4 1/2 2
44 NYLON INSERT JAM LOCK NUT 3/8-16 2
61 SPLIT LOCK WASHER 3/8” 4
Note: Exert caution when
inserting the Carriages
onto the Uprights12.
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30
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3RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
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Step 3 Assembly List
Item # Description Qty.
3 CHIN-UP HANDLE 1
9 TOP CROSS BRACE 2
10 TOP CROSS BRACE CONNECTOR PLATE 1
29 FLAT WASHER SAE 3/8” 16
35 HEX HEAD CAP SCREW 3/8-16 X 4 1/4 4
36 HEX HEAD CAP SCREW 3/8-16 X 5 4
44 NYLON INSERT JAM LOCK NUT 3/8-16 8
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Caution: It is strongly recommended
that at least two persons participate in
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this assembly.
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Note: To facilitate the assembly, use
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two stepladders.
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Step 4 Assembly List
Item # Description Qty.
17 BLACK NYLON PULLEY 3/8 X 1 X 4 1/2 4
29 FLAT WASHER SAE 3/8” 20
31 HEX HEAD CAP SCREW 3/8-16 X 1 3/4 2
33 HEX HEAD CAP SCREW 3/8-16 X 2 3/4 4
36 HEX HEAD CAP SCREW 3/8-16 X 5 4
44 NYLON INSERT JAM LOCK NUT 3/8-16 10
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4 RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
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Step 5 Assembly List
Item # Description Qty.
6 GUIDE ROD 3/4 X 80 4
7 SELECTOR PIN W/COIL 3/8 X 4 2
11 TOP PLATE PULLEY BRACKET 2
13 10 LB STEEL WEIGHT PLATE BLACK 38
14 10 LB TOP PLATE SLTR BAR 2
17 BLACK NYLON PULLEY 3/8 X 1 X 4 1/2 2
25 DECAL-WEIGHT NUMBERS REF TP-10 2
26 FINISHED HEX NUT B/O 1/2-13 2
29 FLAT WASHER SAE 3/8” 4
31 HEX HEAD CAP SCREW 3/8-16 X 1 3/4 2
44 NYLON INSERT JAM LOCK NUT 3/8-16 2
51 RUBBER DONUT 3/4 X 2 1/2 4
60 SPLIT LOCK WASHER 1/2” 2
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5RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
Step 6 Assembly List
Item # Description Qty.
29 FLAT WASHER SAE 3/8” 8
32 HEX HEAD CAP SCREW 3/8-16 X 2 1/2 4
44 NYLON INSERT JAM LOCK NUT 3/8-16 4
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6
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6
6
Note: Lift the Guide Rods
6
6
to allow the insertion of the
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Hex Head Cap Screws
.
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6 RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
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COLOR CHART
BOLD FONT = SUB-ASSEMBLY PARTS
BLACK= HARDWARE
RCO-140WS
Parts List
REV0
ITEM DESCRIPTION REV PART NO. QTY ITEM DESCRIPTION PART NO. QTY
1 ADJUSTABLE CABLE BOLT 0 UP1050 2
2 CARRIAGE 0 UP3966 2
3 CHIN-UP HANDLE 0 UP3967 1
4 CROSSOVER CABLE 0 UP3968 2
5 DOUBLE SWIVEL PULLEY BRACKET 0 UP2448 2
6 GUIDE ROD 3/4 X 80 0 UP3969 4
7 SELECTOR PIN W/COIL 3/8 X 4 0 UP3035 2
8 STABILIZER 0 UP3970 2
9 TOP CROSS BRACE 0 UP3971 2
10 TOP CROSS BRACE CONNECTOR PLATE 0 UP3972 1
11 TOP PLATE PULLEY BRACKET 0 UP1049 2
12 UPRIGHT 0 UP3973 2
13 10 LB STEEL WEIGHT PLATE BLACK 4 9/16 X 9 7/16 BNH1650 38 45 NYLON INSERT LOCK NUT Z/P 5/16-18 BNH2056 4
14 10 LB TOP PLATE W/22" SLTR BAR 19 BLK WTS BNH2020 2 46 PLASTIC HORIZONTAL ELLIPTICAL SHOE BNH1847 4
15 ALUMINUM CAP 1.270" RD (CAP -125) BNH0538 4 47 PLASTIC INSERT CAP 2 X 3 BNH0052 4
16 BLACK NYLON PULLEY 3/8 X 1 X 3 1/2 BNH0553 4 48 PLASTIC INSERT CAP ELLIPTICAL 2 X 4 BNH1794 4
17 BLACK NYLON PULLEY 3/8 X 1 X 4 1/2 BNH0506 8 49
18 BRONZE BUSHING 1/2 X 5/8 X 1/2 X 7/8 X 1/8 BNH0528 4 50 PULL PIN 1/2 X 2 7/8 (YELLOW) BNH0641 2
19 DECAL-ADJUST CABLE HERE BNH0789 2 51 RUBBER DONUT 3/4 X 2 1/2 BNH0068 4
20 DECAL-CAUTION WEIGHT TRAINING SAFETY... BNH0126 1 52 RUBBER GRIP 1.1875 ID X .125 X 15 BNH2075 2
21 DECAL-DANGER TIGHTEN THIS RET… BNH0142 2 53 RUBBER GRIP 1.1875 ID X .125 X 6 1/2 BNH1063 2
22 DECAL-FOR BEST PERFORMANCE BNH0143 2 54 RUBBER GRIP 1/2 X 3 1/2 BNH1221 2
23 DECAL-IMPORTANT CHECK CABLES FOR PROPER... BNH1891 2 55 RUBBER GROMMET 3/4" ID (2867-012) BNH0401 4
24 DECAL-IMPORTANT FOR BEST PERFORMANCE... BNH1894 2 56 SHOULDER BOLT ALLOY 3/8 X 3/4 BNH0718 4
25 DECAL-WEIGHT NUMBERS REF TP-10 (200 lbs) BNH1542 2 57 SNAP LINK Z/P 8MM X 80MM BNH0065 3
26 FINISHED HEX NUT B/O 1/2-13 BNH0201 6 58 SOCKET SET SCREW ALLOY 10-32 X 1/8 BNH0473 10
27 FLAT PHILLIPS SCREW ZINC # 2 X 1/2 BNH1480 2 59 SOCKET SET SCREW ALLOY 3/8-16 X 3/4 BNH0476 2
28 FLAT WASHER SAE Z/P 1/2" BNH2031 6 60 SPLIT LOCK WASHER Z/P 1/2" BNH0572 4
29 FLAT WASHER SAE Z/P 3/8" BNH2030 64 61 SPLIT LOCK WASHER Z/P 3/8" BNH2032 4
30 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 1 BNH2037 4 62 STRAP BRACKET 20 #SF20 BNH0562 2
31 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 1 3/4 BNH2040 8 63 TUFFSTUFF LOGO ALUMINUM SMALL BNH1323 1
32 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 2 1/2 BNH2044 4 64 COIL CHAIN Z/P 3/16 X 12 BNH2055 1
33 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 2 3/4 BNH2045 4
34 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 4 1/2 BNH2052 2
35 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 4 1/4 BNH2074 4
36 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 5 BNH2051 8
37 HEX KEY 3/16" BNH0371 1
38 HEX KEY ALLOY 3/32" BNH0373 1
39 LEATHER ANKLE STRAP (PART # H900A) BNH1231 1
40 LITHIUM GREASE SMALL CONTAINER BNH0705 1
41 NYLON BALL W/THREADED SOCKET 1 3/4 X 5/16 BNH0022 2
42 NYLON D HANDLE (# H834A) BNH1215 2
43 NYLON INSERT JAM LOCK NUT Z/P 1/2-13 BNH2027 2
44 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 BNH2026 30
PLASTIC INSERT ELLIPTICAL GUIDE (60 X 120 X 50 m
BNH2062 4
9RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
RCO-140WS Cable Routing Diagram
D
Step 7 Assembly List
Item # Description Qty.
4 CROSSOVER CABLE 2
41 NYLON BALL 1 3/4 X 5/16 2
42 NYLON D HANDLE (# H834A) 2
45 NYLON INSERT LOCK NUT 5/16-18 4
B
56 SHOULDER BOLT ALLOY 3/8 X 3/4 4
57 SNAP LINK 8MM X 80MM 2
59 SOCKET SET SCREW 3/8-16 X 3/4 2
62 STRAP BRACKET 20 #SF20 2
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RCO-140WS Exploded View Diagram
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RCO-140WS Crossover Pulley W/2 X 200 Lbs Steel Weight Stack
DO NOT DISCARD THIS MANUAL
HOME LIFETIME WARRANTY
TuffStuff products are warranted to the retail purchaser to be free from defects in materials and workmanship.
TuffStuff exclusive Home Lifetime Warranty coverage extends for the life of the product while owned by the
original retail purchaser, and used only in a home or residential setting unless otherwise noted in the owner’s
manual.
This warranty does not cover:
1. TuffStuff products sold for and used in a commercial or institutional setting.
2. Any damage, failure or loss caused by accident, misuse, neglect, abuse, improper assembly, improper
maintenance, or failure to follow instructions or warnings in the owner’s manual and warning labels
posted on the machine.
3. Use of products in a manner for which they were not designed.
4. Original product that is altered, or the use of replacement parts and components of another manufacturer other than TuffStuff.
Limitations:
The foregoing shall constitute the sole remedy of the purchaser and the sole liability of TuffStuff with regard to
warranty, whether express or implied by operation of law or otherwise, including but not limited to any implied
warranties of merchantability or fitness. TuffStuff shall in no event be liable for incidental or consequential
losses, damages or expenses in connection with exercise products. TuffStuff’s liability hereunder is expressly
limited to the repairs or replacements of warranted defective parts.
Procedures:
Warranty service will be performed at TuffStuff’s facility in Pomona, California. TuffStuff will have the option of
either repair or replacement at no charge for any defective product. Purchaser is responsible for installation of
repaired or replaced parts and all transportation and insurance costs on returned or replaced equipment to and
from TuffStuff’s facility in Pomona.
This warranty gives you specific legal rights and you may also have other rights, which may vary from state to
state. Effective July 1, 2004.
This warranty is the final, complete and exclusive agreement of the parties with respect to the quality or performance of the equipment
and no action for breach of this written warranty or any implied warranty shall be commenced more than one (1) year after the accrual
of the cause of action. No modification of this warranty or waiver of its terms shall be binding on either party unless approved in
writing by an authorized representative of the party. Contact TuffStuff at 1325 E. Franklin Avenue, Pomona, California 91766, before
returning any defective equipment.
Note: Retain your sales receipt and be sure to mail in the warranty registration card to insure that a
permanent record of your purchase is on file with the factory and to avoid unnecessary delays in
warranty service.
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
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