Tuff stuff Tuff Gym Series TG-150 Assembly & Instruction Manual

A SSEMBLY INSTRUCTION MAN UAL

TABLE OF CONTENTS:

Introduction- Pg. 1

Assembly for TG-150- Fig. 1-71

Cable Mapping Diagram- Pg. 20

Cable Adjustments- Fig. 42, 65, Pg. 19

Exploded View Diagram- Pg. 22

Parts List- Pg. 23

Basic Exercise Chart- Pgs. 24-26

TG-150

Tuff Gym Series

A merica’s Premium Exercise Equipment

Revision Date 11-98

Revision Date 12-98

L 8’-0” W 6’-2” H 6’-5”

Introduction

About the TUFF GYM SERIES

Congratulations on your new purchase of the. TG-150,
Tuff Gym Series unit.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

Every 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 lifetime
warranty and signature indicating final inspection which was
conducted by our line foreman, is an expression of our
confidence in the completeness, the materials, and
workmanship of this product.

Warranty

SEE WARRANTY REGISTRATION CARD

Registration Card

To avoid unnecessary delays in warranty parts 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.

Safety Information

1) Familiarize yourself and others with the proper operation
and workout recommendations for each piece of Tuff Stuff
equipment prior to use.

2) Consult with your physician before beginning any
exercise program.

3) Use proper discretion when children are present.

4) Frayed or worn cables can be dangerous and may cause

injury. Periodically check these cables for any indication of
wear.

5) Inspect the TG-150 for any sign of parts or hardware
becoming loose.

6) Keep hands and limbs clear from weight stack and all
other moving parts.

Maintenance Information

1) Lubrication of all moving parts is essential to the longevity
and optimal performance of your TG-150. Initial lubrication
of some parts of your gym have been done at the factory, but
the weight stack guide rods must be lubricated at the time of
assembly. We recommend a clear aerosol, silicone or Teflon
spray.

Note: Do not use oil based lubricants as they will attract
dust,dirt, and grime and will eventually gum up and erode
bushings and sealed bearings.

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

3) Check and adjust tension on cables periodically as it will
maintain proper anatomical function.

4) 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.

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

6) All chrome plated surfaces should be cleaned regularly
to prolong the life and luster of the finish. Wipe machine
down with a damp cloth and dry thoroughly each day. At
least once a week your chrome equipment should be
polished with a commercial grade or automotive type chrome
polish.

Tool Requirements

1) Two 3/4” Open-end wrenches

2) Two 9/16” Open-end wrenches

3) One rubber mallet hammer

4) One can Silicone Spray/ Teflon Spray Lubricant

5) Snap ring pliers

6) Hex Key 5/32” (Supplied)

7) Hex Key 3/16 (Supplied)

8) Windex or household glass cleaner

9) Multi-Purpose Grease

10)

Hardware Measurement Diagram

Specifications

1) Maximum Wt. Capacity

2) Total Machine Weight

3) Footprint (LWH)

Note: Due to continuing product improvements, specifications and designs are subject to change

without notice.

1

- 200 Lbs. Fixed

- 650 Lbs.

- See Front cover

TG-150 Tuff Gym Series

FIG. 1 On a flat surface, lay the Platform (#49) down as shown.

Note: When positioning the Platform (#49), consider the complete
area surface of the TG-150. Use the overhead view on the front page
for designing your layout before assembling. Next, insert two Plastic

End Caps w/groove Sq. 2” (#48) and one Plastic End Cap w/groove 2
X 3 (#50) onto the tube-ends of the Platform (#49), as shown above.
Next, insert two Plastic Insert Caps 2 X 3 (#100) into the Platform

(#49), as shown above. Now, insert two Hard Grips .875 X 8 (#47)

onto the tube-ends of the Platform (#49), as shown above in caption.

Note: Use windex or a household glass cleaner for easy insertion of
these grips, as shown above.

FIG. 2 Next, attach one Nylon Pulley 4 1/2 Rd. (#17-Shown with
arrow) to the Platform (#49) and secure it into place using one Hex
Head Cap Screw 3/8-16 X 2 (#67), two Flat Washer SAE 3/8 (#12) and
one Nylon Insert Jam Lock Nut 3/8-16 (#74). Next, attach three Nylon
Pulleys 4 1/2 Rd. (#17) to the Platform (#49), as shown above, and
them into place using three Hex Head Cap Screws 3/8-16 X 1 3/4
(#69), six Flat Washers SAE 3/8 (#12) and three Nylon Insert Jam
Lock Nuts 3/8-16 (#74). Note: Do not completely fasten the hardware

at this time, as it will be completely secured later in the assembly
process.

FIG. 3 Next, attach the Front Frame (#57) to the Platform (#49),
as shown above, and secure it into place using two Hex Head Cap
Screws 3/8-16 X 4 (#70), four Flat Washers SAE 3/8 (#12) and two
Nylon Insert Jam Lock Nuts 3/8-16 (#74). Note: The Bench Press

Seat Tube (#62) and the Bench Press Back Pad Bracket have been

pre-assembled by the factory. Also, do not completely fasten the
hardware at this time, as it will be completely secured later in the
assembly process.

TG-150 Tuff Gym Series

FIG. 4 Next, carefully maneuver the Back Frame (#14) onto the

Platform (#49), as shown above, and secure it into place using two

Hex Head Cap Screws 3/8-16 X 4 (#70), four Flat Washers SAE 3/8
(#12) and two Nylon Insert Jam Lock Nuts 3/8-16 (#74). Note: The

Pec Dec Back Pad Bracket (#15) has been pre-assembled by the

factory.

2

FIG. 5 Continue attaching the Back Frame (#14) to the Front

Frame (#57) and secure it into place using two Hex Head Cap Screws

3/8-16 X 4 (#70), four Flat Washers SAE 3/8 (#12) and two Nylon
Insert Jam Lock Nuts 3/8-16 (#74). Note: Do not completely fasten

the hardware at this time, as it will be completely secured later in the
assembly process.

FIG. 6 Attach the Leg Extension Main Frame (#24), as shown
above, to the Platform (#49) and secure it into place using two Hex
Head Cap Screws 3/8-16 X 3 3/4 (#108), four Flat Washers SAE 3/8
(#12) and two Nylon Insert Jam Lock Nuts 3/8-16 (#74). Note: Do not

completely fasten the hardware at this time, as it will be completely
secured later in the assembly process.

FIG. 7 Next, attach one Nylon Pulley 4 1/2 Rd. (#17), as shown
above in caption, to the Leg Extension Main Frame (#24) and
secure it into place using one Hex Head Cap Screw 3/8-16 X 4 1/4
(#71), one Cable Retainer Bracket (#52), two Flat Washers SAE 3/8
(#12) and one Nylon Insert Jam Lock Nut 3/8-16 (#74). Note: Position
the Cable Retainer Bracket (#52), as shown above in caption. Next,
attach the other Nylon Pulley 4 1/2 Rd. (#17) and the Cable Retainer

Plate (#16) and secure them into place using one Hex Head Cap

Screw 3/8-16 X 1 3/4 (#69) and one Flat Washer SAE 3/8 (#12). Note:
Position the Cable Retainer Plate (#16), as shown above.

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FIG. 8 Affix the Pec Dec Seat Frame (#35) to the Back Frame

(#14) and secure it into place using two Hex Head Cap Screw 3/8-16

X 4 (#70), four Flat Washer SAE 3/8 (#12) and two Nylon Insert Jam
Lock Nuts 3/8-16 (#74). Next, attach the mid-section of the Pec Dec

Seat Frame (#35) to the Leg Extension Seat Frame (#24) and

secure it into place using two Hex Head Cap Screws 3/8-16 X 2 3/4
(#77), four Flat Washers SAE 3/8” (#12) and two Nylon Insert Jam
Lock Nuts 3/8-16 (#74). Note: Do not completely fasten the hardware

at this time, as it will be completely secured later in the assembly
process.

TG-150 Tuff Gym Series

Owners’ Manual: Assembly Instructions

FIG. 9 Locate the L-Arm (#27) and insert two Plastic Insert Cap

Rd. 2” (#98) and one Plastic Insert Cap Sq. 2” (#2) into the tube-ends,
as shown above in caption. Next, affix the Circular Plate w/Axle (#26)
with a Nylon Washer 1 X 1 1/4 (#25) through the receptacle of the L-

Arm (#27), as shown above. Note: The supplied Flat Washer 1” Nylon

(#97) may be used later in the assembly of the Actuator Arm (#20) in

Fig. 12 to relieve any side-to-side movement (if needed) with the

Circular Plate w/Axle (#26) and the Actuator Arm (#20).

FIG. 10 Next, attach the assembled L-Arm (#27) and the Circular

Plate w/Axle (#26) into the receptacle of the Leg Extension Main
Frame (#24). Note: Position the Circular Plate w/Axle (#26),as

shown above in picture. Also, the Ball Bearings #W 516 (#22) have
been pre-assembled by the factory.

FIG. 11 Locate the Actuator Arm (#20) and insert one Plastic
Insert Cap 1 X 2 (#19) into the tube-end, as shown above.

TG-150 Tuff Gym Series

FIG. 12 Next, attach the Actuator Arm (#20) onto the end of

Circular Plate w/Axle (#26), as shown above. Secure it into place

using one Roll Pin 3/8 X 1 1/2 (#18). Note: Be sure Roll Pin 3/8 X 1
1/2 (#18) is completely inserted through the hole and hammed until
one side is flush with the surface.

4

FIG. 13 Next, insert a Foam Foot Roll 1 3/4 X 4 X 16 (#28) over the

L-Arm (#27) and secure it into place using the Foot Roll Collar (#75),

as shown above. Use the supplied Hex Key 5/32” (#95) for fastening
the set screw in the Foot Roll Collar (#75). Next, insert one Plastic
Insert Cap Rd. 2” (#98-Not Shown) into the tube-end of the L-Arm

(#27).

FIG. 14 Locate the Adjustable Hold Down T-Bar (#34) and slide

two Foam Foot Rolls 1 X 4 X 7 (#31) over each end, as shown above.
Next, insert two Foot Roll Plastic End Caps 1” (#36-Not shown) into
the tube-ends of the Adjustable Hold Down T-Bar (#34). Next, insert
one Plastic Insert Cap Sq. 1 1/2 (#23) into the tube-end of the

Adjustable Hold Down T-Bar (#34), as shown above.

FIG. 15 Insert the assembled Adjustable Hold Down T-Bar (#34)

into the receptacle of the Leg Extension Main Frame (#24), as shown
above. Note: Position the Adjustable Hold Down T-Bar (#34) as

pictured above with the selector holes facing the side of the Push-Pull
Pin 3/8 (#92).

5

FIG. 16 Next, locate the Pec Dec Housing Assembly (#6) and
attach it to the Back Frame (#14), as shown above. Secure it into
place using two Hex Head Cap Screws 3/8-16 X 3 (#79), four Flat
Washers SAE 3/8 (#12) and two Nylon Insert Lock Nuts 3/8-16 (#81)

Note: Use the Exploded View Diagram on page 22 for further
illustration of this assembly.

TG-150 Tuff Gym Series

Owners’ Manual: Assembly Instructions

FIG. 17 Next, attach the two Pec Dec Swivel Pulley Brackets

(#40) to the Back Frame (#14), as shown above, and secure them

into place using two Nylon Insert Jam Lock Nuts 1/2-13 (#73) and two
Flat Washers SAE 1/2” (#72). Next, insert one Plastic Insert Cap 2 X 3
(#100) into the tube-end of the Back Frame (#14).

FIG. 18 Next, insert a Nylon Pulley 4 1/2 Rd. (#17) into the Back

Frame (#14) and secure it into place using one Hex Head Cap Screw

3/8-16 X 3 1/2 (#80), two Flat Washers SAE 3/8 (#12) and one Nylon
Insert Jam Lock Nut 3/8-16 (#74).

FIG. 19 Next, locate the two Pec Dec Arms (#1) and insert one
Plastic Insert Cap Sq. 2” (#2) into each tube-end, as shown above.

Note: The Chrome Swivel Handle (#7) and the PVC Handle (#114)
have been pre-assembled by the factory. Next, attach the Pec Dec

Cam Rt (#5) and the Pec Dec Arm (#1) into the receptacle of the Pec
Dec Housing Assembly (#6), as shown above. Note: Be sure to

position the Pec Dec Cam Rt (#5) as pictured above. Repeat the same
procedure for the Pec Dec Cam Lt (#4). Use the Exploded View
Diagram on page 22 for further illustration of this assembly.

TG-150 Tuff Gym Series

FIG. 20 Secure the Pec Dec Cam Rt (#5) and the Pec Dec Cam

Lt (#4) using two Retaining Snap Rings (#8), as pictured above. If

possible, use special snap ring pliers for this job, as shown above. If
not available, carefully work each Retaining Snap Ring (#8) into the
groove , then push down alternately with a screw driver working the
Retaining Snap Ring (#8) into the groove. Note: Be careful not to

distort the Retaining Snap Ring (#8) or bend it.

6

FIG. 21 Locate the Press Bar (#68) and insert four Hard Grips

1.220 X 6” (#66) onto each tube handle, as shown above. Use
Windex or a household glass cleaner for easy insertion of these grips.
Next, insert two Plastic Insert Caps 1 X 2 (#19) into the tube-ends, as
pictured above in caption.

FIG. 22 Next, remove the Pivot Axle 1 X 11 3/4 (#64) from the

Press Bar (#68). Remove the two Socket Set Screws 3/8-16 X 1/2

(#65) in the Press Bar (#68) using the supplied Hex Key 3/16” (#115).

FIG. 23 Attach the Press Bar (#68) to the top of the Front Frame

(#57) receptacle and secure it into place using the Pivot Axle 1 X 11
3/4 (#64). Be sure to position the Press Bar (#68) as pictured

above. Note: Use a rubber mallet hammer until the Pivot Axle 1 X 11

3/4 (#64) is flush with both sides , as shown in Fig. 24. Also, it is

recommended that you grease the Pivot Axle 1 X 11 3/4 (#64) prior to
assembly.

7

FIG. 24 Next, fasten the Pivot Axle 1 X 11 3/4 (#64) on the Press

Bar (#68) using the two Socket Set Screws 3/8-16 X 1/2 (#65) and the

supplied Hex Key 3/16” (#115).

TG-150 Tuff Gym Series

Owners’ Manual: Assembly Instructions

FIG. 25 Locate the Female Adjustment Housing (#53), Cable

Retainer Bracket (LG) (#55) and two Nylon Pulleys 4 1/2 Rd. (#17).

Assemble, as shown above, using one Hex Head Cap Screw 3/8-16 X
4 1/4 (#71), one Nylon Spacer 3/8 X 3/4 (#83), one Nylon Spacer 3/8
X 3/8 (#82), two Flat Washers SAE 3/8 (#12) and one Nylon Insert
Lock Nut 3/8-16 (#81). Refer to Fig. 72 on page 21 for further
clarification of this assembly. Note: Be sure to position the Cable

Retainer Bracket (LG) (#55), as pictured above and in Fig. 26. Also,

the Bench Press Selector Tube (#54) has been pre-assembled into
the Female Adjustment Housing (#53) by the factory.

FIG. 26 Next, attach the assembled Bench Press Selector Tube

(#54) and the Female Adjustment Housing (#53) to the Press Bar
(#68). Secure the Bench Press Selector Tube (#54) into place using

two Hex Head Cap Screws 3/8-16 X 3 (#79), four Flat Washers SAE
3/8” (#12) and two Nylon Insert Lock Nuts 3/8-16 (#81). Note: The

Black Caster 2 X 1 (#59), shown above, has been pre-assembled by
the factory.

FIG. 27 Next, attach a Nylon Pulley 4 1/2 Rd. (#17-Shown with
arrow) and a Cable Retainer Brackets (#52) to the Front Frame

(#57), as shown above. Secure it into place using one Hex Head Cap

Screws 3/8-16 X 4 3/4 (#63), two Flat Washers SAE 3/8” (#12) and
one Nylon Insert Jam Lock Nut 3/8-16 (#74). Next, attach the other
Nylon Pulley 4 1/2 Rd. (#17) and a Cable Retainer Brackets (#52)
to the Front Frame (#57) and secure it into place using one Hex Head
Cap Screw 3/8-16 X 1 3/4 (#69), two Flat Washer SAE 3/8” (#12) and
one Nylon Insert Jam Lock Nut 3/8-16 (#74). Note: Be sure to position
both Cable Retainer Brackets (#52), as pictured above.

TG-150 Tuff Gym Series

FIG. 28 Next, attach one Nylon Pulley 4 1/2 Rd. (#17) and a

Cable Retainer Brackets (#52) to the Front Frame (#57) and secure

it into place using one Hex Head Cap Screw 3/8-16 X 1 3/4 (#69), two
Flat Washer SAE 3/8” (#12) and one Nylon Insert Jam Lock Nut 3/8-16
(#74). Note: Be sure to position both Cable Retainer Brackets (#52),
as pictured above.

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