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TuffStuff THL-78, Assembly Instructions Manual

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TuffStuff THL-78 Assembly Instructions Manual Download Page 13

THL-78

Parts Lis

t

Item

Description

Part No.

Qty

Item

Description

Part No.

Qty

19

CENTER UPRIGHT

UP2212

1

8

4

HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 3/4

BNH0278

3

20

TOP ASSEMBLY

UP2210

1

8

5

HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3

BNH0282

1

21

LAT BAR HOLDER

UP2215

1

8

6

HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4

BNH0312

2

22

TOP GUIDE ROD RETAINER

UP2214

1

8

7

HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 4

BNH0285

2

23

GUIDE ROD 3/4 X 72 5/8

UP2211

2

8

8

HEX KEY 3/16"

BNH0371

1

24

BOTTOM ASSEMBLY HOLDER

UP0536

1

9

1

LAT BAR CHROME 48"

BNH0295

1

25

ADJUSTABLE FOOT SUPPORT

UP2213

1

9

3

L-LOCKING PIN

BNH0045

1

26

ADJUSTABLE PULLEY PLATE 1/8 X 2 X 9

UP0092

2

9

4

LOW ROW BAR 20"

BNH0294

1

27

TOP CABLE ADJUSTER BRACKET

UP0552

1

9

5

NYLON BALL 1 3/4 X 1/4

BNH0047

2

28

LAT CABLE

UP2216

1

9

6

NYLON BUSHING 

BNH0532

4

29

LOW ROW CABLE

UP2217

1

9

9

NYLON INSERT LOCK NUT 3/8-16

BNH0214

5

30

CARRIAGE

UP0540

1

100

NYLON INSERT JAM LOCK NUT 3/8-16

BNH0365

9

31

SPACER TUBE 

UP0549

2

101

NYLON INSERT LOCK NUT 1/2-13

BNH0212

1

32

LEG HOLD-DOWN TUBE

UP0266

1

102

NYLON INSERT LOCK NUT 5/16-18

BNH0203

1

33

FOOT ROLL TUBE

UP0053

1

105

NYLON PULLEY 4 1/2 RD.

BNH0556

6

57

COIL CHAIN 3/16 X 21"

BNH0017

1

108

PLASTIC INSERT CAP 1 3/4" SQ.

BNH0053

1

58

DECAL-ADJUST CABLE HERE

BNH0789

2

109

PLASTIC INSERT CAP 1 7/8" RD. 

BNH0003

2

60

DECAL-CAUTION LAT BAR HOLDER 5 X 1

BNH0140

1

110

PLASTIC INSERT CAP 1 X 2

BNH0008

2

61

DECAL-DANGER TIGHTEN THIS RET..., 3/4 X 1-1/2

BNH0142

1

111

PLASTIC INSERT CAP 1" RD.

BNH0002

4

62

DECAL-FOR BEST PERFORMANCE 1-1/4 X 1-1/2

BNH0143

1

112

PLASTIC INSERT CAP 2 X 3

BNH0052

2

63

DECAL-LARGE TUFFSTUFF LOGO DIAMOND SHAPE

BNH0360

2

113

PLASTIC INSERT CAP 2" RD.

BNH0004

2

66

FINISHED HEX NUT 1/2"

BNH0201

1

118

PUSH-PULL PIN 1/2"

BNH0542

1

69

FLAT WASHER B/O 3/4 X 2"

BNH0878

4

123

RUBBER DONUT 3/4 X 2 1/2

BNH0068

2

7

0

FLAT WASHER SAE 1/2"

BNH0238

2

1

2

4

RUBBER GROMMET 3/4" ID (2867-012)

BNH0401

2

7

1

FLAT WASHER SAE 3/8"

BNH0239

2

8

1

2

6

SHOULDER BOLT 3/8 X 3/4

BNH0718

1

72

FOAM FOOT ROLL 7 X 4 X 1

BNH0043

2

127

SNAP LINK 8MM X 80MM

BNH0065

3

73

FOOT ROLL PLASTIC END CAP 1"

BNH0397

2

130

SPLIT BOLT Z/P 1/2-13 X 1

BNH0479

1

82

HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 

3/4

BNH0274

4

132

SPLIT LOCK Z/P 1/2"

BNH0572

1

83

HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 2 

1/2

BNH0276

2

136

STRAP 

BRACKET #20

BNH0562

1

THL-78_Rev2

COLOR CHART

GRAY= SUB-ASSEMBLY PARTS

BLACK= HARDWARE

High/Low Pulley System

13

Summary of Contents for THL-78

Page 1: ...Pg 13 Exploded View Diagrams Pg 12 Pg 14 Warranty Back Page High Low Pulley System Smith Half Cage Option Includes Assembly for THL 78WS High Low Pulley w 200 Lbs Weight Stack THL 78 High Low Pulley...

Page 2: ...able Foot Support 25 into the receptacle o the Bottom Assembly Holder 24 Caution It is strongly recommended to use another person in assisting with the following assembly Assembly steps only for THL 7...

Page 3: ...123 23 137 51 51 49 50 133 133 137 34 137 34 69 23 24 23 69 69 23 69 31 23 LABEL FIG 6 Attach the Decal Weight Numbers 133 to the Weight Plate 50 49 51 in the corresponding order Begin with the 15 at...

Page 4: ...of the Rubber Donuts 123 Note Be sure the Label on the Carriage 30 is facing out as shown above before sliding the Carriage 30 onto the Guide Rods 23 IG 11 Mount the Top Assembly 20 to the Smith Half...

Page 5: ...Washers SAE 3 8 71 and on Nylon Insert Jam Lock Nut 3 8 16 100 Next thread one Finishe Hex Nut 1 2 13 66 and insert one Flat Washer SAE 1 2 70 to th threaded bolt of the Top Cable Adjuster Bracket 27...

Page 6: ...28 up and over the Nylon Pulley 4 1 2 Rd 105 abeled A then through the Top Assembly s 20 tube Next pull he Lat Cable 28 down through the slot on the bottom side of the Top Assembly 20 Caution Do not p...

Page 7: ...the Lat Cable 28 to the Top Plate Selector Bar 137 using one Split Bolt 1 2 13 X 1 130 and one Split Lock Washer 2 132 Refer to Fig B on page 9 for further illustration of this ssembly Fully Fasten Pr...

Page 8: ...le of the Leg Hold Down Tube 32 then insert two Foam Foot Rolls 7 X 4 X 1 72 over the ube ends of the Foot Roll Tube 33 as shown above Note Use Windex or household glass cleaner for easy insertion of...

Page 9: ...ey System 9 28 130 132 137 126 91 127 FIG A FIG B 29 85 FIG C 102 136 95 28 71 19 71 99 111 91 111 B D C A 111 94 127 57 127 29 111 E F THL 78WS CABLE MAPPING DIAGRAM Note Some parts have been cut awa...

Page 10: ...0 126 91 127 FIG A FIG B 29 85 FIG C 102 136 95 28 71 19 71 99 111 91 111 B D C A 111 94 127 57 127 29 111 E F THL 78 CABLE MAPPING DIAGRAM High Low Pulley System 10 Note Some parts have been cut away...

Page 11: ...TE BNH0904 9 108 PLASTIC INSERT CAP 1 3 4 SQ BNH0053 1 50 15 LB WEIGHT PLATE BNH0926 5 110 PLASTIC INSERT CAP 1 X 2 BNH0008 2 51 5 LB WEIGHT PLATE BNH0927 5 111 PLASTIC INSERT CAP 1 RD BNH0002 4 57 CO...

Page 12: ...110 124 124 70 66 27 100 71 71 82 105 100 71 26 105 26 71 82 82 71 105 71 100 23 23 112 112 71 82 105 86 71 86 71 71 100 19 84 71 105 71 83 71 100 24 71 99 71 113 25 113 118 73 72 108 72 73 33 93 32...

Page 13: ...LL TUBE UP0053 1 105 NYLON PULLEY 4 1 2 RD BNH0556 6 57 COIL CHAIN 3 16 X 21 BNH0017 1 108 PLASTIC INSERT CAP 1 3 4 SQ BNH0053 1 58 DECAL ADJUST CABLE HERE BNH0789 2 109 PLASTIC INSERT CAP 1 7 8 RD BN...

Page 14: ...124 124 70 66 27 100 71 71 82 105 109 109 30 100 71 26 105 26 71 82 82 71 105 71 100 23 23 123 69 31 123 69 31 96 69 112 112 71 82 105 86 71 86 71 71 100 19 84 71 105 71 83 71 100 24 71 99 71 113 25...

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