AMERICA’S PREMIER EXERCISE EQUIPMENT

SP-4416
LEG PRESS
ASSEMBLY MANUAL
REV. 0

85 1/2"

43 1/2"

PLATINUM L 85 1/2" W 43 1/2" H 73"

 Introduction

About the Leg Press SP-4416 Prior to the Assembly of the Leg Press
Congratulations on your new purchase of the Leg Press. We hope 1. We advise you to consult your local Tuff Stuff retailer if you should
you are completely satis ed with this product and wish you many have a question or problem regarding the proper assembly of
years of enjoyment. this unit.
T uff Stuff Equipment
This Tuffstuff product has been built to precise quality standards and Tool Requirements
has been carefully packaged to ensure that damage will not occur 1. One 7/8” combination wrench
during shipment. The TuffStuff Warranty and signature indicating 2. One 3/4” combination wrench
final inspection has been conducted by our line foreman, is an 3. One 9/16” combination wrench
expression of our con dence in the completeness, the materials, 4. One 7/16” combination wrench
and workmanship of this product. 5. One ratchet

Warranty 6. One 3/4” socket

7. One 9/16” socket
SEE A COPY OF WARRANTY ON BACK PAGE. 8. One 7/16” socket
R egistration Card
9. One rubber mallet
10. Windex or household glass cleaner
To avoid unnecessary delays in warranty service and to insure that
11. Measuring tape
a permanent record of your purchase is on le with our factory,
12. Utility knife
be sure to complete the warranty registration card and send it to
TuffStuff Fitness Equipment today.

Hardware Measurement Diagram

Specifications TH
NG
LE
1. Maximum Wt. Capacity - 300 lbs. W
RE
SC
2. Total Machine Weight - 600 lbs. ER
ET
IA M
3. Footprint (LWH) - See Front Cover. R
D
S HE
WA
ER
Note: Due to continuing product improvements, speci cations and designs are subject to change D TH ET
without notice. WI DI
AM
W T
RE NU
SC

Safety Precautions
S afety First
Regardless of how enthusiastic you may be about getting on 4. Frayed or worn cables can be dangerous and may cause injury.
your equipment and exercising, take the time to ensure that your Periodically check the cable for any indication of wear.
safety is not jeopardized. A moment’s lack of attention can result
in an accident, as can failure to observe certain simple safety 5. Use proper discretion when children are present.
precautions.
6. Keep hands, limbs, loose clothing and long hair well out of the
1. Read, study and understand the Assembly Instructions and all the way of moving parts.
warning labels on this product. Furthermore, it is recommended
to familiarize yourself and others with the proper operation and 7. Do not attempt to lift more weight than you can control safely.
workout recommendations for this Tuff Stuff product prior to
use. 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
2. It is imperative that you retain this Assembly Instructions and allow the machine to be used until the defective part is repaired
be sure all warning labels are legible and intact. Replacement or replaced.
Assembly Instructions and labels are available from your local
Tuff Stuff retailer.

3. Consult with your physician before beginning any exercise

program.

2 SP-4416 Leg Press

 Step 1

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63

SP-4416 Leg Press

3 45 66

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Step 2

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14 26 81 28

4 SP-4416 Leg Press

Step 3

51
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44 62
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9 45

53 20 80 48 15 62 44
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SP-4416 Leg Press 5

Step 4 Cable Mapping Diagram

FIG. A
12

A 79

39

82

23

18

B E

6 SP-4416 Leg Press

Step 5 Cable Mapping Diagram

FIG. B

39 80 80 39 4

A
76

64
29
12

E
D

C
B

SP-4416 Leg Press 7

Step 6

43
43

41

78

45 52
2
46 1
51

46
40

51
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51 46 55
52 45

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8 SP-4416 Leg Press

 CHART SP-4416
BOLD FONT = SUB-ASSEMBLY PARTS
REGULAR FONT = HARDWARE Parts List
ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY.

1 ADJUSTABLE BACK PAD TUBE UP5145 1 45 FLAT WASHER SAE B/O 3/8” BNH0239 24
2 BACK PAD UP5146 1 46 FLAT WASHER USS B/O 1/4” BNH0233 8
3 BOTTOM CROSS BRACE UP0909 1 47 FLAT WASHER USS B/O 3/4 X 2” BNH0878 4
4 CABLE TENSION ADJUSTER UP0917 1 48 HEX HEAD CAP SCREW GR-5 B/O 1/2 13 X 1 BNH0259 2
5 FOOT PLATE UP2014 1 49 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 3 3/8 BNH1841 4
6 FOOT PLATE BRACKET UP4016 1 50 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 4 5/8 BNH1843 2
7 FULCRUM UP0911 1 51 HEX HEAD CAP SCREW GR-5 B/O 1/4-20 X 3/4 BNH0890 8
8 FULCRUM WITH BRACKETS UP5148 1 52 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 1/2 BNH0303 4
9 GUIDE ROD 3/4 X 71 3/4 UP5142 2 53 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 1 3/4 BNH0274 7
10 GUIDE ROD RETAINER UP5068 1 55 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 1/4 BNH0312 3
11 LEFT HANDLE UP2178 1 56 HEX KEY 1/8” BNH0767 1
12 LEG PRESS CABLE UP0918 1 57 HEX KEY 3/16” BNH0371 1
13 MAIN FRAME UP5144 1 58 HEX KEY 3/32” BNH0372 1
14 PIVOT AXLE 1 X 5 7/16 UP2234 4 59 HEX KEY 5/32” BNH0373 1
15 REAR CROSS BRACE UP0910 1 60 HEX KEY 7/32” BNH0575 2
16 RIGHT HANDLE UP2179 1 61 NYLON INSERT JAM LOCK NUT B/O 3/8-16 BNH0365 5
17 SEAT PAD UP5147 1 62 NYLON INSERT LOCK NUT B/O 1/2-13 BNH0212 8
18 SELECTOR PIN W/COIL 3/8 X 4 UP3035 1 63 NYLON INSERT LOCK NUT B/O 3/8-16 BNH0214 6
19 WEIGHT SHROUD UP3650 1 64 NYLON INSERT LOCK NUT B/O 5/16-18 BNH0215 1
20 WEIGHT SHROUD W/HOLES UP5143 1 65 NYLON PULLEY 3/8 X 1 X 4 1/2 BLACK BNH0506 6
21 WEIGHT STACK FRAME 72” UP5141 1 66 PLASTIC BLACK KNOB W/NYLON STUD 1/2-13 BNH0796 1
22 WEIGHT STACK SPACER 4” UP0786 2 67 PLASTIC END CAP 2 X 3 BNH0606 2
23 10 LB TOP PLATE W/ADJ. SLTR BAR 14 WTS BNH1097 1 68 PLASTIC INSERT CAP 1 3/4” SQ 10-14 GA BNH0053 1
24 15 LB CAST WEIGHT PLATE GREY BNH0926 14 69 PLASTIC TUBE GUIDE W/LIP-TEETH 2 1/4” SQ BNH0059 2
25 ALUMINUM CAP 1” RD. (CAP-100) BNH0537 2 70 PULL PIN 1/2 X 3 1/2 LIGHT SPRING BNH0603 1
26 CHROME WASHER 3/8 X 1 1/2 BNH1015 8 71 RETAINING SNAP RING EXT 1.8865 X 2.1990 BNH1832 8
27 BALL BEARING W/GROVE 620SRS BNH1831 8 72 RUBBER BUMPER 3/8 X 2 1/2 BNH0511 1
28 BUTTON HEAD SOC CAP SCREW B/O 3/8-16 X 1 BNH0115 8 73 RUBBER DONUT 3/4 X 2 1/2 BNH0068 2
29 CLEVIS BRACKET 3/16” BNH0076 1 74 RUBBER GRIP 1 ID X .125 X 7 1/4 BNHO963 2
30 DECAL-ADJUST CABLE HERE BNH0789 2 75 RUBBER GROMMET 3/4” ID (2867-012) BNH0401 2
31 DECAL-CAUTION 1 3/4 X 5 1/2 BNH0126 1 76 SHOULDER BOLT ALLOY 3/8 X 3/4 BNH0718 1
32 DECAL-DANGER TIGHTEN..., 3/4 X 1 1/2 BNH0142 1 77 SOCKET SET SCREW 10-32 X 1/8 BNH0473 4
33 DECAL-EXERCISE SP-4416 LEG PRESS BNH1692 1 78 SOCKET SET SCREW ALLOY 1/4-20 X 1/4 BNH0790 2
34 DECAL-FOR BEST PERFORMANCE 1 1/4 X 1 1/2 BNH0143 1 79 SPLIT HEX TAP BOLT GR-5 B/O 1/2-13 X 3 1/2 BNH1131 1
35 DECAL-WARNING KEEP HANDS AND FINGERS... BNH0620 1 80 SPLIT LOCK WASHER B/O 1/2” BNH0653 5
36 DECAL-WEIGHT NUMBERS REF TP-20 (300 lbs) BNH1543 1 81 SPLIT LOCK WASHER B/O 3/8” BNH0658 9
37 EDGE PROTECTOR CHROME 11 GA BNH1724 4 82 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 3 5/8 BNH1842 2
39 FINISHED HEX NUT B/O 1/2-13 BNH0201 3 83 STEEL BUMPER WASHER Z/P 3/8” BNH0498 1
40 PLASTIC SHROUD GAP COVER 3” BNH1829 1 84 SUPER LUBE TEFLON LUBRICANT 82340 BNH0704 2
41 PLASTIC SHROUD LID 5/8 X 14 1/8 X 10 BNH0185 1 85 TUFFSTUFF LOGO ALUMINUM LARGE BNH1837 1
42 FLAT HEAD SOC CAP SCREW B/O 3/8-16 X 1 1/4 BNH0667 4 86 URETHANE BUMPER 1 3/4 BNH0229 4
43 FLAT HEAD SOCKET CAP SCREW B/O 3/8-16 X 3 BNH0787 2 87 U-STYLE TAPPED HOLE NUT 1/4-20 BNH0708 8
44 FLAT WASHER SAE B/O 1/2” BNH0238 16 88 U-STYLE TAPPED HOLE NUT 3/8-16 BNH1211 2

SP-4416 Leg Press 9

 Maintenance

TuffStuff Basic Strength Equipment Safety and General Maintenance

All TUFFSTUFF strength equipment is designed and manufactured to offer maximum, long-life service
with minimal maintenance. However, safety inspection and routine maintenance in your facility should be
the upmost importance in your daily operation. Information presented in these pages will serve as a basic
guideline to design your own inspection procedures.

Part One: General Inspection and Cleaning

Equipment should be wiped down with a damp cloth and dried on a daily basis. The powder coat nish
should be polished with a good car wax on a monthly basis. A daily wipe down of the upholstery with a lano-
lin based hand cleaner or Naugahyde Cleaner. Do not use cleaners such as Lysol or Windex as they will
dry out and crack the vinyl. Lanolin hand cleaner dissolves the sweat and lubricates the vinyl, maintaining
its natural exibility. Sweat is corrosive and when left on the frame and components will eventually cause
corrosion or rust. When performing these cleaning sessions, it is the perfect time to inspect the equipment
and note any problems for the maintenance personnel to correct.

1. Check equipment if it is operating properly.

2. Check the cable for loose ttings or frayed cable and is seating properly on the pulleys and
cams.
3. Make sure that the proper weight stack selector pin is with each machine and that the pin func-
tions properly.
4. If something appears loose be sure to have it tightened immediately.
5. If a piece of equipment appears damaged or not operation properly, place the piece out-of-ser-
vice immediately.

Part Two: Maintenance

In this paragraph, we will discuss the inspection of the cables, pulleys and their associated components. If
there exists the potential for injury to occur on a machine, it will most likely lie in the cable system. It is im-
portant to inspect the cables frequently and let it be known to all users that it is their responsibility to report
any worn-out cable to prevent a sudden failure that can result in an injury. Cables are moving parts, mean-
ing cable-wear will occur regardless of the type or size used. In the advent of the 3/16” mill-spec cable this
wear takes longer to become apparent and this is why frequent inspections are so important.

1. Check the cable termination at the weight stack. To perform any cable tension adjustment,
loosen the hex jam nut and thread the hex tap bolt in or out to give cable the proper tension.
Re-tightened the hex jam nut when adjustment is complete and make sure the hex tap bolt is
threaded 1/2” into the socket of the selector bar top plate.

2. Check the cable as it terminates at the cam. Check the end tting for any signs of fraying in this
area. Inspect the bolt and nut and/or screw holding the tting and be sure that it is tight.

3. Check the cables as it passes over all pulley wheels. Visually inspect the cables and pulleys. A
cable that is wearing will exhibit a ballooned surface that passes over the pulley. This is and early
warning sign to replace the cable.

10 SP-4416 Leg Press

 Maintenance

Part Three: Lubrication

Bearing and linear bearings systems have advanced over the years but they must be maintained on a regu-
lar basis if you expect them to last and perform ef ciently. TuffStuff uses only the highest quality bearings
and linear motion components that are virtually trouble-free but requires the regular preventive maintenance
to insure long-lasting performance.

1. Bronze and nylon bushings, we recommend on a monthly basis to spray a te on-base lubricant
(silicone-free) directly onto the shaft as it passes through these bushings. Spray a small amount
onto the shaft and rotate it through its complete movement and wipe off any excess.

2. Weight stack guide rods and bushings, again use te on spray lubricant and this time spray onto
a rag and wipe the guide rods down with this rag on a weekly basis. Do not use WD-40 or other
lubricants as they attract dirt and will crate a mess between the weight plates and bushings.

3. Sealed bearings pivot points, as the name implies are protected from the outside environment
and require no lubrication. During the machine wipe down, wipe the external bearing surfaces
with the damp rag and dried to prevent the build up of dust and sweat.

4. Linear bearing systems are precision, high load components that require regular maintenance.
Dirt and corrosion are the major culprits in linear bearing failure. The hardened shafts must be
wiped down weekly and lubricated with a light layer of te on grease. We recommend a te on-
base (silicone-free) gel/grease for this purpose. Lack of care and maintenance will result in cor-
rosion of the linear shaft causing the bearings to clogged and jammed.

If you religiously perform the maintenance procedures, you will increase the life of the machine and ulti-
mately lower your maintenance costs with fewer replaced components and downtime.

Any doubts, equipment with mechanical problems should be placed “Out-of-Service” until all problems are
corrected. If replacement parts are required or maintenance questions, please contact:

TuffStuff Fitness Equipment, Inc.

Service Department
1325 E. Franklin Avenue
Pomona, CA 91766
1-800-961-9377
e-mail: [email protected]

SP-4416 Leg Press 11

DO NOT DISCARD THIS MANUAL

TUFFSTUFF WARRANTY
TuffStuff warrants to the original purchaser that TuffStuff equipment will be free from defects in material and
workmanship. All warranty periods begin to run from the date of delivery to the original purchaser. The warranty
and remedies set forth herein are conditioned upon proper storage, installation, use and maintenance and confor-
mance with any recommendations of TuffStuff. This warranty does not cover products not manufactured by
TuffStuff or products which are altered without the express written consent of TuffStuff. This warranty as speci-
fied:
FULL COMMERCIAL WARRANTY (more than 5 hours of use per day): a) Frames, welds, cams and
weight plates -- Lifetime, b) Pivot bearings, pulleys, bushings, gas shocks and guide rods -- Five (5) years, c)
Belts, linear bearings and pull-pin components -- One (1) year, and d) Upholstery, cables, finish and rubber grips
-- Six (6) months.
LIGHT COMMERCIAL WARRANTY (less than 5 hours of use per day): a) Frames, welds, cams and weight
plates -- Lifetime, b) Pivot bearings, pulleys, bushings, gas shocks and guide rods -- Five (5) years, c) Linear
bearings, finish and pull-pin components -- One (1) year, and d) Upholstery, cables and rubber grips -- Three
(3) months, and all other parts not mentioned elsewhere in this warranty will expire one (1) year from the date of
delivery to the original purchaser. The obligation of TuffStuff under this warranty is limited to repairing or re-
placing warranted defective parts, as TuffStuff may elect, at TuffStuff’s facility in Pomona, California, without
charge to purchaser for either parts or labor. 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.

THE FOREGOING SHALL CONSTITUTE THE SOLE REMEDY OF THE PURCHASER AND THE
SOLE LIABILITY OF TUFFSTUFF WITH REGARD TO WARRANTY. NO IMPLIED STATUTORY
WARRANTY OR IMPLIED STATUTORY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE SHALL APPLY. IN NO EVENT, WHETHER AS A RESULT OF
BREACH OF CONTRACT, WARRANTY, NEGLIGENCE OR OTHERWISE, SHALL TUFFSTUFF BE
LIABLE FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT
LIMITED TO, LOSS OF PROFITS OR REVENUE, LOSS OF USE OF EQUIPMENT, COST OF CAPI-
TAL, COST OF SUBSTITUTION EQUIPMENT, DOWNTIME COST, OR CLAIMS OF CUSTOMERS
OR PURCHASER FROM SUCH DAMAGE.

This written 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 Fitness Equipment, Inc. at 1325 E. Franklin Avenue, Pomona, California 91766,
before returning any defective equipment.

TuffStuff Fitness Equipment, Inc.

1325 E. Franklin Avenue
Pomona, CA 91766, USA
Ph: 909-629-1600 Fax: 909-629-4967
E-mail: [email protected] Net: www.tuffstuff.net