Tuff stuff SBU-400 User manual

76 1/2"
70 1/2"
L 70 1/2" W 76 1/2" H 82 1/2"
ASSEMBLY INSTRUCTIONS
TABLE OF CONTENTS:
Introduction
Pg. 2
Safety Precautions
Pg. 3 - Pg. 4
Assembly Instructions
Pg. 5 - Pg. 9
SBU-400 Exploded View Diagram
Pg. 10
SHS-410 Exploded View Diagram
Pg. 11
SLS-420 Exploded View Diagram
Pg. 12
Decal Placement
Pg. 13
Decal Reference
Pg. 14
Warranty
Back Page
Smith-Half Cage Series
Includes Assembly for:
SBU-400
Base Unit Kit
SHC-410
Half Cage Conversion Kit
SLS-420
Linear Bearing Press System Kit
Revision Date 05-10-06
America’s Premier Exercise Equipment
SBU-400 Rev1

2Smith-Half Cage Series
About the Smith-Half Cage Series
Congratulations on your new purchase of the Smith-Half Cage
Series. 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.
TuffStuff 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 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.
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
TuffStuff Fitness Equipment today.
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.
Prior to the Assembly of the Smith-Half Series
1. We advise you to consult your local TuffStuff retailer if you should
have a question or problem regarding the proper assembly of
this unit.
2. Consider the complete surface area of the Smith-Half Cage
Series. Use the overhead view located on the front page for
designing your layout before assembling. Once the Smith-Half
Cage Series has been fully assembled it will be heavy and
difficult to move, therefore you should assemble the unit in the
area where it is to be used upon completion.
3. It is recommended that another person assist you with the
assembly of this unit.
4. Neatly organize and identify all parts according to the Parts List
and the Exploded View Diagrams.
Tool Requirements
1. One 3/4” combination wrench
2. One 9/16” combination wrench
3. One ratchet
4. One 3/4” socket
5. One 9/16” socket
6. One rubber mallet
7. Measuring tape
8. Utility knife
Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.
Specifications
SBU-400 SHC-410 SLS-420
1. Maximum Wt. Capacity N/A 400 lbs. 300 lbs.
2. Total Machine Weight 220 lbs. 40 lbs. 80 lbs.
3. Footprint (LWH) - See Front Cover
SCREWW
IDTH
WASHERDIAMETER
NUTDIAMETER
SCREWLENGTH
Hardware Measurement Diagram

3
Smith-Half Cage Series
Safety 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 Assembly Instructions 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 TuffStuff product prior to use. Some of
this information can be obtained in this Assembly Instructions, as-
well-as from your local TuffStuff Retailer.
2. It is imperative that you retain this Assembly Instructions and be
sure all warning labels are legible and intact. Replacement of the
Assembly Instructions and labels are available from your local
TuffStuff Retailer.
3. Consult with your physician before beginning any exercise
program.
4. Use proper discretion when children are present.
5. Keep hands, limbs, loose clothing and long hair well out of the way
of moving parts.
6. Do not attempt to lift more weight than you can control safely.
7. Inspect the Smith-Half Cage 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 defective part is repaired
or replaced.
8. The Press Bar (#12) has a swivel locking mechanism that allows
you to safely lock out the Press Bar (#12) at virtually any setting.
See Fig. A.
9. If you are adding or storing weight plates on the Olympic Adapters
(#10), do not over-load them. Allow enough space for weight collars.
See Fig. B
10. Pay special attention to the Turn/ Pull Pins w/Knob (#134) located
on the Bar Holders (#9) and the Bar Safety Spotters (#7, #8). Be
sure they are fully engaged into the selectorized holes of the Front
Uprights (#3). Refer to Fig. C for further illustration.
Fig. C Caution: Check that all Turn/Pull Pins
w/Knob (#134) to be fully engaged into the selected
holes of the Front Uprights (#3).
Turn/Pull Pin w/Knob
Fully Engaged
Fig. A Illustration above depicts the Press Bar
(#12) locking mechanism.
Fig. B Caution: Use collars to prevent the weight
plates from falling off the Olympic Adaptors (#10).
Weight Prong
Olympic Bar Collar
Barbell Weight Plates
Unlock
Lock
12
3
11
Safety Precautions

4Smith-Half Cage Series
Safety Precautions
Unlocking Unlocking
Locking Locking
Press Bar
Correctly Engaged
Disengaged Press Bar
During Exercise
Locking Unlocking
11. DANGER: Once the unit is completely assembled take the time to ensure
that the unit is assembled correctly square and perpendicular. Pay special
attention to the Press Bar (#12) making sure both hooks engage uniformly and
completely into each locking position. If both of the Press Bar Hooks are not
engaging uniformly into the receptacle holes, it will be necessary to loosen
some frame hardware then re-align the frame and re-tighten the hardware.
If Problem persists, Do Not Use the Machine and contact your TuffStuff
Retailer.
12
12
15
14
58 58
3 3
12
12
12. The illustrations above depict the Press Bar disengaged setting which is used
during exercise.
13. DANGER: The Safety Spotter Hooks (#14, #15) prevent the Press Bar from
being lowered below required point and avoid getting crushed under the Press
Bar (#12) if the weight is too heavy to control. Use the Decal-numbers (#58)
on the Front Uprights (#3) to ensure that the Safety Spotter Hooks (#14,#15)
are set to an equal adjustment setting (same height).
Before you add weight plates to the Press Bar (#12), you must first set-up the
Safety Spotter Hooks (#14,#15) for the required exercise. It is recommended
that you test the desired setting without weight plates on the Press Bar (#12)
to make sure the Safety Spotter Hooks (#14,#15) are set to the appropriate
exercise setting.

5
Smith-Half Cage Series
Step 1 Assembling Base Unit
A. Locate the two Bottom Side Frames (#2) and attach them to the Bottom Cross Brace (#1) using hardware shown.
B. Attach the two Front Uprights (#3) to the two Bottom Side Frames (#2) using hardware shown.
Note: Make sure to assemble the Front Uprights (#3) with the oval hole pattern towards the back of the Unit, and the
Decal-Numbers (#58) towards the inside of the Unit.
Assembly List
Item # Description Qty.
1 BOTTOM CROSS BRACE 1
2 BOTTOM SIDE FRAME 2
3 FRONT UPRIGHT 2
58 DECAL-NUMBERS 1-20 TEFLON 2
65 FLAT WASHER 1/2 X 1 3/4 8
67 FLAT WASHER SAE 1/2” 8
72 HEX HEAD CAP SCREW 1/2-13 X 3 1/4 4
74 HEX HEAD CAP SCREW 1/2-13 X 4 1/4 4
101 NYLON INSERT LOCK NUT 1/2-13 8
65
2
65
101
67
101
72
67
67
101
65
65
72
67
72
67
3
58
58 3
1101
67
67
101
67
65
72
65
2
65
65
101
74
74

6Smith-Half Cage Series
A. Slide the two Bar Safety Spotters (#7, #8) onto the Front Uprights (#3).
B. Slide the two Bar Holders (#9) onto the Front Uprights (#4).
Assembly List
Item # Description Qty.
7 LEFT SIDE BAR SAFETY SPOTTER 1
8 RIGHT SIDE BAR SAFETY SPOTTER 1
9 BAR HOLDER 2
63 FLAT PHILLIPS SCREW 8-32 X 1/4 4
134 TURN/PULL PIN W/KNOB AND LOCK 4
Step 2 Assembling the Half Cage Conversion Kit (SHC-410)
9
8
7
9
3
3
63
134
63
134

7
Smith-Half Cage Series
A. Insert the Linear Shafts 1 X 69 11/16 (#13) into the receptacles of the Bottom Side Frames (#2).
B. Insert the Safety Spotter Assemblies (#14, #15) onto the Linear Shafts (#13).
Caution: It is strongly recommended to use another person in assisting with the following assembly.
C. Align the Chrome Press Bar Housings (#11) with the Linear Shafts (#13) and carefully begin sliding the Chrome Press
Bar Assembly (#12) onto the Linear Shafts (#13).
Assembly List
Item # Description Qty.
12 CHROME PRESS BAR ASSEMBLY 1
13 LINEAR SHAFT 1 X 69 11/16 2
14 LEFT SAFETY SPOTTER ASSEMBLY 1
15 RIGHT SAFETY SPOTTER ASSEMBLY 1
Step 3 Assembling the Press Bar (SLS-420)
15 11
13
11
13
12
14
2
2

8Smith-Half Cage Series
A. Attach the two Shaft Retainer Brackets (#17) to the Linear Shafts (#13).
B. Affix the two Rear Side Supports (#5) to the two Bottom Side Frames (#2) using hardware shown.
C. Affix the two Rear Side Supports (#5) to the two Front Uprights (#3) using hardware shown.
D. Secure the two Shaft Retainers Brackets (#17) along with the two confined Linear Shafts (#13) to the Rear Side
Supports (#5) using hardware shown.
Assembly List
Item # Description Qty.
5 REAR SIDE SUPPORT 2
17* SHAFT RETAINER BRACKET 2
65 FLAT WASHER 1/2 X 1 3/4 8
67 FLAT WASHER SAE 1/2” 8
68* FLAT WASHER SAE 3/8” 4
72 HEX HEAD CAP SCREW 1/2-13 X 3 1/4 4
74 HEX HEAD CAP SCREW 1/2-13 X 4 1/4 4
84* HEX HEAD CAP SCREW 3/8-16 X 4 2
101 NYLON INSERT LOCK NUT 1/2-13 8
102* NYLON INSERT LOCK NUT 3/8-16 2
* Items Required Only for SLS-420
Step 4 Assembling the Rear Side Supports
65
65
101
65
65
101
67
72
72
67
5
67
101
17
68
84
13
67
101
68
74
65
102
72
67
5
65
3
65
67
101
17
68
102
13
68
84
101
67
74

9
Smith-Half Cage Series
A. Attach the Top Cross Brace (#6) to the Front Uprights (#3) using hardware shown.
B. Insert Plastic Insert Caps 1 7/8” Rd. (#110) into the tube-ends of the Olympic Adapters w/Plate (#4).
C. Attach the six Olympic Adapters w/Plate (#4) to the two Rear Side Supports (#5) using hardware shown.
Assembly List
Item # Description Qty.
6TOP CROSS BRACE 1
4OLYMPIC ADAPTER W/PLATE 6
51 CHROME WASHER 3/8 X 1 1/2 12
65 FLAT WASHER 1/2 X 1 3/4 4
67 FLAT WASHER SAE 1/2” 4
68 FLAT WASHER SAE 3/8” 12
74 HEX HEAD CAP SCREW 1/2-13 X 4 1/4 4
84 HEX HEAD CAP SCREW 3/8-16 X 4 12
101 NYLON INSERT LOCK NUT 1/2-13 4
102 NYLON INSERT LOCK NUT 3/8-16 12
110 PLASTIC INSERT CAP 1 7/8” RD. 6
Step 5 Assembling the Top Cross Brace and the Olympic Adapters
4
68
5
65
65
74
68
84
110
102
84
68
110
84
68
4
74
84
102
51
102
51
51
102
67
101
6
101
67
84
68
110
68
84
4
68
84
110
65
65
51
102
101
67
51
102
4
68
84
51
102
3
74

10 Smith-Half Cage Series
SBU-400 Exploded View Diagram
101
65
65
2
101
65 67
101
1
101
67
65
101
65
2
65 65 74
65
4
68 84
110
84
68
67
72
67
51
102 51
54
74
65
65
67
101
67
65
74
65
67
101
67
101
101
67
101
67
5
5
67
101
67
74
65
3
58
110
84
68
4
68
84
72
67
72
67
74
65
65
65
101
72
51
67
102
51
67
101
65
101
72
67
72
67
67
101
67
101
74
72
72
6
133
64
58
3
65
65
ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY.
1 BOTTOM CROSS BRACE UP3482 1 67 FLAT WASHER SAE 1/2” BNH0238 20
2 BOTTOM SIDE FRAME UP3481 2 68 FLAT WASHER SAE 3/8” BNH0239 12
3 FRONT UPRIGHT UP3483 2 72 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 3 1/4 BNH0576 8
4OLYMPIC ADAPTER W/PLATE UP2202 6 74 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 4 1/4 BNH0291 12
5 REAR SIDE SUPPORT UP3484 2 84 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 4 BNH0285 12
6TOP CROSS BRACE UP3485 1 101 NYLON INSERT LOCK NUT 1/2-13 BNH0212 20
51 CHROME WASHER 3/8 X 1 1/2 BNH1015 12 102 NYLON INSERT LOCK NUT 3/8-16 BNH0214 12
54 DECAL-CAUTION 1 3/4 X 5 1/2 BNH0126 1 110 PLASTIC INSERT CAP 1 7/8” RD. BNH0003 6
58 DECAL-NUMBERS 1-20 TEFLON BNH1547 2 133 TUFFSTUFF LOGO ALUMINUM (LG) BNH1324 1
64 FLAT PHILLIPS SCREW ZINC # 5 X 1/2 BNH1481 2 139 DECAL-REFERENCE LEFT SIDE ( L ) BNH1850 1
65 FLAT WASHER 1/2 X 1 3/4 BNH0241 20 140 DECAL-REFERENCE RIGHT SIDE ( R ) BNH1851 1
SBU-400
Parts List
CHART
BOLD FONT = SUB-ASSEMBLY PARTS
REGULAR FONT = HARDWARE