Tuff stuff TBU-335 Smith-Half Cage Series User manual

ASSEMBLY INSTRUCTIONS
TABLE OF CONTENTS:
Introduction
Pg. 1
Safety Precautions
Pg. 2
Assembly Instructions
Pg. 3 - Pg. 6
TBU-335 Exploded View Diagram
Pg. 7
THC-43C Exploded View Diagram
Pg. 8
TSM-45L Exploded View Diagram
Pg. 9
Maintenance
Pg. 10
Warranty
Back Page
Smith-Half Cage Series
Includes Assembly for:
TBU-335
Base Unit
THC-43C
Half Cage Conversion Kit
TSM-45L
Smith Linear Bearing Press Kit
Revision Date 04-03-03
America’s Premium Exercise Equipment
67 3/4"
76 1/2"
L 67 3/4" W 76 1/2" H 82"

A
bout the Smith-Half Cage Series
C
ongratulations on your new purchase of the Smith-Half Cage
S
eries. This gym is capable of a variety of different exercises, as-
w
ell-as, smooth and user-friendly adjustment features. In addition,
his gym has been designed to meet the needs and performance
r
equirements for a suitable home exercise machine. We hope you
a
re completely satisfied with this product and wish you many years
o
f enjoyment.
T
uff Stuff Equipment
T
his Tuffstuff product has been built to precise quality standards
a
nd has been carefully packaged to ensure that damage will
n
ot occur during shipment. The Home Lifetime Warranty and
s
ignature indicating final inspection has been conducted by our line
f
oreman, is an expression of our confidence in the completeness,
he materials, and workmanship of this product.
W
arranty
S
EE A COPY OF WARRANTY ON BACK PAGE.
R
egistration Card
T
o avoid unnecessary delays in warranty service and to insure that
a
permanent record of your purchase is on file with our factory, be
s
ure to complete the warranty registration card and send it to Task
ndustries today.
P
rior to the Assembly of the Smith-Half Series
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.
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 on pages 7 - 9.
T
ool 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. Windex or household glass cleaner
8. One can silicone spray/ teflon spray lubricant
9. Measuring tape
1
0. Utility knife
About the Icons
The icons displayed in this Assembly Instructions are used t
o
facilitate the correct assembly and safe use of this Product, as
-
well-as to prevent injury to yourself or anyone else.
Note provides information necessary to properl
y
complete a procedure or information which wil
l
make the procedure easier to understand.
Caution indicates a potentially hazardou
s
situation, which, if not avoided, may result in mino
r
or moderate injury. It may also be used to aler
t
against unsafe practices.
Loosely Fasten provides a instruction to loosel
y
fasten (ex: hand tighten) a hardware assembl
y
only. This instruction is intended for the alignmen
t
of hardware components during the assembl
y
process.
Fully Fasten provides a instruction to fully fasten
(ex: completely tighten) a hardware assembly.
SCREWfiWIDTH
WASHERfiDIAMETER
NUTfiDIAMETER
SCREWfiLENGHT
Hardware Measurement Diagram
Assembly Notes
1. Read and follow each step of this Assembly Instruction Manu
a
in sequence. Do not skip ahead, as it will result in an imprope
assembly or in having to disassemble parts later.
2. During the assembly of this unit you will be instructed to leav
e
some Hex Head Cap Screws loosely fastened. Naturally, the
y
will be fully fastened later in the assembly process. This is don
e
to prevent any difficulty with alignment of some parts during thi
s
assembly.
Note: Due to continuing product improvements, specifications and designs are subject to change
without notice.
Smith-Half Cage Serie
s
1
S
pecifications
TBU-335 THC-43C TSM-45L
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

S
afety First
R
egardless of how enthusiastic you may be about getting on your equipment and
e
xercising, take the time to ensure that your safety is not jeopardized. A moment’s
a
ck of attention can result in an accident, as can failure to observe certain simple
s
afety 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
Tuff Stuff product prior to use. Some of this information can be obtained in this
Assembly Instructions, as-well-as from your local Tuff Stuff 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 Tuff Stuff 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 (#15) has a swivel locking mechanism that allows you to safely
lock out the Press Bar (#15) at virtually any setting. See Fig. A.
9
.The Safety Spotter Hooks (#11, #12) prevent the bar from being lowered
below desired point and avoid getting crushed under the Press Bar (#15) if the
weight is too heavy to control. Use the Decal-numbers 1-20 (#64) on the Front
Uprights (#4) to ensure that the Safety Spotter Hooks (#11,#12) are set to an
equal adjustment setting (same height).
10. Before you add weight plates to the Press Bar (#15), you should first set-up the
Safety Spotter Hooks (#11,#12) for the desired exercise. It is recommended
that you test the desired setting without weight plates on the Press Bar (#15)
to make sure the Safety Spotter Hooks (#11,#12) are on the appropriate
exercise setting.
11. If you are adding or storing weight plates on the Olympic Adapters (#7) or the
Press Bar (#15), do not over-load them. Allow enough space to put a weight
collar into place. See Fig. B
12. Do not drop heavy weight on the Safety Spotter Brackets (#10), as it can
result in damage to the equipment.
13. Pay special attention to the Turn/ Pull Pins w/Knob (#138) located on the Bar
Holders (#18) and the Bar Safety Spotters (#17). Be sure they are fully en-
gaged into the selectorized holes of the Front Uprights (#4). Refer to Fig. C
for further illustration.
Safety Precautions
Fig. C Caution: Check that all Turn/Pull Pi
n
w/Knob (#138) to be fully engaged into the select
e
holes of the Front Uprights (#4).
Turn/Pull Pin w/Kno
b
Fully Engaged
Fig. A Illustration above depicts the Press B
a
(#15) locking mechanism.
Fig. B Caution: Use collars to prevent the weig
h
plates from falling off the Olympic Adaptors (#7)
o
the Press Bar (#15).
Weight Prong
Olympic Bar Colla
Barbell Weight Plates
Unlock
Lock
15
4
13
S
mith-Half Cage Series 2

Smith-Half Cage Serie
s
3
IG. 3 Next, attach the Decal Numbers 1-20 (#64) to both Front
U
prights (#4). Center the number 20 with the second adjustment hole of
h
eFront Upright (#4). A great way to make sure you don’t trap any air
ubbles under the decal is by using the wedge method. Press the side of
o
ur index finger against the decal and as you slide your finger down, with
h
e other hand, slowly remove the rest of the backing off the decal.
1
2
4
4
4
64 4
4
64
FIG. 2 Attach the two Front Uprights (#4) to the two Botto
m
Frames (#1, #2), in the position as shown above, and secure the
m
into place using four Hex Head Cap Screws 1/2-13 X 4 1/4 (#78), fo
u
Flat Washers SAE 1/2” (#70), four Flat Washers 1/2 X 1 3/4 (#68), an
four Nylon Insert Lock Nuts 1/2-13 (#101).
Note: Make sure to assemble the Front Uprights (#4) with
the oval hole pattern towards to the back of the Unit.
FIG. 4 Next, slide the Bar Safety Spotters (#17) onto the Fro
n
Uprights (#4). Then, slide the Bar Holders (#18) onto the Fro
n
Uprights (#4) as shown above.
18
4
17
4
18
17
IG. 1 Locate the two Bottom Frames (#1, #2) and the Bottom
C
ross Brace (#3) and attach them, in the position as shown above,
sing four Hex Head Cap Screws 1/2-13 X 3 1/2 (#77), four Flat
W
ashers SAE 1/2” (#70), and two Nylon Insert Lock Nuts 1/2-13
#
101).
Caution: It is strongly recommended to use another person
in assisting with the following assembly.
2
3
1
T
BU-335 TBU-335
T
BU-335 THC-43C

IG. 7 Align the Chrome Press Bar Housings (#13) with the
L
inear Shafts (#9) and carefully begin sliding the assembled Press
B
ar down onto the Linear Shafts (#9).
9
9
1
2
44
99
11 12
10
10
15
9
9
13
13
IG. 5 Insert the Linear Shafts 1 X 70 (#9) into the receptacles of
h
eBottom Frames (#1, #2).
14
14
9
9
15
S
mith-Half Cage Series 4
FIG. 8 Next, insert the Shaft Retainers (#14), in the position
a
shown above, to the Linear Shafts (#9).
Caution: It is strongly recommended to use another perso
in assisting with the following assembly.
FIG. 6 Insert the assembled Safety Spotter Brackets (#10) onto th
Linear Shafts (#9).
Caution: It is strongly recommended to use another person
i
assisting with the following assembly.
T
SM-45L TSM-45L
T
SM-45L TSM-45L
Assembly
Instruction

FIG. 10 Next, affix the two Rear Side Supports (#5) to the t
w
Front Uprights (#4) using four Hex Head Cap Screws 1/2-13 X 4 1
/
(#78), four Flat Washers 1/2 X 1 3/4 (#68), four Flat Washers SAE 1/
2
(#70), and four Nylon Insert Lock Nuts 1/2-13 (#101).
Smith-Half Cage Serie
s
5
2
5
1
5
5
5
4
4
14
14
9
9
556
4
8
8
4
IG. 9 Affix the two Rear Side Supports (#5) to the two Bottom
rames (#1, #2) using four Hex Head Cap Screws 1/2-13 X 3 1/2
#
77), eight Flat Washers SAE 1/2” (#70), and four Nylon Insert Lock
N
uts 1/2-13 (#101).
Loosely Fasten: Do not completely fasten this hardware
assembly at this time, as it will be completely fastened later
in the assembly process.
FIG. 12 Attach the Top Cross Brace (#6) to the top of both Fro
n
Uprights (#4) using two Reinforcement Plates 3 X 7 (#8), four H
e
Head Cap Screws 1/2-13 X 3 1/2 (#77), eight Flat Washers SAE 1/
2
(#70), and four Nylon Insert Lock Nuts 1/2-13 (#101).
Fully Fasten: Proceed to align and fully fasten this hardwa
r
assembly and all of the previous assemblies that were le
loosely fastened.
IG. 11 Secure the two Shaft Retainers (#14) along with the two
o
nfined Linear Shafts 1 X 70 (#9) to the Rear Side Frames (#5)
sing four Hex Head Cap Screws 3/8-16 X 3 (#85), eight Flat Washers
S
AE 3/8” (#71), and four Nylon Insert Lock Nuts 3/8-16 (#99).
T
BU-335 TBU-335
T
SM-45L TBU-335

IG. 13 Using a rubber mallet, insert one Plastic Insert Cap 1 7/8”
R
d. (#109) into the tube-end of each one of the Olympic Adapters
w
/Plate (#7). Next, attach the six Olympic Adaptors w/Plate (#7) to
h
e two Rear Side Frames (#5) using twelve Hex Head Cap Screws
/
8-16 X 3 (#85), twenty-four Flat Washers SAE 3/8” (#71), and twelve
N
ylon Insert Lock Nuts 3/8-16 (#99).
5
7
109
5
7
7
7
7
FIG. 14 Picture of the assembled TBU-335 Base Unit with the
THC-43C Half Cage Conversion Kit.
S
mith-Half Cage Series 6
F
IG. 3
IG. 15 Picture of the assembled TBU-335 Base Unit with the
TSM-45L Smith Linear Bearing Press System Kit.
FIG. 16 Picture of the assembled TBU-335 Base Unit with the
THC-43C Half Cage Conversion Kit and the
TSM-45L Smith Linear Bearing Press System Kit.
Assembly
Instruction

TBU-335
Parts Lis
t
t
em Description Part No. Qty Item Description Part No. Qt
y
1RIGHT SIDE BOTTOM FRAME UP2205 1 68 FLAT WASHER 1/2 X 1 3/4 BNH0241 8
2LEFT SIDE BOTTOM FRAME UP2206 1 70 FLAT WASHER SAE 1/2" BNH0238 3
2
3BOTTOM CROSS BRACE UP2203 1 71 FLAT WASHER SAE 3/8" BNH0239 2
4
4FRONT UPRIGHT UP2207 2 77 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 3 1/2 BNH0263 1
2
5REAR SIDE SUPPORT UP2204 2 78 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 4 1/4 BNH0291 8
6TOP CROSS BRACE UP0519 1 85 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 BNH0282 1
2
7OLYMPIC ADAPTER W/PLATE UP2202 6 99 NYLON INSERT LOCK NUT 3/8-16 BNH0214 1
2
8REINFORCEMENT PLATE 3 X 7 UP0543 2 101 NYLON INSERT LOCK NUT 1/2-13 BNH0212 2
0
59 DECAL-CAUTION 1 3/4 X 5 1/2 BNH0126 1 109 PLASTIC INSERT CAP 1 7/8" RD. BNH0003 6
63 DECAL-LARGE TUFFSTUFF LOGO BNH0360 1 112 PLASTIC INSERT CAP 2 X 3 BNH0052 2
64 DECAL-NUMBERS 1-20 (TEFLON) BNH1304 2
TBU-335_Rev2
C
OLOR CHART
G
RAY= SUB-ASSEMBLY PARTS
B
LACK= HARDWARE
Smith-Half Cage Serie
s
7
TBU-335 Exploded View Diagram
101
68
68
1
101
70 70
101
3
101
70
68
101
68
2
101
70
70 77
70
7
71
85
109
85
71
70
77
70
71
99
71
59
77
70
70
8
70 101
70
112
68
78
68
64
70
101
70
101
6
63
101
70
101
70
5
5
70
101
70
112
8
70
7
0
68
78
68
4 64
109
85
71
7
71
85
78
70
78
70
77
70
101
70
70
101
77
71
70
99
71
70
101
70
101
78
70
78
70
70
101
70
101
7
7

S
mith-Half Cage Series 8
THC-43C Exploded View Diagram
116
17
116
116
116
18
67
138
67
138
18
17
THC-43C
Parts Lis
t
t
em Description Part No. Qty Item Description Part No. Qt
y
17 BAR SAFETY SPOTTER UP0520 2116 PLASTIC TUBE GUIDE W/LIP 2 1/2 X 3 1/2 BNH0057 8
18 BAR HOLDER UP0521 2138 TURN/PULL PIN W/KNOB AND LOCK BNH0989 4
67 FLAT PHILLIPS MACHINE SCREW 8-32 X 1/4 BNH0408 4
THC-43C_Rev2
C
OLOR CHART
G
RAY= SUB-ASSEMBLY PARTS
BLACK= HARDWARE

TSM-45L
Parts List
Item Description Part No. Qty Item Description Part No. Qt
y
9LINEAR SHAFT 1 X 70 UP0553 285HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 BNH0282 4
10 SAFETY SPOTTER BRACKET UP0523 290HEX KEY M14 BNH1303 1
11 SAFETY HOOK RT UP0524 192LINEAR BEARING BNH0770 4
12 SAFETY HOOK LT UP0525 197NYLON BUSHING 1 X 1 1/2 BNH0531 4
13 CHROME PRESS BAR HOUSING UP0680 298NYLON INSERT JAM LOCK NUT 1/2-13 BNH0366 2
14 SHAFT RETAINER UP0528 299NYLON INSERT LOCK NUT 3/8-16 BNH0214 4
15 CHROME PRESS BAR W/HOOKS UP0678 1106 NYLON WASHER 1 1/8 X 2 X 1/4 BNH0388 2
16 CHROME OLYMPIC ADAPTER UP0679 2119 INTERNAL RETAINING RING 1 9/16" BNH0095 4
54 BRONZE BUSHING 1 1/8 X 1 11/32 X 3/4 BNH0735 2 120 INTERNAL RETAINING RING 1 7/16" BNH1308 4
70 FLAT WASHER SAE 1/2" BNH0238 4 125 SHOULDER BOLT 14 mm X 14 mm THREAD 1/2-13 BNH0426 2
71 FLAT WASHER SAE 3/8" BNH0239 8 134 STEEL NEEDLE-ROLLER BEARING (HMK-2830) BNH1307 4
75 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 1 1/2 BNH0727 2
TSM-45L_Rev3
C
OLOR CHART
G
RAY= SUB-ASSEMBLY PARTS
B
LACK= HARDWARE
Smith-Half Cage Serie
s
9
99
71
71
71
85
71
9
119
92
13
15
92
119
97
10
70
98
97
1
70
7
5
90
125
16
120
134
13
92
119
106
120
134
119
92
97
70
75
97
12
70
98
9
85
71
71
14
71
99 71
14
54
TSM-45L Exploded View Diagram

S
mith-Half Cage Series 10
M
aintenance Information
1. Lubrication of all moving parts is essential to the
longevity and optimal performance of your Smith-
Half Cage Series. Initial lubrication of some parts of
your gym has been done at the factory, but the Linear
Shafts must be lubricated at the time of assembly. We
recommend a light layer of teflon grease.
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. Periodically check all moving parts for signs of wear or
damage. If there is a problem or replacement part is
necessary, STOP USING THE EQUIPMENT and im-
mediately contact your local Tuff Stuff retailer or call our
Customer Service Department. Replace parts using
only genuine Tuff Stuff parts.
3. The unit should be wipe down with a damp cloth and
dried on a daily basis. The powder coat finish should
be polished with a good car wax on a weekly basis.
The chrome-plated surfaces should be polished with a
commercial grade or automotive type chrome polish on
a weekly basis.
Maintenance
4. Linear bearing systems are precision, high loa
components that require regular maintenance. Th
Linear Shafts must be wipe down weekly and lubricate
with a light layer of teflon grease. Lack of care an
maintenance will result in corrosion of the Linear Shaf
t
causing the bearings to clogged and jammed.
5. When checking the bolts and nuts, be sure they are
a
fully fastened. If there is a bolt or nut that continuousl
loosens obtain a replacement through your local Tu
Stuff retailer or call our Customer Service Departmen
t
6. Check welds to be free of cracks.
7. Failure to perform routine maintenance could result i
personal injury and/or equipment damage.

DO NOT DISCARD THIS MANUAL
TASK INDUSTRIES, INC.
1325 E. Franklin Ave., Pomona, CA 91766
Ph: 909-629-1600 Fax: [phone]
E-mail: [email protected] Net: www.tuffstuff.net
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 manufac-
turer 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.