85"
OWNER’S MANUAL
80"
RSM-600
Basic Smith-Half Cage
TuffStuff Fitness Equipment, Inc.
1325 E. Franklin Avenue
Pomona, CA 91766, USA
Ph: 909-629-1600 Fax: 909-629-4967
E-mail: service@tuffstuff.net Net: www.tuffstuff.net
AMERICA’S PREMIER EXERCISE EQUIPMENT
71 1/2"
RSM-600 Rev2
Revision Date 08-04-2008
Introduction
About the RSM-600 Basic Smith-Half Cage
Congratulations on your new purchase of the Basic Smith-Half
Cage . We hope you are completely satisfi ed 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 fi nal inspection has been conducted by our line foreman,
is an expression of our confi dence 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 fi le with our factory,
be sure to complete the warranty registration card and send it to
TuffStuff Fitness Equipment today.
Specifi cations
1. Maximum Wt. Capacity - 500 lbs.
2. Total Machine Weight - 680 lbs.
3. Footprint (LWH) - See Front Cover.
Note: Due to continuing product improvements, specifi cations and designs are subject to change
without notice.
Maintenance
Prior to the Assembly of the Basic Smith-Half Cage
We advise you to consult your local TuffStuff retailer if you should
have a question or problem regarding the proper assembly of this
unit.
Tool Requirements
One 3/4” combination wrench1.
One 9/16” combination wrench2.
One ratchet3.
One 3/4” socket4.
One 9/16” socket5.
Rubber Mallet6.
Windex or household glass cleaner7.
Measuring tape8.
Utility knife9.
Hardware Measurement Diagram
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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 fi nish should be
polished with a good car wax on a monthly basis. A daily wipe down of the upholstery with a lanolin 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 fl 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 fi 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 functions 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-service immediately.
2 RSM-600 Basic Smith-Half Cage
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 important 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, meaning 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 fi tting for any signs of fraying in this area.
Inspect the bolt and nut and/or screw holding the fi 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.
Part Three: Lubrication
Bearing and linear bearings systems have advanced over the years but they must be maintained on a regular basis
if you expect them to last and perform effi 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 tefl 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 tefl 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 tefl on grease. We recommend a tefl on-base (silicone-free) gel/grease
for this purpose. Lack of care and maintenance will result in corrosion 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 ultimately 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 Service Department:
Phone: 909-629-1600 Fax: 909-629-4967 e-mail: service@tuffstuff.net
3RSM-600 Basic Smith-Half Cage
Step 1
Step 1 Assembly List
Item # Description Qty.
2 BOTTOM CROSS BRACE 1
3 BOTTOM SIDE FRAME LT 1
4 BOTTOM SIDE FRAME RT 1
37 FLAT WASHER SAE 3/8” 4
43 HEX HEAD CAP SCREW 3/8-16 X 3/4 4
56 RUBBER FOOT FOR 6 X 4 1/4 PLATE 4
63 SPLIT LOCK WASHER Z/P 3/8” 4
63
43
37
56
37
63
43
3
37
63
43
2
43
37
63
4
56
4 RSM-600 Basic Smith-Half Cage
Step 2
Step 2 Assembly List
Item # Description Qty.
16 SAFETY SPOTTER POST 2
37 FLAT WASHER SAE 3/8” 4
40 HEX HEAD CAP SCREW 3/8-16 X 1 3/4 2
50 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 2
16
3
16
40
37
40
37
4
37
50
50
37
5RSM-600 Basic Smith-Half Cage
Step 3
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Step 3 Assembly List
Item # Description Qty.
6 PRESS BAR HOUSING RT 1
8 LINEAR SHAFT 1 X 69 11/16 1
15 SAFETY SPOTTER BRACKET RT 1
18 SHAFT RETAINER PLATE 1
21 WEIGHT LIFT BAR 1
55 RUBBER DONUT 1 X 2 1/2 2
6 RSM-600 Basic Smith-Half Cage
Step 4
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8
18
5
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6
21
3
Step 4 Assembly List
Item # Description Qty.
5 PRESS BAR HOUSING LT 1
8 LINEAR SHAFT 1 X 69 11/16 1
14 SAFETY SPOTTER BRACKET LT 1
18 SHAFT RETAINER PLATE 1
55 RUBBER DONUT 1 X 2 1/2 2
8
18
5
55
14
55
8
21
3
NOTE:
TWO PEOPLE ARE REQUIRED TO DO THIS STEP.
7RSM-600 Basic Smith-Half Cage
Step 5
Step 5 Assembly List
Item # Description Qty.
1 BAR HOLDER 2
7 NICKLE FRONT UPRIGHT 2
19 SIDE BAR SAFETY SPOTTER 2
37 FLAT WASHER SAE Z/P 3/8” 8
42 HEX HEAD CAP SCREW 3/8-16 X 3 4
50 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 4
1
1
19
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42
37
7
42
37
4
7
42
37
37
42
37
50 37
3
NOTE:
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50 37
1. SOME PARTS NOT SHOWN
FOR CLARITY.
8 RSM-600 Basic Smith-Half Cage
Step 6
Step 6 Assembly List
Item # Description Qty.
9 OLYMPIC ADAPTER 1 X 8 8
10 REAR SIDE SUPPORT LT 1
11 REAR SIDE SUPPORT RT 1
36 FLAT WASHER SAE Z/P 1/2” 8
37 FLAT WASHER SAE Z/P 3/8” 16
39 HEX HEAD CAP SCREW 1/2-13 X 1 1/4 8
40 HEX HEAD CAP SCREW 3/8-16 X 1 3/4 2
42 HEX HEAD CAP SCREW 3/8-16 X 3 4
43 HEX HEAD CAP SCREW 3/8-16 X 3/4 4
50 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 6
58 RUBBER WASHER 1 7/8 ID X 4 1/4 OD X 9/16 8
62 SPLIT LOCK WASHER Z/P 1/2” 8
63 SPLIT LOCK WASHER Z/P 3/8” 4
11
40
37
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42
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3
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37
NOTE:
TWO PEOPLE ARE REQUIRED TO DO THIS STEP.
9RSM-600 Basic Smith-Half Cage
Step 7
Step 7 Assembly List
Item # Description Qty.
9 OLYMPIC ADAPTER 1 X 8 2
18 SHAFT RETAINER PLATE 2
22 TOP STABILIZER 1
36 FLAT WASHER SAE Z/P 1/2” 6
37 FLAT WASHER SAE Z/P 3/8” 8
41 HEX HEAD CAP SCREW 3/8-16 X 2 3/4 4
50 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 4
58 RUBBER WASHER 1 7/8 ID X 4 1/4 OD X 9/16 2
62 SPLIT LOCK WASHER Z/P 1/2” 2
67 HEX HEAD CAP SCREW 1/2-13 X 4 3/4 2
68 HEX HEAD CAP SCREW 1/2-13 X 1 1/2 2
70 NYLON INSERT JAM LOCK NUT Z/P 1/2-13 2
70
22
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36
68
62
37
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36
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18
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10
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51
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10 RSM-600 Basic Smith-Half Cage
Step 8
Step 8 Assembly List
Item # Description Qty.
20 TOP CROSS BRACE 1
37 FLAT WASHER SAE 3/8” 8
44 HEX HEAD CAP SCREW 3/8-16 X 5 4
50 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 4
10
11
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44
37
37
50
44
37
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37
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20
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11RSM-600 Basic Smith-Half Cage
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Fold-Out Page 12
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EXPLODED VIEW DIAGRAM
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RSM-600 Basic Smith-Half Cage
RSM-600 Parts List
COLOR CHART
BOLD FONT = SUB-ASSEMBLY PARTS
BLACK= HARDWARE
ITEM DESCRIPTION REV PART NO. QTY ITEM DESCRIPTION PART NO. QTY
1 BAR HOLDER 0 UP5180 2
2 BOTTOM CROSS BRACE 0 UP5181 1
3 BOTTOM SIDE FRAME LT 0 UP7043 1
4 BOTTOM SIDE FRAME RT 0 UP7044 1
5 PRESS BAR HOUSING LT 0 UP7045 1
6 PRESS BAR HOUSING RT 0 UP7046 1
7 NICKEL FRONT UPRIGHT 0 UP5270 2
8 LINEAR SHAFT 1 X 69 11/16 0 UP5187 2
9 OLYMPIC ADAPTER 1 X 8 0 UP5188 10
10 REAR SIDE SUPPORT LT 0 UP7047 1
11 REAR SIDE SUPPORT RT 0 UP7048 1
12 SAFETY HOOK LT 0 UP7049 1
13 SAFETY HOOK RT 0 UP7050 1
14 SAFETY SPOTTER BRACKET LT 0 UP7051 1
15 SAFETY SPOTTER BRACKET RT 0 UP7052 1
16 SAFETY SPOTTER POST 0 UP7053 2
17 SAFETY SPOTTER PIN 0 UP5196 32
18 SHAFT RETAINER PLATE 0 UP5197 2
19 SIDE BAR SAFETY SPOTTER 0 UP5198 2
20 TOP CROSS BRACE 0 UP5199 1
21 WEIGHT LIFT BAR 0 UP7054 1
22 TOP STABILIZER 0 UP5256 1
23 ABS SLEEVE 1 1/2 X 8 1/8 BNH1527 10 59 SAFETY SPOTTER PLASTIC STRIP BNH2078 2
24 ALUMINUM CAP 1.270" RD BNH0538 2 60 SOCKET SET SCREW Z/P 10-32 X 1/8 BNH2088 4
25 BLACK RUBBER GRIP 1/2 X 4 7/8 BNH1818 2 62 SPLIT LOCK WASHER Z/P 1/2" BNH0572 10
26 BRONZE BUSHING Ø25 X Ø19 X 20 mm BNH1926 2 63 SPLIT LOCK WASHER Z/P 3/8" BNH2032 40
27 BRONZE BUSHING Ø31 X Ø25.4 X Ø19 X 20 mm BNH1925 2 64 TUFFSTUFF LOGO ALUMINUM SMALL BNH1323 1
28 BUTTON HEAD SOCKET CAP SCREW B/O 3/8-16 X 1 BNH0115 32 65 TURN/PULL PIN W/KNOB AND LOCK BNH0989 4
29 DECAL-DANGER ENGAGE SAFETY SPOTTER... BNH1848 2 66 ABS SLEEVE 1 1/2 X 13 BNH2260 2
30 DECAL-IMPORTANT FOR BEST PERFORMANCE... BNH1894 2 67 HEX HEAD CAP SCREW GR-5 Z/P 1/2-13 X 4 3/4 BNH2168 2
31 DECAL-CAUTION WEIGHT TRAINING SAFETY… BNH0126 1 68 HEX HEAD CAP SCREW GR-5 Z/P 1/2-13 X 1 1/2 BNH2171 2
32 DECAL-WARNING ATTENTION USERS! MOVING... BNH1895 2 69 HEX KEY ALLOY 5/32" BNH0373 1
33 FLAT HEAD SOCKET CAP SCREW Z/P M7X1.0 BNH2079 6 70 NYLON INSERT JAM LOCK NUT Z/P 1/2-13 BNH2027 2
34 FLAT PHILLIPS MACHINE SCREW 8-32 X 1/4 BNH0408 4 71 NYLON SNAP-IN FINISHING PLUG 3/8" BNH0720 20
35 FLAT PHILLIPS SCREW ZINC # 2 X 1/2 BNH1480 2 72 URETHANE BUMPER 962 BNH0244 2
RSM-600
Parts List
REV2
36 FLAT WASHER SAE Z/P 1/2" BNH2031 14
37 FLAT WASHER SAE Z/P 3/8" BNH2030 80
39 HEX HEAD CAP SCREW GR-5 Z/P 1/2-13 X 1 1/4 BNH2167 8
40 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 1 3/4 BNH2040 4
41 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 2 3/4 BNH2045 4
42 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 3 BNH2046 8
43 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 3/4 BNH2036 8
44 HEX HEAD CAP SCREW GR-5 Z/P 3/8-16 X 5 BNH2051 4
45 HEX KEY ALLOY 3/32" BNH0372 1
46 HEX KEY ALLOY 7/32" BNH0575 1
47 INTERNAL RETAINING RING 1 9/16" BNH0095 4
48 LINEAR BEARING BNH0770 4
49 NYLON BUSHING 1 X 1 1/2 X 7/8 X 1 3/4 X 1/8 BNH0531 4
50 NYLON INSERT JAM LOCK NUT Z/P 3/8-16 BNH2026 20
51 PLASTIC INSERT CAP 1 7/8" RD. BNH0003 12
52 PLASTIC INSERT CAP ELLIPTICAL 2 X 4 BNH1794 4
53 PLASTIC INSERT ELLIPTICAL GUIDE (2 3/8 X 4 3/4) BNH2062 8
54 ROLL PIN Z/P 1/4 X 9/16 BNH2090 4
55 RUBBER DONUT 1 X 2 1/2 BNH0062 4
56 RUBBER FOOT FOR 6 X 4 1/4 PLATE BNH1647 4
57 RUBBER GRIP 1.1875 ID X .125 X 17 BNH0953 2
58 RUBBER WASHER 1 7/8 ID X 4 1/4 OD X 9/16 TK BNH0933 12
13RSM-600 Basic Smith-Half Cage
DO NOT DISCARD THIS MANUAL
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 manufacturer 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.
TuffStuff Fitness Equipment, Inc.
1325 E. Franklin Avenue
Pomona, CA 91766, USA
Ph: 909-629-1600 Fax: 909-629-4967
E-mail: service@tuffstuff.net Net: www.tuffstuff.net
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