TuffStuff SBU-400, SHC-410, SLS-420 Assembly Instructions Manual

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

76 1/2"

70 1/2"

America’s Premier Exercise Equipment

L 70 1/2" W 76 1/2" H 82 1/2"

SBU-400 Rev1

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, as­well-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 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.

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
diffi cult to move, therefore you should assemble the unit in the
area where it is to be used upon completion.

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

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

Note: Due to continuing product improvements, specifi cations and designs are subject to change
without notice.

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

Hardware Measurement Diagram

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A

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2

Smith-Half Cage Series

Safety Precautions

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.

3

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, as­well-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.

Lock

11

Fig. A Illustration above depicts the Press Bar

(#12) locking mechanism.

Barbell Weight Plates

Olympic Bar Collar

Fig. B Caution: Use collars to prevent the weight
plates from falling off the Olympic Adaptors (#10).

Unlock

12

Weight Prong

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.

Smith-Half Cage Series

Turn/Pull Pin w/Knob

Fully Engaged

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).

3

Safety Precautions

Press Bar

Correctly Engaged

12

Locking Locking

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

Disengaged Press Bar

During Exercise

12

Unlocking Unlocking

12. The illustrations above depict the Press Bar disengaged setting which is used

during exercise.

12

58 58

Locking

14

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 fi rst 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.

3 3

Unlocking

15

4

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

3

58

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

72

72

67

67

65

101

65

74

65

2

65

67

101

58 3

67

101

72

67

72

67

101

1

67

101

67

65

65

74

Smith-Half Cage Series

2

65

101

65

5