Tuff stuff TBU-335 Smith-Half Cage Series, THC-43C Smith-Half Cage Series, TSM-45L Smith-Half Cage Series Assembly Instruction Manual

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Page 1

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

76 1/2"

67 3/4"

America’s Premium Exercise Equipment

L 67 3/4" W 76 1/2" H 82"

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bout the Smith-Half Cage Series

y y

ongratulations on your new purchase of the Smith-Half Cage eries. This gym is capable of a variety of different exercises, as-

ell-as, smooth and user-friendly adjustment features. In addition, his gym has been designed to meet the needs and performance equirements for a suitable home exercise machine. We hope you

re completely satisﬁ ed with this product and wish you many years f enjoyment.

uff Stuff Equipment

his Tuffstuff product has been built to precise quality standards nd has been carefully packaged to ensure that damage will ot occur during shipment. The Home Lifetime Warranty and

ignature indicating ﬁ nal inspection has been conducted by our line oreman, is an expression of our conﬁ dence in the completeness, he materials, and workmanship of this product.

arranty

EE A COPY OF WARRANTY ON BACK PAGE.

egistration Card

o avoid unnecessary delays in warranty service and to insure that

permanent record of your purchase is on ﬁ le with our factory, be

ure to complete the warranty registration card and send it to Task ndustries today.

peciﬁ cations

About the Icons

The icons displayed in this Assembly Instructions are used t 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 complete a procedure or information which wil make the procedure easier to understand.

Caution indicates a potentially hazardou situation, which, if not avoided, may result in mino or moderate injury. It may also be used to aler against unsafe practices.

Loosely Fasten provides a instruction to loosel fasten (ex: hand tighten) a hardware assembl only. This instruction is intended for the alignmen of hardware components during the assembl process.

Fully Fasten provides a instruction to fully fasten (ex: completely tighten) a hardware assembly.

TBU-335 THC-43C TSM-45L

. Maximum Wt. Capacity N/A 400 Lbs. 300 Lbs.

. Total Machine Weight 220 Lbs. 40 Lbs. 80 Lbs.

. Footprint (LWH) - See Front Cover

rior to the Assembly of the Smith-Half Series

. 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.

. 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.

. It is recommended that another person assist you with the

assembly of this unit.

. Neatly organize and identify all parts according to the Parts List

and the Exploded View Diagrams on pages 7 - 9.

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/ teﬂ on spray lubricant

9. Measuring tape

0. Utility knife

Assembly Notes

1. Read and follow each step of this Assembly Instruction Manu 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 some Hex Head Cap Screws loosely fastened. Naturally, the will be fully fastened later in the assembly process. This is don to prevent any difﬁ culty with alignment of some parts during thi assembly.

Hardware Measurement Diagram

SCREWﬁLENGHT

WASHERﬁDIAMETER

SCREWﬁWIDTH

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

NUTﬁDIAMETER

Smith-Half Cage Serie

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Safety Precautions

h o

afety First

egardless of how enthusiastic you may be about getting on your equipment and

xercising, take the time to ensure that your safety is not jeopardized. A moment’s

ck of attention can result in an accident, as can failure to observe certain simple

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

Lock

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.

. 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.

. Consult with your physician before beginning any exercise program.

Unlock

. Use proper discretion when children are present.

Fig. A Illustration above depicts the Press B

(#15) locking mechanism.

. Keep hands, limbs, loose clothing and long hair well out of the way of moving

parts.

. Do not attempt to lift more weight than you can control safely.

Barbell Weight Plates

Olympic Bar Colla

. 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.

. 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.

. 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 ﬁ rst 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.

Weight Prong

Fig. B Caution: Use collars to prevent the weig plates from falling off the Olympic Adaptors (#7) the Press Bar (#15).

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.

Turn/Pull Pin w/Kno

Fig. C Caution: Check that all Turn/Pull Pi

w/Knob (#138) to be fully engaged into the select holes of the Front Uprights (#4).

mith-Half Cage Series 2

Fully Engaged

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m u

n n

BU-335 TBU-335

IG. 1 Locate the two Bottom Frames (#1, #2) and the Bottom

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

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.

FIG. 2 Attach the two Front Uprights (#4) to the two Botto

Frames (#1, #2), in the position as shown above, and secure the

into place using four Hex Head Cap Screws 1/2-13 X 4 1/4 (#78), fo 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.

BU-335 THC-43C

IG. 3 Next, attach the Decal Numbers 1-20 (#64) to both Front

prights (#4). Center the number 20 with the second adjustment hole of

e Front 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

ur index ﬁ nger against the decal and as you slide your ﬁ nger down, with

e other hand, slowly remove the rest of the backing off the decal.

FIG. 4 Next, slide the Bar Safety Spotters (#17) onto the Fro

Uprights (#4). Then, slide the Bar Holders (#18) onto the Fro Uprights (#4) as shown above.

Smith-Half Cage Serie

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SM-45L TSM-45L

Assembly Instruction

IG. 5 Insert the Linear Shafts 1 X 70 (#9) into the receptacles of

e Bottom Frames (#1, #2).

FIG. 6 Insert the assembled Safety Spotter Brackets (#10) onto th

Linear Shafts (#9).

Caution: It is strongly recommended to use another person assisting with the following assembly.

SM-45L TSM-45L

IG. 7 Align the Chrome Press Bar Housings (#13) with the

inear Shafts (#9) and carefully begin sliding the assembled Press

ar down onto the Linear Shafts (#9).

FIG. 8 Next, insert the Shaft Retainers (#14), in the position shown above, to the Linear Shafts (#9).

Caution: It is strongly recommended to use another perso in assisting with the following assembly.

mith-Half Cage Series 4

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/ 2

BU-335 TBU-335

IG. 9 Afﬁ x 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

uts 1/2-13 (#101).

FIG. 10 Next, afﬁ x the two Rear Side Supports (#5) to the t

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/ (#70), and four Nylon Insert Lock Nuts 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.

SM-45L TBU-335

IG. 11 Secure the two Shaft Retainers (#14) along with the two

nﬁ ned 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

AE 3/8” (#71), and four Nylon Insert Lock Nuts 3/8-16 (#99).

FIG. 12 Attach the Top Cross Brace (#6) to the top of both Fro

Uprights (#4) using two Reinforcement Plates 3 X 7 (#8), four H

Head Cap Screws 1/2-13 X 3 1/2 (#77), eight Flat Washers SAE 1/ (#70), and four Nylon Insert Lock Nuts 1/2-13 (#101).

Fully Fasten: Proceed to align and fully fasten this hardwa assembly and all of the previous assemblies that were le loosely fastened.

Smith-Half Cage Serie

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IG. 3

Assembly Instruction

IG. 13 Using a rubber mallet, insert one Plastic Insert Cap 1 7/8”

d. (#109) into the tube-end of each one of the Olympic Adapters

109

FIG. 14 Picture of the assembled TBU-335 Base Unit with the

THC-43C Half Cage Conversion Kit.

/Plate (#7). Next, attach the six Olympic Adaptors w/Plate (#7) to

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

ylon Insert Lock Nuts 3/8-16 (#99).

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.

mith-Half Cage Series 6

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TBU-335 Exploded View Diagram

101

112

101

112

101

109

101

109

101

OLOR CHART

RAY= SUB-ASSEMBLY PARTS

LACK= HARDWARE

TBU-335

Parts Lis

em Description Part No. Qty Item Description Part No. Qt

1 RIGHT SIDE BOTTOM FRAME UP2205 1 68 FLAT WASHER 1/2 X 1 3/4 BNH0241 8

2 LEFT SIDE BOTTOM FRAME UP2206 1 70 FLAT WASHER SAE 1/2" BNH0238 3

3 BOTTOM CROSS BRACE UP2203 1 71 FLAT WASHER SAE 3/8" BNH0239 2

4 FRONT UPRIGHT UP2207 2 77 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 3 1/2 BNH0263 1

5 REAR SIDE SUPPORT UP2204 2 78 HEX HEAD CAP SCREW GR-5 B/O 1/2-13 X 4 1/4 BNH0291 8

6 TOP CROSS BRACE UP0519 1 85 HEX HEAD CAP SCREW GR-5 B/O 3/8-16 X 3 BNH0282 1

7 OLYMPIC ADAPTER W/PLATE UP2202 6 99 NYLON INSERT LOCK NUT 3/8-16 BNH0214 1

8 REINFORCEMENT PLATE 3 X 7 UP0543 2 101 NYLON INSERT LOCK NUT 1/2-13 BNH0212 2

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

Smith-Half Cage Serie

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138

THC-43C Exploded View Diagram

116

138

OLOR CHART

RAY= SUB-ASSEMBLY PARTS

BLACK= HARDWARE

em Description Part No. Qty Item Description Part No. Qt

17 BAR SAFETY SPOTTER UP0520 2 116 PLASTIC TUBE GUIDE W/LIP 2 1/2 X 3 1/2 BNH0057 8

18 BAR HOLDER UP0521 2 138 TURN/PULL PIN W/KNOB AND LOCK BNH0989 4

67 FLAT PHILLIPS MACHINE SCREW 8-32 X 1/4 BNH0408 4

THC-43C_Rev2

THC-43C

Parts Lis

mith-Half Cage Series 8

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119

TSM-45L Exploded View Diagram

119

134

120

119

TSM-45L

125

OLOR CHART

RAY= SUB-ASSEMBLY PARTS

LACK= HARDWARE

119

106

120

Parts List

Item Description Part No. Qty Item Description Part No. Qt

9 LINEAR 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 1 106 NYLON WASHER 1 1/8 X 2 X 1/4 BNH0388 2 16 CHROME OLYMPIC ADAPTER UP0679 2 119 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

Smith-Half Cage Serie

Page 11

Maintenance

aintenance Information

1. Lubrication of all moving parts is essential to the longevity and optimal performance of your SmithHalf 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 teﬂ on 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 immediately 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 ﬁ nish 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.

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 teﬂ on grease. Lack of care an maintenance will result in corrosion of the Linear Shaf causing the bearings to clogged and jammed.

5. When checking the bolts and nuts, be sure they are 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

6. Check welds to be free of cracks.

7. Failure to perform routine maintenance could result i personal injury and/or equipment damage.

mith-Half Cage Series 10

Page 12

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.

TASK INDUSTRIES, INC.

1325 E. Franklin Ave., Pomona, CA 91766

Ph: 909-629-1600 Fax: 909-629-4967

E-mail: service@tuffstuff.net Net: www.tuffstuff.net