BodyCraft EXP Series Assembly Manual
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BodyCraft EXP Series Assembly Manual

Dual inner / outer thigh (dio)
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Dual Inner / Outer Thigh (DIO)
Base Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _
Purchased Date: ___ / ___ / ______
Dealer's Name:__________________________
Please register your products at:
https://www.bodycraft.com/product-registration/
For the Owner's Manual,
Assembly STEPS in
FULL COLOR
& additional information,
scan this QR code.
Assembly Manual
1
Open your Camera
App and point it at
the QR Code
DIO_AM v1.3

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Summary of Contents for BodyCraft EXP Series

  • Page 1 App and point it at the QR Code Base Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _ Purchased Date: ___ / ___ / ______ Dealer’s Name:__________________________ Please register your products at: https://www.bodycraft.com/product-registration/ Assembly Manual DIO_AM v1.3...
  • Page 2 Thank you for selecting BODYCRAFT. Your choice reflects a wise investment in you and your facility. We hope you use it for many healthy years! BODYCRAFT offers a complete array of high-quality fitness equipment. Please refer to our website www.bodycraft.com to view more ways to enhance your lifestyle.

  • Page 3: Table Of Contents

    Table of Contents, Dual Inner / Outer Thigh (DIO) Page Product Safety Information Product Safety ……………………………………………………………... Important Notes, Recommended Tools & Cleaners …………………….. Warning Labels, Maintenance Schedule & Serial Number….…………..Product Overview 7 - 8 Assembly Parts & Hardware List……………………………………………. Shipping Boxes Dims &...

  • Page 4: Product Safety

    It is imperative that you retain this Assembly Instructions and be sure all warning labels are legible and intact. Replacement Assembly Instructions and labels are available from BODYCRAFT. If you are unsure about the proper use of the BODYCRAFT strength machine call your local BODYCRAFT dealer or our Customer Service Department. Contact BODYCRAFT at 800-990-5556 or support@bodycraft.com...

  • Page 5: Important Notes, Recommended Tools & Cleaners

    Important Notes, Recommended Tools & Cleaners, (DIO) Important Notes and Tips: Before assembly, read all instructions thoroughly and preview diagrams to help make the installation easier. 2. Make sure all parts are accounted for and in proper condition before beginning assembly. See the parts list.

  • Page 6: Warning Labels, Maintenance Schedule & Serial Number

    Warning Labels, Maintenance Schedule & Serial Number, (DIO) Carefully read ALL warning, caution & maintenance schedule labels Open your Camera App and point it at the QR Code For the label placement on the DIO go directly to the Owner’s Manual...
  • Page 7 Assembly Parts, Dual Inner / Outer Thigh (DIO) 1 of 2 Part # Assembly Parts List DIO-001-ASM Frame, Weight Stack - Assembly DIO-002-ASM Frame, Main - Assembly Frame, Pivot Axle Support Tube - DIO-003-ASM Assembly Frame, Cam Support Tube - DIO-004-ASM Assembly DIO-005...
  • Page 8 Assembly Parts, Dual Inner / Outer Thigh (DIO) 2 of 2 NOTE: For a complete service parts list, please refer to the detailed parts list & exploded view …………………………………….at the rear of this manual. Part # Assembly Parts List Guide Rod for Weight Stack, 0.75" OD x 50.3" L, 3/8" Inner DIO-024 Thread on One End DIO-028-ASM...

  • Page 9: Shipping Boxes Dims & What's Inside

    CWP15(5) Size: 13'' L x 6'' W x 6'' H ea. (310mm L x 130mm W x 140mm H) BODYCRAFT reserves the right to make improvements at any time which may affect color, parts, materials, size, weight, or any other aspect.

  • Page 10: Pre-Assembly Tips

    Product Assembly, Preassembly Tips, Dual Inner / Outer Thigh (DIO) PREASSEMBLY TIP #1 – “Stage Right”. During the assembly process we will be stating Right, Left, Front, Back, Top, or Bottom. These all are in the perspective of the user in the machine with feet facing towards the ground. See below images as examples.
  • Page 11 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 1: Install Main Frame to Weight Stack Frame Please Hand Tighten All Frame Nuts & Bolts Until STEP 6 Part # Assembly Parts list DIO-001-ASM Frame, Weight Stack - Assembly DIO-002-ASM Frame, Main - Assembly Part # Assembly Hardware...
  • Page 12 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 2: Install Leg Arm Frames & Cams w/ Pivot Axle to Main Frame Part # Assembly Parts List DIO-004-ASM Frame, Cam Support Tube - Assembly DIO-007-ASM Frame, Leg Arm, Left - Assembly DIO-008-ASM Frame, Leg Arm, Right - Assembly DIO-009-ASM...
  • Page 13 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 3a: Install Pivot Axle Support Tube Frames Note: Loosen pre-assembled #80 Nuts, then #58 Bolts before placing Support Tube Frames over Pivot Axles. Recommended Tools: 9/16 WRENCH 9/16 SOCKET Note: Confirm #46 Pivot Axles have the “Notches”...
  • Page 14 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 3b: Fully Install Pivot Axle Support Tube Frames ONLY Tighten STEP 3b Hardware to the Recommendations Below Recommended Tools: TORQUE WRENCH w/ 9/16 SOCKET & 9/16 WRENCH Tighten to the Recommended 17 ft-lbs Torque Specs at this time.
  • Page 15 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 4: Install Pivot Actuator Plate ONLY Tighten STEP 4 Hardware to the Recommendations Below Recommended Tools: TORQUE WRENCH w/ 9/16 SOCKET & 9/16 WRENCH Tighten both 3/8” Nuts (for the Pivot 12.5 ft-lbs Actuator Plate) to the recommended (+/- 1 lbs)
  • Page 16 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 5a: Install & Lube Guide Rods, Stack Spacers, Rubber Cushions, Weight Plates & Top Plate Standard 150 lb Stack 1 box, 4ea of 10 lb plates = 40 lbs per CWP10(4) box Please Hand Tighten 2 boxes, 5ea of 10 lb plates = 50 lbs per CWP10(5) box All Bolts Until STEP 6...
  • Page 17 Product Assembly, Weight Stack Stickers Installation, (DIO) TEP 5b: Clean Weight Stack IMPORTANT: Before installing the weight stack stickers, it is important to let the weight plates acclimate to room temperature. Clean Top Plate & Weight Plates front surface with: MINIMUM 65 DEGREES &...
  • Page 18 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 6: “Torque Time” on ALL Frame Nuts & Bolts from STEP 1 & STEP 5 NOTE: These recommended torque Example of being specs should be followed for correct overtightened not using the assembly and safe operation of this recommended torque specs.
  • Page 19 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 7: Install Upper Cable, Floating Pulley Bracket & Selector Pin w/ Lanyard Please Hand Tighten All Cable Nuts & Bolts Until STEP 8b NOTE: Actual color of the Cables are black. Shown in the assembly STEP 7 &...
  • Page 20 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 8a: Install Lower Cable Part # Pre-Installed Hardware List DIO-072 Bolt, Recessed Flat Head, 7/16" x 5/8" L DIO-073 Screw, Umbrella Head, 1/4 " x 3/4" L Part # Assembly Parts List DIO-019 Cable, Lower 124-1/2"...
  • Page 21 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 9: Install Handlebar Frame & Leg Pad Pivot Bracket Frames Tighten STEP 9 Hardware to the Recommendations Below 17 ft-lbs (+/- 2 lbs) Recommended Tools: TORQUE WRENCH w/ 9/16 SOCKET & 9/16 WRENCH 17 ft-lbs (+/- 2 lbs) Part #...
  • Page 22 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 10: Install Leg Pads & Rubber Stoppers Tighten STEP 10 Hardware to the Recommendations Below Recommended Tools: TORQUE WRENCH w/ 1/4" Hex Bit Sockets, 9/16 Socket 12.5 ft-lbs (+/- 1 lbs) Tighten all 3/8”Bolts (for the Leg Pads) to the recommended torque specs of 12.5 ft-lbs (+/- 1 lbs).
  • Page 23 Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 11: Install Seat & Back Pads Tighten STEP 10 Hardware to the Recommendations Below Recommended Tools: TORQUE WRENCH w/ 9/16 Socket 12.5 ft-lbs (+/- 1 lbs) Tighten to the Recommended Torque Specs at this time. 12.5 ft-lbs (+/- 1 lbs) Part #...

  • Page 24: Assembly Parts & Hardware List

    Product Assembly, Dual Inner / Outer Thigh (DIO) TEP 12: Install Weight Stack Shrouds & Cover Top Assembly 5 ft-lbs (+/- 0.5 lbs) NOTE: When lowering down the Shroud Covers, confirm the back taps are behind the frame slots, locking in the Shroud Cover to the frame.

  • Page 25: Step 1 - Step

    Product Assembly, Final Assembly Clean up, Lube & Polish, (DIO) STEP 13a: Remove any & all Assembly Stickers, i.e. Part Numbers & Right / Left Circles ● Easy to remove with fingernail or plastic scraper ● If adhesive residue is on frame: ○...

  • Page 26: Strength Cable Wear Indicators

    Strength Cable Wear Indicators, Dual Inner / Outer Thigh (DIO)

  • Page 27: Detailed Parts Exploded View

    Detailed Parts, Exploded View, Dual Inner / Outer Thigh (DIO) 1 page A.M. version NOTE: Parts are not to scale...

  • Page 28: Detailed Parts List

    Detailed Parts List, Dual Inner / Outer Thigh (DIO) 1 of 3 Part # Detailed Parts List DIO-001 Frame, Weight Stack DIO-002 Frame, Main DIO-003 Frame, Pivot Axle Support Tube DIO-004 Frame, Cam Support Tube DIO-005 Frame, Leg Pad Pivot Bracket DIO-006 Frame, Handlebar DIO-007...
  • Page 29 Detailed Parts List, Dual Inner / Outer Thigh (DIO) 2 of 3 Part # Detailed Parts List DIO-039 Clip Nut, M6 I.D. Pop-Pin, Aluminum , 1/2" x 135mm L, Stiff Spring DIO-040 - BLUE DIO-041 Ring, Aluminum Inner for Handlebar - BLUE End Cap, Aluminum, for Handlebar w/ center DIO-042 recessed hole - BLUE w/ BC logo...
  • Page 30 Detailed Parts List, Dual Inner / Outer Thigh (DIO) 3 of 3 Part # Detailed Parts List DIO-075 Washer, Spring, 3/8" DIO-076 Washer, Spring, 1/2" DIO-077 Washer, Flat, 3/8" DIO-078 Washer, Flat, Large,3/8" DIO-079 Nut, Hex, 1/2" DIO-080 Nut, Hex, 3/8" (85) DIO-081 Nut, Nylon Lock, Thin, 3/8"...

  • Page 31: Product Warranty Registration

    Warranty Registration, Strength, Dual Inner / Outer Thigh (DIO) Thank you for purchasing a BODYCRAFT product. To validate the product warranty the fast and easy way, please go on-line now to https://www.bodycraft.com/product-registration.html and register your product. The information you provide will never be distributed to any other individuals or agencies for any purpose. If you prefer to mail your warranty card, have the owner of the product complete the information below and return it to BODYCRAFT within 30 days from the date of equipment installation.

  • Page 32: Contact Us & Required Info Before Initiating A Service Case

    Required Information BEFORE Initiating a Service Case The following information is needed to help expedite troubleshooting and to ensure the correct part(s) are sent if needed for a repair: What product / model # do you have? Unit serial number? Installed by a dealer or direct sale? Date of installation? Date of service issue?

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