Body Craft EXP Series User manual

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Dual Inner / Outer Thigh (DIO)
Serial Number
Assembly Manual
Base Serial Number: _ _ _ _ _ _ _ _ _ _ _ _ _
Purchased Date: ___ / ___ / ______
Dealer’s Name:__________________________
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Congratulations and Welcome to the BODYCRAFT Family
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
at www.bodycraft.com to view more ways to enhance your lifestyle.
Your BODYCRAFT machine has all the quality and design elements to make your workout
extremely efficient and comfortable. Your new unit is a serious strength training machine that will
keep you motivated, challenged and within reach of your fitness goals. Strength & cardiovascular
training is vital for all ages which will provide an effective workout, producing results that will
encourage you to reach your fitness goals and maintain the body you have always wanted.
Spending 15 to 30 minutes a day, three times a week, is all you need to start seeing the
benefits of a regular exercise program.
As a premium exercise equipment manufacturer, we are committed to your complete satisfaction. If
you have questions, suggestions or find missing or damaged parts, we guarantee your complete
satisfaction through our authorized dealer network or by contacting us directly. Please call your
local dealer or BODYCRAFT.
BODYCRAFT (a division of Recreation Supply, Inc.)
7699 Green Meadows Dr.
Lewis Center, OH 43035
Phone: [phone] am - 5 pm EST Email: [email protected]
Proof of purchase must be supplied to validate warranty and the product must have been
registered with BODYCRAFT via online at www.bodycraft.com or by calling 800-990-5556
or 740-965-2442 M-F 9 a.m. - 5 p.m. EST.
For parts orders, owner’s manuals, software
update files, exercise guides and contact
information scan this QR code.
Or go to:
https://www.bodycraft.com/customer-support

Product Safety Information
Product Safety ……………………………………………………………...
Important Notes, Recommended Tools & Cleaners ……………………..
Warning Labels, Maintenance Schedule & Serial Number….…………....
Product Overview
Assembly Parts & Hardware List…………………………………………….
Shipping Boxes Dims & What’s Inside…………………………………
Product Assembly
Pre-Assembly Tips ………………………………………………………....
STEP 1 - STEP 12……………………….……………………………………….
STEP 13 - Final Assembly Clean Up, & Polish………………………...
Maintenance & Repair
Strength Cable Wear Indicators ………………………………………….
Detailed Parts Exploded View……………………………………………..….
Detailed Parts List ……………………………………………………………….
Warranty
Product Warranty Registration ............................................….….…….....
Contact Us & Required Info BEFORE Initiating a Service Case….…..
Table of Contents, Dual Inner / Outer Thigh (DIO)
Page
4
5
6
7 - 8
9
10
11- 24
25
26
27
28- 30
31
32

There is a risk assumed by individuals who use this type of equipment. A
moment’s lack of attention can result in an accident, as can failure to
observe certain simple safety precautions.
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 BODYCRAFT product
prior to use.
● Before beginning this or any other exercise program, consult your physician. This is
especially important for individuals over the age of 35 or persons with preexisting health
problems. Recreation Supply, Inc. assumes no responsibility for personal injury or property
damage sustained by or through use of this product.
●Exercise with care to avoid injury. Do not attempt to lift more weight than you can control
safely.
● This product must be assembled on a flat, level surface to assure its proper function.
● Clean pads and frame on a regular basis. We recommend warm, soapy water. Do not use
harsh or abrasive chemicals.
● Inspect and tighten all parts before every use. Replace any worn parts immediately.
Failure to do so may result in serious injury.
● Keep children away from any BODYCRAFT strength
machines at all times.
● Keep your hands away from cables and pulleys during operation,
other than the designated handles.
●Keep hands, limbs, loose clothing and long hair well out of the way of moving parts.
●Make certain all cables are seated within the pulleys before every use. Frayed or worn cables
can be dangerous and may cause injury. Periodically check the cable for any indication of wear.
● Inspect the unit 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 the defective part is
repaired or replaced.
●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 [e-mail]
Product Safety - Functional Trainers, Duals & Multi-Gyms
4

Important Notes and Tips:
1. 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.
3. Be cautious not to damage the flooring when assembling. Place a protectant down such as a
rubber mat or shipping blanket.
4. Let plastics and weight stacks acclimate to room temperature before you begin assembly.
5. Two people are recommended for the safe assembly of this equipment.
6. Insert all bolts in the same direction when possible. Do not tighten until instructed.
7. Carefully install plastic caps using a rubber mallet.
8. When measuring bolt lengths, only measure the shank.
9. When the installation is complete, be sure to
regularly check for rust or damage, and
perform preventative maintenance.
Important Notes, Recommended Tools & Cleaners, (DIO)
THE FOLLOWING TOOLS ARE RECOMMENDED FOR EASIER ASSEMBLY:
SOCKET SET WITH 3“ & 6”
EXTENSION for 13mm & 17mm
OPEN & CLOSED WRENCHES
for 13mm & 17mm
ALLEN WRENCHES SET
4mm to 10mm)
PHILLIPS SCREWDRIVERS
#2 w/ Magnetic TIP
TIP ON FRAME ONLY: For extra
protection from fingerprints,
sweat stains or just plain dirt,
apply an automotive grade
cleaner wax if desired. Also
makes future cleaning easier.
THE FOLLOWING IS RECOMMENDED FOR CLEANING:
100% COTTON
CLEANING CLOTHS (Do Not Use on the Upholstery)
MILD CLEANING
SOLUTION 5
ALLEN WRENCH SET
1/16” thu 3/8" SAE
Recommended Tools
ALLEN WRENCH SET
(Only 7/32 is needed)
TORQUE WRENCH
3/8 DRIVE
SOCKET SET 3/8 DRIVE & 6” EXT
(Only 9/16 Socket is needed)
OPEN, CLOSED &
ADJUSTABLE WRENCHES
(Only 9/16 is needed)
TORQUE WRENCH
3/8 DRIVE
(w/ 5/32", 7/32 &1/4
Hex Bit Socket)
THE FOLLOWING TOOLS ARE RECOMMENDED FOR ASSEMBLY:
RUBBER MALLET &
ALLEN WRENCH SET
(w/ 5/32", 7/32 &1/4 are
needed)
ALLEN WRENCH SET
(Only 5/16 & 3mm
are needed)

Warning Labels, Maintenance Schedule & Serial Number, (DIO)
6
Carefully read ALL warning, caution & maintenance schedule labels
122
For the label placement on the DIO go directly to the Owner’s Manual
Open your Camera
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(110)
(111)
(112)
(103)
(104)
(105)
(106)
(107)
(108) (109)
(113) (114)
(115) (116)

Assembly Parts, Dual Inner / Outer Thigh (DIO) 1 of 2
7NOTE: Parts are not to scale
Part # Assembly Parts List QTY
DMP-001-ASM Frame, Weight Stack - Assembly 1
DMP-002-ASM Frame, Main - Assembly 1
DMP-003 Frame, Connector, Rear 1
DMP-004 Frame, Connector, Bottom 1
DMP-005-ASM Frame, Front Stabilizer - Assembly 1
DMP-006 Frame, Selector Rail for Seat Adjustments 1
DMP-007-ASM Frame, Support for Back Pad - Assembly 1
DMP-008-ASM Frame, Connector for Back Pad - Assembly 1
DMP-009-ASM Frame, Support for Seat Pad, w/ Roller Wheels - Assembly 1
DMP-010-ASM Press Arm - Assembly 1
DMP-011-ASM Frame, Pivot for Press Arm - Assembly 1
DMP-014
Axle, for Press Arm, w/ One Side Flat Notch, 25.4mm OD ×
3/8“ Threaded ID × 146mm L 2
DMP-015 Pad, Head 1
DMP-016 Pad, Seat 1
DMP-017 Pad, Back 1
DMP-018-ASM Cable, Main 200.7“ (5,100mm）L - Assembly 1
DMP-020-ASM Weight Stack Shroud Cover, Top - Assembly 1
DMP-021 Weight Stack Shroud Cover, Rear 1
DMP-022-ASM Weight Stack Shroud Cover, Front - Assembly 1
DMP-023 Rubber Cushion for Weight Stack 4
DMP-029 Stopper, Rubber w/ Washer for Bottom of Back Pad Frame 1
DMP-034 Selector Pin w/ Lanyard, Aluminum - BLUE 1
DMP-035-ASM Top Plate w/ Selector Rod- Assembly 1
DMP-036
Guide Rod for Weight Stack, 0.75" OD x 50.3" L, 3/8" Inner
Thread on One End 2
DMP-041 Pulley, 90mm (3-1/2") x δ26mm ID 1
DMP-082 Weight Plate, 10lbs (4.5kg) 19
DMP-085 Clevis Bracket for Cable End attachment, 24mm OD×47mm L 1
DMP-086 Sticker Set for Weight Stack 1
DMP-091 Silicone Lube Bottle, for Guide Rods 1
Part # Assembly Parts List QTY
DIO-001-ASM Frame, Weight Stack - Assembly 1
DIO-002-ASM Frame, Main - Assembly 1
DIO-003-ASM Frame, Pivot Axle Support Tube -
Assembly 2
DIO-004-ASM Frame, Cam Support Tube -
Assembly 1
DIO-005 Frame, Leg Pad Pivot Bracket 2
DIO-006-ASM Frame, Handlebar - Assembly 1
DIO-007-ASM Frame, Leg Arm, Left - Assembly 1
DIO-008-ASM Frame, Leg Arm, Right -
Assembly 1
DIO-009-ASM Cam, w/ Adjustment Holes -
Assembly 1
DIO-010-ASM Floating Pulley Bracket -
Assembly 1
DIO-011 Pivot Actuator Plate 1
DIO-013 Stack Spacer, Short 3.25" 2
DIO-014-ASM Weight Stack Shroud Cover, Top
- Assembly 1
DIO-015-ASM Weight Stack Shroud Cover,
Front - Assembly 1
DIO-016 Weight Stack Shroud Cover,
Rear 1
DIO-018 Cable, Upper 63.5" (1,613mm) L 1
DIO-019 Cable, Lower 124-1/2"
(3,163mm) L 1
DIO-020 Pad, Leg 2
DIO-021 Pad, Seat 1
DIO-022 Pad, Back 1

8NOTE: Parts are not to scale
NOTE: For a complete service parts list, please refer to the detailed parts list & exploded view
…………………………………….at the rear of this manual.
Assembly Parts, Dual Inner / Outer Thigh (DIO) 2 of 2
Part # Assembly Hardware QTY
DMP-055 Bolt, Hex, 3/8″ x 1″ L 4
DMP-056 Bolt, Hex, 3/8″ x 1-1/4″ L 11
DMP-057 Bolt, Hex, 3/8″ x 1-3/4″ L 1
DMP-059 Bolt, Hex, 3/8″ x 3″ L 4
DMP-060 Bolt, Hex, 3/8″ x 3-1/2″ L 2
DMP-061 Bolt, Hex, 3/8″ x 5″ L 2
DMP-063 Bolt, Hex, 1/2″ x 5-1/4″ L 1
DMP-064 Bolt, Hex, 1/2″ x 5-1/2″ L 1
DMP-065 Bolt, Hex, 1/2″ x 5-3/4″ L 1
DMP-067 Bolt, Recessed Flat Head, 3/8" x 1-1/2" L 1
DMP-069 Bolt, Recessed Countersunk Head, M6 x 50mm L 1
DMP-071 Bolt, Shoulder, 5/16" x φ9.5mm x 19mm L 1
DMP-073 Washer, Spring, 3/8" 15
DMP-074 Washer, Spring, 1/2" 1
DMP-075 Washer, Flat, 3/8″ 27
DMP-076 Washer, Flat, 1/2" 6
DMP-077 Washer, Flat, Large, 3/8″ 6
DMP-079 Nut, Nylon Lock, Thick, 5/16″ 1
DMP-080 Nut, Nylon Lock, Thin, 1/2″ 3
DMP-081 Nut, Nylon Lock, Thin, 3/8″ 9
DMP-087 Wrench, Hex, 3/32" 1
DMP-088 Wrench, Hex, 4mm 1
DMP-089 Wrench, Hex, 7/32" 1
DMP-090 Wrench, Hex, 1/4" 1
Part # Assembly Parts List QTY
DIO-024 Guide Rod for Weight Stack, 0.75" OD x 50.3" L, 3/8" Inner
Thread on One End 2
DIO-028-ASM Top Plate - Assembly 1
DIO-031 Selector Pin w/ Lanyard, Aluminum - BLUE 1
DIO-034 Stopper, Rubber on Cable to Top Plate 1
DIO-037 Stopper, Rubber w/ Washer for Leg Pad 2
DIO-045 Rubber Cushion for Weight Stack 2
DIO-046 Axle, Pivot, 1" x 13-1/4" for Leg Arms w/ Dual Notched Top
Side & Solid Round Bottom Side 2
DIO-047 Weight Plate, 10 lbs (4.5kg), Standard 150 lb Stack 14
DIO-47B-OPT OPTION - Weight Plate, 15 lbs (6.8kg), Upgraded 175 lb
Weight Stack w/ 9 each #47 Plates 5
DIO-048 Sticker Set for Weight Stack, 10 lbs to 175 lbs 1
DIO-085 Silicone Lube Bottle, for Guide Rods 1
Part # Assembly Hardware QTY
DIO-055 Bolt, Split, 1/2" x 1-1/4" L 1
DIO-056 Bolt, Split, 1/2" x 3-1/2" L 1
DIO-057 Bolt, Hex, 3/8" x 1" L 4
DIO-059 Bolt, Hex, 3/8" x 1-1/2" L 2
DIO-062 Bolt, Hex, 3/8" x 2-5/8" L 2
DIO-063 Bolt, Hex, 3/8" x 2-3/4" L 3
DIO-065 Bolt, Hex, 3/8" x 3-1/4" L 4
DIO-067 Bolt, Hex, 3/8" x 5-1/8" L 2
DIO-068 Bolt, Recessed Countersunk
Head, M6 x 50mm L 1
DIO-071 Bolt, Flat Head, 3/8" x 1-3/4" L 2
DIO-075 Washer, Spring, 3/8" 12
DIO-076 Washer, Spring, 1/2" 2
DIO-077 Washer, Flat, 3/8" 21
DIO-078 Washer, Flat, Large,3/8" 5
DIO-079 Nut, Hex, 1/2" 1
DIO-081 Nut, Nylon Lock, Thin, 3/8" 9
DIO-082 Wrench, Hex, 5/32" 1
DIO-083 Wrench, Hex, 7/32" 1
DIO-084 Wrench, Hex, 1/4" 1

Shipping Boxes & What’s Inside Each One, Dual Inner / Outer Thigh (DIO)
9
Large Box 1 of 2
Net Weight: 150 lbs (68 KG)
Gross Weight: 167 lbs (75.6 KG)
Box Size: 67'' L x 41'' W x 15'' H
(1,700mm L x 1,035mm W x 372mm H)
Large Box 2 of 2
Net Weight: 106 lbs (49 KG)
Gross Weight: 125 lbs (56.4 KG)
Box Size: 60'' L x 24'' W x 14'' H
(1,500mm L x 595mm W x 347mm H)
Small Boxes 3 ea. (total)
Upgraded to 175 lb Stack?
1 box, 4ea of 10 lb plates = 40 lbs per CWP10(4) box
1 box, 5ea of 10 lb plates = 50 lbs per CWP10(5) box
1 box, 5ea of 15 lb plates = 75 lbs per CWP15(5) box
BODYCRAFT reserves the right to make improvements at any time which may affect color, parts, materials, size, weight, or any other aspect.
Standard 150 lb Stack
1 box, 4ea of 10 lb plates = 40 lbs per CWP10(4) box
2 boxes, 5ea of 10 lb plates = 50 lbs per CWP10(5) box
Upgraded to 250 lb Stacks?
2 box, 4ea of 10 lb plates = 40 lbs per CWP10(4) box
2 box, 5ea of 10 lb plates = 50 lbs per CWP10(5) box
2 boxes, 5ea of 15 lb plates = 75 lbs per CWP15(5) box
Standard 200 lb Stacks
2 box, 4ea of 10 lb plates = 40 lbs per CWP10(4) box
6 box, 5ea of 10 lb plates = 50 lbs per CWP10(5) box
CWP10(4) Size: 11'' L x 5'' W x 5'' H ea.
(264mm L x 110mm W x 115mm H)
CWP10(5) Size: 11'' L x 5'' W x 6'' H ea.
(264mm L x 110mm W x 140mm H)
CWP15(5) Size: 13'' L x 6'' W x 6'' H ea.
(310mm L x 130mm W x 140mm H)

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.
PREASSEMBLY TIP #2 – Unpackaging & organizing.
PREASSEMBLY TIP #3 – Keep hardware loose until asked to tighten.
During the assembly, hardware needs to be finger tight until the STEPS of “Torque Time”. This will
ensure sub-frame and other parts will easily fit together and not strip out bolt threads during assembly.
10
The best practice in assembly is to take all the
parts out of the boxes & bags and line up in order
of assembly. This enables a mindset of what you
will be assembling, their physical sizes and what
challenges you might face BEFORE you begin.
Right Side
Back
Front
Left Side
Top