Pro-Form XP 160 831.28645.1 User manual

ELLIPTICAL EXERCISER

User’s Manual

CAUTION

Read all precautions and instruc-

tions in this manual before using

this equipment. Keep this manu-

al for future reference.

Serial Number

Decal

(on underside

of frame)

Model No. 831.28645.1

Serial No.

• Assembly

• Operation

• Maintenance

• Part List and Drawing

Sears, Roebuck and Co., Hoffman Estates, IL 60179

TABLE OF CONTENTS

WARNING DECAL PLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

HOW TO USE THE ELLIPTICAL EXERCISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

EXERCISE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

PART LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

EXPLODED DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

90 DAY FULL WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover

WARNING DECAL PLACEMENT

The warning decal shown here has

been applied in the location shown.

If the decal is missing or illegible,

call 1-888-533-1333 and request a

free replacement decal. Apply the

decal in the location shown. Note:

The decal may not be shown at

actual size.

1. Before beginning any exercise program,

consult your physician. This is especially

important for persons over the age of 35 or

persons with pre-existing health problems.

2. It is the responsibility of the owner to ensure

that all users of the elliptical exerciser are

adequately informed of all precautions.

3. Your elliptical exerciser is intended for home

use only. Do not use your elliptical exerciser

in a commercial, rental, or institutional set-

ting.

4. Keep your elliptical exerciser indoors, away

from moisture and dust. Place your elliptical

exerciser on a level surface, with a mat

beneath it to protect the floor or carpet.

Make sure that there is enough clearance

around your elliptical exerciser to mount,

dismount, and use it.

5. Inspect and properly tighten all parts regu-

larly. Replace any worn parts immediately.

6. Keep children under age 12 and pets away

from your elliptical exerciser at all times.

7. Your elliptical exerciser should not be used

by persons weighing more than 275 lbs.

(124 kg).

8. Wear appropriate exercise clothes when

exercising; do not wear loose clothes that

could become caught on your elliptical exer-

ciser. Always wear athletic shoes for foot

protection.

9. Hold the handgrip pulse sensor or the upper

body arms when mounting, dismounting, or

using your elliptical exerciser.

10. Keep your back straight while using your

elliptical exerciser; do not arch your back.

11. The pulse sensor is not a medical device.

Various factors, including the user’s move-

ment, may affect the accuracy of heart rate

readings. The pulse sensor is intended only

as an exercise aid in determining heart rate

trends in general.

12. When you stop exercising, allow the pedals

to slowly come to a stop.

13. If you feel pain or dizziness while exercising,

stop immediately and cool down.

14. Use your elliptical exerciser only as

described in this manual.

WARNING: To reduce the risk of serious injury, read all important precautions and

instructions in this manual and all warnings on your elliptical exerciser before using your elliptical

exerciser. Sears assumes no responsibility for personal injury or property damage sustained by or

through the use of this product.

IMPORTANT PRECAUTIONS

BEFORE YOU BEGIN

Thank you for selecting the new PROFORM®XP 160

elliptical exerciser. The PROFORM XP 160 elliptical

exerciser provides a wide array of features designed

to make your workouts at home more effective and

enjoyable.

For your benefit, read this manual carefully before

you use the elliptical exerciser. If you have ques-

tions after reading this manual, please see the back

cover of this manual. To help us assist you, note the

product model number and serial number before con-

tacting us. The model number and the location of the

serial number decal are shown on the front cover of

this manual.

Before reading further, please familiarize yourself with

the parts that are labeled in the drawing below.

Handgrip Pulse Sensor

Handlebar

Wheel

Pedal

Console

Water Bottle Holder*

Accessory Tray

Leveling Foot

Fan

*No water bottle is included

M8 Split

Washer (72)–2

M4 x 16mm

Self-tapping

Screw (79)–10

M8 x 42mm Bolt

(71)–4

M10 x 20mm x

1mm Washer

(81)–2

M4 x 16mm

Screw (86)–4

M10 Spacer

(76)–2

M6 x 35mm Phillips

Screw (87)–8

M6 Split

Washer (88)–8

M10 x 23mm Shoulder

Screw (80)–2

M4 x 13mm

Washer (93)–2

M10 x 25mm

Washer

(94)–10

M8 Nylon

Locknut (96)–4

M10 Nylon

Locknut (97)–2

Star Washer

(92)–3

M10 x 20mm Patch

Screw (91)–10

Wave Washer

(98)–8

M8 x 16mm Patch

Screw (95)–3

M8 x 48mm Patch

Screw (78)–2

M10 x 62mm Patch Bolt (89)–4 M10 x 78mm Patch Screw (90)–2

ASSEMBLY

Assembly requires two persons. Place all parts of the elliptical exerciser in a cleared area and remove the

packing materials. Do not dispose of the packing materials until assembly is completed. In addition to the

included hex keys, assembly requires a Phillips screwdriver , an adjustable

wrench , and a rubber mallet .

As you assemble the elliptical exerciser, use the drawings below to identify small parts. The number in parentheses

below each drawing is the key number of the part, from the PART LIST near the end of this manual. The number

following the parentheses is the quantity needed for assembly. IMPORTANT: Some small parts may have been

pre-assembled. If a part is not in the parts bag, check to see if it has been pre-assembled. If a part is

missing, call 1-888-533-1333.

Orient the the Front Stabilizer (35) as shown.

Attach the two Wheels (25) to the Front Stabilizer

with two M10 x 62mm Patch Bolts (89) and two

M10 Nylon Locknuts (97).

Attach two Feet (26) to the underside of the

Front Stabilizer (35).

2. Have a second person tip the Frame (2) back-

ward. Attach the Front Stabilizer (35) to the

Frame with two M10 x 78mm Patch Screws (90).

To make assembly easier, read the

information on page 5 before you begin

assembling the elliptical exerciser.

3. Orient the Base (1) near the Frame (2) as

shown. See the inset drawing. Attach two Feet

(26) to the underside of the Base.

Have a second person tip the Frame (2) forward.

Insert the Base (1) into the Frame. Attach the

Base with two M10 x 62mm Patch Bolts (89), two

M10 Spacers (76), two M8 x 48mm Patch

Screws (78), and two M8 Split Washers (72).

4. Have a second person hold the Upright (6) near

the Frame (2) as shown.

Pull the Wire Harness (48) out of the Frame (2)

and insert it upward through the Upright (6). Do

not let the Wire Harness fall into the Upright; use

a piece of tape or an elastic band to hold the

Wire Harness in place until step 12.

Insert the Upright (6) into the Frame (2). Attach

the Upright with three M8 x 16mm Patch Screws

(95) and three Star Washers (92). Avoid pinch-

ing the Wire Harness (48) between the

Upright and the Frame.

5. Identify the Left Roller Leg (12), which is marked

with a “Left” sticker. Orient the Left Roller Leg as

shown near the left Crank Arm (36).

Apply a small amount of the included grease to

both sides of a Wave Washer (98). Also, apply

grease to the Roller (22) on the Left Roller Leg

(12); spread the grease evenly around the

Roller.

Slide the Wave Washer (98) onto the left Crank

Arm (36). Next, slide the Left Roller Leg (12)

onto the Crank Arm and set the Roller (22) on

the Base (1). Attach the Left Roller Leg with an

M10 x 20mm Patch Screw (91), a Crank Axle

Cap (30), and an M10 x 25mm Washer (94).

Repeat this step to attach the Right Roller

Leg (21) to the right Crank Arm (not shown).

536

Grease

91 12

Grease

6. Identify the Left Handlebar (8), which is marked

with a “Left” sticker. Insert the Left Handlebar into

one of the Handlebar Legs (11) as shown.

Attach the Left Handlebar (8) with two M8 x

42mm Bolts (71) and two M8 Nylon Locknuts

(96). Make sure that the Nylon Locknuts are

inside the hexagonal holes.

Assemble the Right Handlebar (not shown)

and the other Handlebar Leg (not shown) in

the same way.

11 71

Hexagonal

Hole

Hexagonal

Hole

7. Position an Inner Handlebar Cover (18) and an

Outer Handlebar Cover (19) around the Left

Handlebar (8) as shown.

Attach the Inner and Outer Handlebar Covers

(18, 19) with three M4 x 16mm Self-tapping

Screws (79) and an M4 x 13mm Washer (93).

Start all three Self-tapping Screws before

tightening them.

Repeat this step for the Right Handlebar (not

shown).

18 79

8. Apply a generous amount of grease to the Pivot

Axle (65) and insert it into the Frame (2).

Attach the two Frame Covers (17) to the Frame

(2) with four M4 x 16mm Screws (86) as shown.

886

Grease

9. Apply a small amount of grease to both sides of

a Wave Washer (98). Slide the Wave Washer

onto the left side of the Pivot Axle (65). Next,

slide the Left Handlebar (8) onto the Pivot Axle

as shown.

Attach the Left Handlebar (8) with an M10 x

23mm Shoulder Screw (80) and an M10 x 20mm

x 1mm Washer (81).

Repeat this step to attach the Right

Handlebar (9) to the Pivot Axle (65).

Grease

10. Identify the Left Pedal (13) and the Left Pedal

Leg (14), which are marked with “Left” stickers,

and orient them as shown.

Attach the Left Pedal (13) to the Left Pedal Leg

(14) with four M6 x 35mm Phillips Screws (87)

and four M6 Split Washers (88). Start all four

Phillips Screws before tightening them.

Repeat this step to attach the Right Pedal

(not shown) to the Right Pedal Leg (not

shown).

88 88

11. Apply a generous amount of grease to two Pedal

Leg Axles (32). Insert one Pedal Leg Axle into

the bottom of the left Handlebar Leg (11). Insert

the other Pedal Leg Axle into the Left Roller

Leg (12).

Apply a small amount of grease to both sides of

two Wave Washers (98). Place a Wave Washer

on each Pedal Leg Axle (32).

Orient the Left Pedal Leg (14) as shown, and

slide it onto the Pedal Leg Axles (32). Attach the

Left Pedal Leg to the left Handlebar Leg (11) with

two M10 x 20mm Patch Screws (91), two Axle

Caps (31), and two M10 x 25mm Washers (94).

Attach the Left Pedal Leg (14) to the Left Roller

Leg (12) with two M10 x 20mm Patch Screws

(91) and two M10 x 25mm Washers (94); do not

overtighten the Patch Screws. The Legs (11,

14, 12) must be able to pivot freely.

Repeat this step for the Right Pedal Leg (not

shown).

14 94

94 91

Grease

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