Assembly Manual Cross-Trainer ,,Astro" Item # 7853-690 Assembly must be carried out by an adult! Environmentaly friendly: printed on 100% recycled paper Assembly Instructions Please, thoroughly read these instructions prior to assembly and first use. You will get important information about your safety as well as the use and maintenance of your Cross-Trainer. Keep these instructions for reference and/or for maintenance work or spare parts orders. For Your Safety: Only use the Cross-Trainer for its intended purpose, i.e. for the physical training of adult persons. Any other use is inadmissible and may be dangerous. The manufacturer cannot be made liable for damage caused by a use that does not correspond with the intended purpose. You train with an equipment that has been designed in accordance with the latest state of the art regarding safety. Possible danger spots that may cause injuries have been avoided and safeguarded as well as possible. Improper repairs and design changes (disassembly of original parts, installation of inadmissible parts, etc.) may cause hazards for the user. Defective parts may impair your safety and the service life of your equipment. Therefore, please exchange defective or worn parts immediately. If you have any doubt or any queries, please contact your specialised dealer. If you train regularly and intensively, please check all equipment parts ­ in particular bolts and nuts ­ every 1 to 2 months. This is particularly true for the attachment of grip strap and running plate. Inform present persons (especially children) about possible hazards during your exercises. Prior to taking up training, have your family doctor check whether your state of health is sufficient to train with this equipment. The medical findings should be the basis for the build-up or your training program. Wrong or excessive training may lead to damage to your health. By all means observe the information about the organisation of training in the training instructions. Our products are subject to a constant innovative quality assurance. We reserve the right to perform technical changes resulting therefrom. Handling the equipment Before using the equipment for exercise, check carefully to ensure that it has been correctly assembled. It is not recommended to use or store the apparatus in a damp room as this may cause it to rust. Please ensure that no part of the machine comes in contact with liquids (drinks, perspiration etc.). This may cause corrosion. The Cross-Trainer is designed for use by adults and children should not be allowed to play with it. Children at play behave unpredictably and dangerous situations may occur for which the manufacturer cannot be held liable. If, in spite of this, children are allowed to use the equipment, ensure that they are instructed in its proper use and supervised accordingly. The Cross-Trainer complies with the DIN EN 957 - 1/5, class B. It is therefore unsuitable for therapeutic use. On principle, the equipment does not require any special maintenance. All bearings are pre-lubricated (further lubrication is not required) and require little maintenance. Do not use corrosive or abrasive materials to clean the equipment. Ensure that such materials are not allowed to pollute the environment. The exercise cycle has a brake system, which require little maintenance and does not require any adjusting work. To operate correctly, the pulse function requires a minimum voltage of 2,7 volts. The Cross-Trainer is dependent of revolutions per minute. Please ensure that liquids or perspiration never enter the machine or the electronics. Before use, always check all screws and plug-in connections as well as respective safety devices fit correctly. Please keep original packaging of this article, so that it may be used for transport at a later date, if necessary. Instructions for Assembly Ensure that you have received all the parts required ( see check list ) and that they are undamaged. Should you have any cause for complaint, please contact your KETTLER dealer. Before assembling the equipment, study the drawings carefully and carry out the operations in the order shown by the diagrams. The correct sequence is given in capital letters. The equipment must be assembled with due care by an adult person. If in doubt call upon the help of a second person, if possible technically talented. Please note that there is always a danger of injury when working with tools or doing manual work. Therefore please be careful when assembling this machine. Ensure that your working area is free of possible sources of danger, for example don't leave any tools lying around. Always dispose packaging material in such a way that it may not cause any danger. There is always a risk of suffocation if children play with plastic bags! The fastening material required for each assembly step is shown in the diagram inset. Use the fastening material exactly as instructed. The required tools are supplied with the equipment. Bolt all the parts together loosely at first, and check that they have been assembled correctly. Tighten the locknuts by hand until resistance is felt, then use spanner to finally tighten nuts completely against resistance (locking device). Then check that all screw connections have been tightened firmly. Attention: once locknuts have been unscrewed they no longer function correctly (the locking device is destroyed), and must be replaced. For technical reasons, we reserve the right to carry out preliminary assembly work (e.g. addition of tubing plugs). List of spare parts When ordering spare parts, always state the full article number, sparepart number, the quantity required and the inspection number stamped on the back. Example order: Art. no. 7853-090 / spare-part no. 94313288/ 2 pieces / inspection no. ......... Important: spare part prices do not include fastening material; if fastening material (bolts, nuts, washers etc.) is required, this should be 2 clearly stated on the order by adding the words ,,with fastening material". Checklist M 10 x 105 M 8 x 16 2 6 4 4 1 2 1 6 2 2 4 1 4 1 2 1 1 1 M 8 x 70 M 5 x 45 M 5 x 90 1 M 10 M5 1 ø 21 M8 2 ø 25 / 8, 4 ø 25 / 10,4 ø 14,5 ø 12 1 3,9 x 19 1 1 2 3,9 x 32 1 ø 10x49 1 1 ø 22 2 2 2 ø 44 1 1 2 4 8 2 2 3 1a 1b 2 3 IZE AL S ACTU 4 4 6 1 klick..... IZE AL S ACTU A 5 F 7 ACT UAL SIZ E B ! 1. ,,D" 2. ,,E" ! A C B E D ACT UAL A B SIZE IZE AL S ACTU 5 8 A A B B yellowl- ! E SIZ AL TU AC max.0,12 inches 6 9 ACTUAL S IZE 10 ACTU AL S IZE 7 11 IZE LS A TU AC 12 IZE LS A TU AC 8 13 ACTUAL SIZE Handling ! ! 9 Spare parts drawing 46 50 28 27 29 16 32 56 37 40 47 39 63 57 5 11 31 36 2 17 7 58 3 9 59 15 4 12 55 13 10 6 23 44 30 25 61 14 51 51 48 41 45 54 26 24 43 68 67 34 66 62 70 65 8 34 33 50 49 53 69 21 21 22 23 42 1 19 18 KETTLER International Inc., P.O. Box 2747, Virginia Beach, VA 23450-2747, call (800) 733-7999, fax (757) 427-0183. For parts or service call 757-427-2400 ext 30 or send e-mail to: PARTS@KETTLERUSA.COM KETTLER International Inc. · 1355 London Bridge Road · USA-Virginia Beach, Virginia 23456 USA World Wide Web address: www.kettlerusa.com 10 List of spare parts Cross-Trainer Astro. pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52 53 54 55 56 57 58 59 60 61 7853-090 qty. 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 2 1 1 2 2 1 1 2 1 2 2 1 2 1 1 1 2 4 1 1 2 2 2 1 1 1 2 2 1 1 2 6 1 2 2 2 1 1 2 1 3 1 description Grundgestell Geschwindigkeitsabnehmer Welle mit Bef.-Mat. Lageraufnahme mit zwei Buchsen (Z-Nr. 2579) Riemenscheibe Magnetbügel mit 3 Magnetsegmentteilen Befestigungsblech Schwungrad (montiert) Poly-V-Riemen Spannwinkel mit Kugellager (montiert) Laufrad (genietet) mit Adapter Magnetsegmentteil Zugfeder Umlenkrolle Bowdenzug kpl. Lageraufnahme mit zwei Buchsen (Z-Nr. 3418) Pulsaufnehmer/Ohrclip Abdeckkappe Verkleidung (rechts) Verkleidung (links) Bodenrohr Bodenschoner mit Höhenverstellung Rollenschonerpaar Lenkerrohr (kpl. mit Lagerbuchsen und Achse) Lagerbuchse Achse ø11,95x350mm für Lageraufnahme Lageraufnahme für Armhebel Lagerschale für Armhebel Verstelleinheit (kpl.) Kugellager 6001-ZZ Bolzen 20x133 m. Linksgewinde Computer ST 2302-8 Verlängerungskabel Pedalarm mit Kugellagern 6203-ZZ Kugellager 6203-ZZ Armhebel links (kpl. mit Griffschlauch, Stopfen für ø28mm, Lagerschale, Lageraufnahme und Kugellagern 6200-ZZ und 6001-ZZ) Armhebel rechts (kpl. mit Griffschlauch, Stopfen für ø28mm, Lagerschale, Lageraufnahme und Kugellagern 6200-ZZ und 6001-ZZ) Griffschlauch 680mm Stopfen für ø28mm Distanzhülse für Pedalarm Lenkerrohrabdeckung Fußtritt (rechts) Fußtritt (links) Dichtscheibe ø22x9,2x1mm mit Beschichtung Abdeckkappe Handpulsaufnehmer WP 1007-5C Bolzen 20x133 m. Rechtsgewinde Distanzrohr ø20x4,5x59mm Kugellager 6200-ZZ Schraubenbeutel Spezialschraube M10x105mm Abdeckkappe Kugellager 6300-ZZ für Spannwinkel Cockpit-Oberteil Cockpit-Unterteil Kugellager 6203-ZZ C3 für Grundrahmen Zugfeder MITTO-Plastikschraube 4x35mm Griffbügel (kpl. mit Griffschläuchen und Handpulsaufnehmer) spare parts no. 94314072 67000707 11300055 98585006 94313544 94313513 94314076 91140381 67005127 94313541 94313542 67000170 25635052 94314141 98585046 67000653 70128360 70128602 70128603 94313506 94312961 94601783 94314060 70128410 11300090 70128405 70128400 10121160 33100030 10900071 67000728 67000549 94314077 33100038 94313923 94313926 10118034 10100018 70133275 70128604 70128398 70128399 10505000 70128335 67000658 10900061 97201447 33100036 94314219 10206111 70130860 33100031 70128598 70128599 33100017 25615060 10224072 94314213 11 List of spare parts 62 63 64 65 66 67 68 69 70 Rändelmutter M5 Griffschlauch 280mm Folienpapier für Bodenrohre (ohne Abb.) Rundblockmagnet Gelenk-Seitenverkleidung (rechts) Gelenk-Seitenverkleidung (links) Gelenkpunkt-Verkleidung (Teil 1) Gelenkpunkt-Verkleidung (Teil 2) Spreizniete ø6x9,5mm 4 2 2 1 2 2 2 2 8 10104000 10118058 34010120 67000080 70128421 70128422 70128413 70128414 10418503 HEINZ KETTLER GmbH & Co.KG · Postfach 1020 · D- 59463 Ense-Parsit USA In case of complaint, please state this control number. docu 913a/09.02 ...