Ironman Fitness 235r User manual

315-00124
11/07 Rev B
SERIAL TAG IS LOCATED ON THE FRAME
Model Name: 235r
Date of Purchase:
Serial Number:
Owner’s Manual
Ironman 235r Recumbent
CAUTION! Read all precautions
and instructions in this manual
before using this equipment.
Customer Service
1.800.750.IRON
1.800.750.4766
4009 Distribution Drive
Suite 250
Garland, TX 75041
www.ironmanfitness.com

2
Important Safety Information 3
Assembly 5
Console Instructions 11
Monitoring Your Heart Rate 13
Warm-Up Exercises 15
Moving Instructions 18
Parts List 19
Exploded View 20
Warranty Information 21
Table of Contents

3
WARNING! Before using this unit or starting any exercise program, consult your physician.
This is especially important for persons over the age of 35 and/or persons with pre-existing
health problems. The manufacturer or distributor assumes no responsibility for personal injury
or property damage sustained by or through the use of this product.
WARNING! To reduce the risk of electrical shock, burns, fire, or other possible injuries to the
user, it is important to review this manual and the following precautions before operation.
SAFETY PRECAUTIONS AND TIPS
1. It is the owner's responsibility to ensure that all users of this unit have read the Owner's
Manual and are familiar with warnings and safety precautions.
2. This unit has a user maximum capacity of 275 pounds.
3. The unit should only be used on a level surface and is intended for indoor use only. The
unit should not be placed in a garage, patio, or near water and should never be used while
you are wet. Ironman Fitness recommends a mat be placed under the unit to protect floor
or carpet and for easier cleaning.
4. Follow safety information in regards to plugging in your unit. Do not run the power cord
underneath your unit. Do not operate the unit with a damaged or frayed power cord.
5. Wear comfortable, good-quality walking or running shoes and appropriate clothing. Do not
use the unit with bare feet, sandals, socks or stockings.
6. Always examine your unit before using to ensure all parts are in working order.
7. Allow the unit to fully stop before dismounting.
8. Pets should never be allowed near the unit.
9. Do not leave children unsupervised near or on the unit.
10. Never operate the unit where oxygen is being administered, or where aerosol products are
being used.
11. Never insert any object or body parts into any opening.
12. For safety and to prevent damage to your unit, no more than one person should use the
unit at a time.
13. Always unplug the unit before cleaning and/or servicing. Service to your unit should only be
performed by an authorized service representative, unless authorized and/or instructed by
the manufacturer.
14. Failure to follow these instructions will void the unit warranty.
Important Safety Information

4
Important Safety Information
PULSE GRIP
HANDLEBARS
CONSOLE
HANDLEBARS
FRONT STABILIZER w/
TRANSPORT WHEELS RIGHT PEDAL
LEFT PEDAL
Thank you for purchasing the Ironman 235r Recumbent Bike! The quality product you have
chosen was designed to meet your needs for cardiovascular exercise. Before you start, please
read the Owner’s Manual and become familiar with the operation of your new unit.
Remember to take time to perform stretching exercises, provided in this manual, to help avoid
injury.
If you are taking medication, consult your physician to see what effect the medication will have
on your exercise heart rate.
If you have heart problems, you are not active, and/or are over the age of 35 years, do not
use the pre-set programs or start an exercise program without first contacting and receiving
approval from your physician.
To avoid the risk of electrical shock, always keep the console dry. Do not spill liquids on the
console. Ironman Fitness recommends a sealed water bottle for beverages consumed while
using the unit.
Please review the following drawing below to familiarize yourself with the listed
parts.
BACK PAD
SEAT PAD
REAR STABILIZER

5
Getting Started - The Ironman Fitness 235r will require some assembly. Unpack the box in
a clear area. Remove packing material. Do not dispose of packing material until assembly
is complete and unit is working properly. Place the unit on a clean level surface for assem-
bly. Make sure there is easy access to an electrical outlet. Before assembling, the unit should
be placed as close as possible to its final location. If you are missing any parts, please call
Ironman Fitness at 1-888-340-0482. Tools have been provided to assist with product assem-
bly.
Assembly
Figure 1
Step 1:
Attach the rear stabilizer (4A) onto the
rear of main frame (1) using carriage
bolts (19), arc washers (49), and cap
nuts (21).
Step 2:
Attach the front stabilizer (4) onto the
front of the main frame (1) using carriage
bolts (19), washers (49), and cap nuts
(21).
Note: The stabilizer with roller wheels is
the front stabilizer.

6
Assembly
Figure 3
Step 1:
Attach the seat (9) to the seat carriage
(3) using screws (62) and washers (63).
Figure 4
Step 1:
Attach the back pad (60) to the seat car-
riage (3) using screws (62) and washers
(63).
Figure 2
Step 1:
Attach the seat handlebar (16) to the seat
carriage (3) using hex head bolts (73),
washers (49), and nylon nuts (50).

7
Assembly
Figure 5
Step 1:
Remove hex head screws (55) and screws
(70) from carriage tube (5).
Figure 6
Step 1:
Remove the left and right carriage tube
caps (13 & 14).
Figure 7
Step 1:
Remove hex head screw (55) and washer
(49) from the rear of carriage tube (5).

8
Assembly
Figure 9
Step 1:
Slide the seat carriage (3) onto the car-
riage tube (5) and secure using the lock-
ing knob located on the right hand side.
Step 2:
Connect pulse wires (64) coming from the
seat carriage to the pulse wires (75) com-
ing out of the carriage tube.
Step 3:
Use the clamp (69) and screw (70) to
secure the pulse wires in position.
Figure 10
Step 1:
Reconnect the extension pulse wire (75)
coming from the carriage tube to pulse
wire (57) from the main frame.
Step 2:
Attach the carriage tube (5) to the main
frame (1) by sliding the carriage tube
onto the carriage tube mount located on
the main frame. Secure using hex head
screws (55).
Step 3
Secure the rear of the carriage tube (5)
to main frame (1) using hex head screw
(55) and washer (49).
Figure 8
Step 1:
Slide the carriage tube (5) off of the main
frame (1).
Step 2:
Carefully disconnect pulse wire (57) from
extension pulse wire (75). Be sure not
to pull the pulse wires from the tube or
frame.

9
Assembly
Figure 12
Step 1:
Attach the left pedal (30) to the left
crank. The left pedal is marked with
an "L". Turn the threads on the pedal
counter-clockwise to secure it to the
crank.
Step 2:
Attach the right pedal (31) to the right
crank. The right pedal is marked with
an "R". Turn the threads on the pedal
clockwise to secure it to the crank.
Step 3:
Attach the pedal straps (30A and 31A)
to the appropriate pedal. Each strap is
marked with an "L" or an "R". The side
with 2 holes will go on the clip towards
the inside of the unit.
Figure 13
Step 1:
Attach the front handlebar (10) to the
console tube (2) using hex head screws
(55) and washers (49).
Figure 11
Step 1:
Reattach the carriage tube caps (13 & 14)
using screws (70).

10
Assembly
Figure 15
Step 1:
Connect the wires coming from the con-
sole (15) to pulse wires (66) and wire
harness (58).
Step 2:
Secure the console (15) to the console
tube (2) using screws (39).
Note: The screws are already pre-
installed into the back of the console.
Figure 14
Step 1:
Connect pulse wire (57) and wire har-
ness (38) coming from the main frame
to pulse wire (66) and wire harness (58)
from the console tube.
Step 2:
Slide the console tube (2) onto main
frame (1) and secure using hex head
screws (55) and curved washers (56).
Congratulations!
You have completed assembly of your new 235r bike!

11
Console Instructions
The 235r's console is a single LCD that displays RPM, SPEED, TIME, DISTANCE, CALORIES,
WATTS, and HEART RATE.
Power Modes
Power On: Make sure the AC adapter is plugged into an outlet. Press any button to turn on
the console. A long beep will sound and the entire LCD display will light up for 2 seconds.
Sleep: This occurs if the unit senses no pedal movement or if the console buttons have not
been pressed for 3 minutes.
Active: After the console enters sleep mode, press any button to turn on the console back on.
Buttons
Up/Down
During Setup Mode: They are used to select the workout program. They are also used to
change Time, Calories, and Distance.
During Workout: You can press the Up/Down buttons to increase or decrease the resistance
levels with increments of 1.
Start/Stop
During Setup Mode: This button is used as an enter key to confirm the Time, Calories,
Distance, and Pulse.
During Workout: It is used to pause workout mode. All workout data is stored during pause
mode.
Mode
During Setup Mode: This button is used to select the desired setting you wish to change
and to confirm the values entered (Time, Calories, Distance, Pulse).
Recovery
During Workout: This button is used to test the user's fitness level. The user must press
the button, then hold the pulse grips until the console counts down 60 seconds.

12
Program Operation
The 235r's console is set up with 12 workout modes, P1-P11, plus USER mode.
1. Press any button to turn on the console.
2. Use the Up/Down buttons to select the desired program.
3. Press the Mode button to confirm the program you wish to use.
4. Programs 1-10: These programs allow you to adjust your desired settings.
Example: If you wish to set a specific distance to your workout, press
the mode button until the Distance window is flashing, then use the Up/Down
buttons to set the desired distance. Press the Mode button once again to
confirm. Once all the desired parameters are set, press the Start/Stop button to
begin your workout.
Program 11: This program allows you to set your target heart rate (THR).
Example: During the setup mode for P11, the Pulse window will flash. Use the
Up/Down buttons to set your desired THR. You will be asked to set an upper and
lower limit. Press the Mode button to confirm the values then press the Start/
Stop button to begin. During the workout, an alarm will sound if your heart rate
exceeds the upper limit. You must use the pulse grips for this program to work.
See MONITORING YOUR HEART RATE section for more information.
Program 12: This user program lets you establish which resistance levels you want
at each time segment.
Example: After you select user program, enter the desired workout settings as
you would for P1-P10. Once you set your workout settings, you will be able to
adjust the workout profile. Press the Up/Down buttons to adjust the first
resistance level segment. Press the Mode button to confirm. Continue this
process until all 10 resistance level segments have been set. Once complete,
press the Start/Stop button to begin your workout.
Recovery Mode
This mode is used to determine your physical conditioning. This fitness test compares
your pulse rate before and after training. You will notice that your fitness will improve
with regular exercise.
During your workout, press the Recovery button. The Time window will begin to count
down 60 seconds. Hold onto the pulse grips until the 60 seconds has expired. Once
the console is done counting down, your score will be displayed in a value ranging from
F1 to F6, F1 being the best.
Console Instructions

13
Monitoring Your Heart Rate
Monitoring Your Heart Rate
To obtain the greatest cardiovascular benefits from your exercise workout, it is important to
work within your target heart rate zone. The American Heart Association (AHA) defines this
target as 60%-75% percent of your maximum heart rate.
Your maximum heart rate may be roughly calculated by subtracting your age from 220. Your
maximum heart rate and aerobic capacity naturally decreases as you age. This may vary from
one person to another, but use this number to find your approximate effective target zone. For
example, the maximum heart rate for an average 40 year-old is 180 bpm. The target heart
rate zone is 60%-75% of 180 or 108-135 bpm. See Fitness Safety below.
Before beginning your workout, check your normal resting heart rate. Place your fingers lightly
against your neck, or against your wrist over the main artery. After finding your pulse, count
the number of beats in 10 seconds. Multiply the number of beats by six to determine your
pulse rate per minute. We recommend taking your heart rate at these times; at rest, after
warming up, during your workout and two minutes into your cool down, to accurately track
your progress as it relates to better fitness.
During your first several months of exercising, the AHA recommends aiming for the lower part
of the target heart rate zone-60%, then gradually progressing up to 75%.
According to the AHA, exercising above 75% of your maximum heart rate may be too strenu-
ous unless you are in top physical condition. Exercising below 60% of your maximum will result
in minimal cardiovascular conditioning.
Check your pulse recovery rate – If your pulse is over 100 bpm five minutes after you stop
exercising, or if it’s higher than normal the morning after exercising, your exertion may have
been too strenuous for your current fitness level. Rest and reduce the intensity next time.
Fitness Safety The Heart Rate chart indicates average rate zones for different ages. A variety
of different factors (including medication, emotional state, temperature and other conditions)
can affect the target heart rate zone that is best for you. Your physician or health care profes-
sional can help you determine the exercise intensity that is appropriate for your age and condi-
tion.
(MHR) = Maximum Heart Rate
(THR) = Target Heart Rate
220 - age = maximum heart rate (MHZ)
MHZ x .60 = 60% of your maximum heart rate.
MHZ x .75 = 75% of your maximum heart rate.
For example, if you are 30 years old, your calculations will be as
follows:
220 - 30 = 190
190 x .60 = 114 (low end or 60% of MHZ)
190 x .75 = 142 (high end or 75% of MHZ)
30 year-old (THR) Target Heart Rate would be 114-142

14
Monitoring Your Heart Rate
100%
85%
75%
60%
Serious
athletic
training range
Cardiovascular
conditioning
range
Fat burning
range
20 25 30 35 40 45 50 55 60 65
AGE
200
195
190 185 180 175
170
165 160
155
170 166 162 157
153 149
145
140
136
132
150 146 143
139 135 131 128 124 120
116
120
117 114 111 108 105 102 99 96
93
TARGET HEART RATE ZONE

15
Warm Up Exercises
EXERCISE GUIDELINES
WARNING! Before beginning this or any exercise program, you should consult your physician.
This is especially important for individuals over the age of 35 or individuals with pre-existing
health problems.
Flexibility is a key to fitness. Stretch all major muscle groups at least two to three times per
week after a 5 to 10 minute warmup. Stretch just to the point of a gentle tug. If you have
back, joint, or other health problems, talk to your doctor first.
Prone on Elbows
Lie on your stomach with
your feet together. Rest
on your forearms with your
elbows directly under your
shoulders. Relax lower back
and abdomen into oor. Hold
for 30-60 seconds or until
muscles feel looser.
Supline Lumbar Rotation
Lie on your back with your
knees bent. Keeping your
knees together and your shoul-
ders against the oor, roll your
knees to one side until you feel
a stretch in your back or hip.
Hold for 30-60 seconds or until
muscles feel looser. Repeat on
opposite side.
Knees to Chest
Lie on your back. Bend your
knees, and lift your feet off the
oor. Grasp your knees with
your arms and pull your knees
toward your chest. Hold for 20
seconds. Repeat three to ve
times.
Cat and Camel
Rest on your hands and
knees. Round your back by
contracting your abdominal
muscles and tucking in your
pelvis; hold for ve seconds.
Then allow your back to sag
toward the oor as you lift
your chest and head; hold
for ve seconds. Repeat the
combination 10 times
Cervical Side Bends
Tilt your head gently toward
one shoulder, keeping your
shoulders level and your face
pointed straight ahead. Hold
for ve seconds, then tilt your
head toward the other shoulder
and hold for ve seconds. Re-
peat ve times on each side.
Shoulder Circles
In a smooth, continuous mo-
tion, make a circle with your
shoulders: Raise them up
towards your ears, pull them
together behind you, lower
them to a resting position,
then roll them forward. Repeat
10 times.

16
Warm Up Exercises
Wrist Extensor
Extend your right arm in front
of you with your palm up and
your elbow straight. Point
your ngertips toward the
oor by bending at the wrist.
Using your left hand, pull the
back of your right hand to-
ward you gently. Hold for 20
seconds; repeat three to ve
times with each arm.
Triceps Stretch
Place your right hand behind
your head, palm facing your
head. With your left hand,
grasp your right elbow and
pull downward until you feel
a stretch in the back of your
right arm. Hold for 20 sec-
onds; repeat three to ve
times with each arm.
Piriformis Stretch
Lie on your back. Bend your
right knee and lift it halfway
to your chest. Grasp your
knee with your left hand and
pull it toward your left shoul-
der, keeping both buttocks
against the oor. Hold for 20
seconds; repeat three to ve
times with each leg.
Groin (Adductors) Stretch
Sitting with your back
straight, bring the soles of
your feet together. Let your
knees lower toward the oor.
Hold for 30-60 seconds or
until muscles feel looser.
One-Arm Pectoralis Stretch
Stand against an immobile
structure like a wall or a tree.
While facing the wall, raise
your right hand out to your
side at chest height, palm
against the wall. Turn your
body toward the left, away
from the wall and your ex-
tended arm, until you feel a
stretch. Hold for 20 seconds;
repeat three to ve times with
each arm.
WARNING! Before beginning this or any exercise program, you should consult your physician.
This is especially important for individuals over the age of 35 or individuals with pre-existing
health problems.
Wrist Flexor
Extend your right arm in front
of you, palm down, elbow
straight. Point your ngertips
toward the oor by bending
at the wrist. Using your left
hand, pull your right palm to-
ward you gently. Hold for 20
seconds; repeat three to ve
times with each arm.

17
Warm Up Exercises
Standing Quadriceps Stretch
Steady yourself with one hand.
With the other, grab outside leg
at ankle, keeping body straight
from knee to hip. Gently pull
foot up and towards the but-
tocks until you feel a stretch
along the front of the thigh.
Thigh should be pulled straight
back and not drift to outside.
Hold 20-30 seconds. For varia-
tion, grab opposite ankle (i.e.,
grab right ankle with left hand).
Do two to three repetitions per
leg.
Achilles Stretch
Face the wall with your left
foot ahead of your right, toes
straight ahead. Bend both
knees, press your hips forward,
and lean into the wall. Keep
both heels down and both
knees in line with your feet.
Hold for 20 seconds; repeat
three to ve times with each
leg.
Calf Stretch
Face a solid structure such as
a wall with your left foot ahead
of your right, toes straight
ahead. Bend your left knee,
press your hips forward, and
lean into the wall. Keep both
heels down, your right leg
straight, and you left knee
over your ankle. Hold for 20
seconds; repeat three to ve
times with each leg.
WARNING! Before beginning this or any exercise program, you should consult your physician.
This is especially important for individuals over the age of 35 or individuals with pre-existing
health problems.

18
Moving Instructions
CAUTION! TO REDUCE THE POSSIBILITY OF INJURY WHILE LIFTING, BEND YOUR LEGS AND
KEEP YOUR BACK STRAIGHT. AS YOU LEAN THE UNIT, LIFT USING YOUR LEGS, NOT YOUR
BACK.
First, kneel down and grasp the rear support tube with both hands as shown in Figure 1. Next,
with a firm grasp on rear support tube stand up bringing the rear of the bike up in the air and
tilt the unit until it rolls freely on the transport wheels. Using extreme caution, move the unit to
the desired location as shown in Figure 2. Do not attempt to move the unit over an uneven or
rough surface.
Note: The unit you purchased may not be identical to the one pictured.
Figure 1 Figure 2

19
Ref # Part # Descri
p
tion
Q
t
y
Ref # Part # Descri
p
tion
Q
t
y
2 323-00628 CONSOLE TUBE, W/DECAL, 235R 1 41 302-00399 ADJUSTMENT CHANNEL ALL MACRO BIKES 2
3 323-00343 SEAT CARRIAGE, HT640R 1 42 302-01598 NUT CAP, 3/8*26MM, 540r/235r 2
4 323-00609 FRONT STABILIZER, HT540r/235r 1 43 302-00368 6MM HEX NUT MACRO 4
4A 323-00623 REAR STABILIZER, HT540r/235r 1 44 302-00402 M10X19x2.0 MM WASHER,220E/240E/240R/240U 2
5 323-00610 CARRIAGE TUBE, 540r/235r 1 45 319-00398 BELT TENSION BRACKET, 540r/235r 1
6 311-00105 PULLEY WITH CRANK ASSEMBLY, 540r/235r 1 46 311-00106 IDLER PULLEY, 540r/235r 1
7 311-00068 MAG BRAKE TRI-6.0R/640R/640U 1 47 306-01005 PLASTIC COIL TUBE, 540r/235r 1
8 313-00440 GEAR BOX WITH WIRE, 540r/235r 1 48 302-01599 HEX HEAD SCREW, M8*30MM, 540r/235r 1
9 328-00088 SEAT PAD, 540r/235r 1 49 302-00449 M8X19MM WASHER BLACK U/R/E 220/240/250 12
10 323-00611 FRONT HANDLEBAR, 540r/235r 1 50 302-00455 M8 NYLON NUT
(
THICK
)
220R/240R/640R/250R 4
11 305-01618 BOTTOM, LEFT HOUSING, W/DECAL, 235R 1 51 302-01600 SPRING, 540r/235r 1
12 305-01619 BOTTOM, RIGHT HOUSING, W/DECAL, 235R 1 52 302-00467
T
P M3 X8MM SCREW 220R/240R/640R/520e/250 2
13 306-00997 CARRIAGE TUBE CAP, LEFT, 540r/235r 1 53 302-01022 FRONT HANDLEBAR SLEEVE 30*3*200MM,HT640R 2
14 306-00998 CARRIAGE TUBE CAP, RIGHT, 540r/235r 1 54 302-01198 HEX HEAD SCREW, M8 X 20MM 1
15 307-00747 CONSOLE, 235R 1 55 302-00411 M8 X15 HEX HEAD SCREW 14
16 323-00612 SEAT HANDLEBAR, 540r/235r 1 56 302-01601 CURVED WASHER, M8*18, 540r/235r 5
17 319-00397 ROLLER, 540r/235r 2 57 313-00442 PULSE WIRE, 540r/235r 1
18 306-00999 FOOT CAP, 540r/235r 2 58 313-00443 EXTENSION WIRE, 540r/235r 1
19 302-01594 CARRIAGE BOLT, M8*65MM, 540r/235r 4 59 306-01006 PLASTIC INNER BUSHING, 50*60, 540r/235r 2
20 302-01200 M24X38MMX1.5T WASHER 1 60 328-00089 BACK PAD, 540r/235r 1
21 302-01595 ACORN NUT CAP, 8MM, 540r/235r 4 61 302-00443 M5 X10MM SCREW 220E/240E/240R/240U/640R/ 2
22 331-00022 SLOTTED BEARING NUT 1 62 302-00356 M6X15MM SCREW 10
23 331-00006 BEARING CM535/550/560/750/DCV6.0RU/R/640 2 63 302-00444 WASHER, M6X16MM
(
BLACK
)
6
24 331-00088 BEARING CUP, HT640R 2 64 313-00444 HAND PULSE GRIP, 540r/235r 2
25 331-00015 NOTCHED BEARING NUT CM535/550/560/750 DC 1 65 306-00372 1 1/4" BALL PLUG 220R/240R/240U/640R/520 2
26 302-01596 SPACER, M8*12.5*10.5L, 540r/235r 1 66 313-00445 SHORT EXTENSION PULSE WIRE, 540r/235r 1
27 331-00087 CRANK WASHER, HT640R 1 67 302-01658 BASE SPACER, HT540r/235r 1
28 302-01635 CRANK NUT, TRI-6.0R/640R/640U 2 68 306-00569 1" BALL PLUG TRI-6.0R/HT640R/HT640U 2
29 307-00739 DC POWER CORD, 540r/235r 1 69 319-00399 CLAMP, 540r/235r 1
30 306-01000 PEDAL, LEFT, 540r/235r 1 70 302-01602 SCREW, TP M4*16MM, 540r/235r 11
30A 306-01001 PEDAL STRAP, LEFT, 540r/235r 1 71 302-01603 SCREW, TP M5*30MM, 540r/235r 10
31 306-01002 PEDAL, RIGHT, 540r/235r 1 72 302-00456 M8 NYLON NUT
(
THIN
)
220R/240R/240U/640R 1
31A 306-01003 PEDAL STRAP, RIGHT, 540r/235r 1 73 302-00524 HEX HEAD BOLT M8X45
(
MM
)
2
32 306-00640 END PLUG, HT640
R
1 74 306-00632 30X60 END CAP 1
33 302-01215 HAND SLEEVE, HT640R 2 75 313-00446 LONG EXTENSION PULSE WIRE, 540r/235r 1
34 310-00173 MAGNET, HT640U/HT640
R
1 76 319-00415 REAR LEFT CHAIN COVER, 235R 1
35 304-00028 V-BELT, 540r/235
r
1 77 319-00416 REAR, RIGHT CHAIN COVER, 235R 1
36 302-01214 LOCKING KNOB
(
22MM
)
1 78 302-01604 HEX HD SCREW,M6*15MM, 540r/235r*USE 302-00385 1
37 306-01004 S
Q
UARE CAP, 50*50, 540r/235r 1 # 315-00124 OWNER'S MANUAL, 235r 1
38 313-00441 SENSOR WIRE WITH SENSOR, 540r/235r 1 # 313-00465 ADAPTER 540R/235R 1
39 302-01597 METAL SCREW, M5*10MM, 540r/235r 4
40 302-01195 EYEBOLT 6 X 40MM 3
235R PARTS LIST REV. B
Parts List

20
Exploded View
A