Pro-Form 595E PFEL04900 User manual

CAUTION
Read all precautions and instruc-
tions in this manual before using
this equipment. Keep this manual
for future reference.
Model No. PFEL04900
Serial No.
Serial Number Decal
USERÕS MANUAL
QUESTIONS?
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have questions, or if there are
missing parts, we will guarantee
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CALL DIRECT TO OUR TOLL-
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customer hot line will provide
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new products, prizes,
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TABLE OF CONTENTS
IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HOW TO USE THE ELLIPTICAL CROSSTRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
MAINTENANCE AND TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CONDITIONING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
PART LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
EXPLODED DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
HOW TO ORDER REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
2

3
1. Read all instructions in this manual before
using the elliptical crosstrainer.
2. It is the responsibility of the owner to ensure
that all users are adequately informed of all
precautions.
3. Place the elliptical crosstrainer on a level
surface, with a mat beneath it to protect the
floor or carpet. Keep the elliptical crosstrain-
er indoors, away from moisture and dust.
4. Inspect and tighten all parts regularly.
Replace any worn parts immediately.
5. The elliptical crosstrainer should not be used
by persons weighing more than 250 pounds.
6. Keep children under age 12 and pets away
from the elliptical crosstrainer at all times.
7. Wear appropriate exercise clothing when
using the elliptical crosstrainer. Always wear
athletic shoes for foot protection.
8. Always hold the handlebar or the upper
body arms when mounting, dismounting, or
using the elliptical crosstrainer.
9. Keep your back straight when using the ellip-
tical crosstrainer; do not arch your back.
10. The pulse sensor is not a medical device.
Various factors, including the userÕs 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.
11. If you feel pain or dizziness while exercis-
ing, stop immediately and begin cooling
down.
12. When you stop exercising, allow the pedals
to slowly come to a stop before dismounting
the elliptical crosstrainer.
13. The elliptical crosstrainer is intended for in-
home use only. Do not use it in any commer-
cial, rental, or institutional setting.
WARNING: Before beginning this or any exercise program, consult your physician.
This is especially important for persons over the age of 35 or persons with pre-existing health prob-
lems. Read all instructions before using. ICON assumes no responsibility for personal injury or
property damage sustained by or through the use of this product.
IMPORTANT PRECAUTIONS
WARNING: To reduce the risk of serious injury, read the following important precau-
tions before using the elliptical crosstrainer.

4
BEFORE YOU BEGIN
Congratulations for selecting the revolutionary PRO-
FORM¨595E elliptical crosstrainer. The PROFORM
595E is an incredibly smooth exerciser that moves
your feet in a natural elliptical path, minimizing the
impact on your knees and ankles. And the unique
595e features adjustable resistance and incline to
help you get the most from your exercise. Welcome to
a whole new world of natural, elliptical-motion exercise
from PROFORM.
For your benefit, read this manual carefully before
you use the PROFORM¨595E. If you have additional
questions, please call our Customer Service
Department toll-free at 1-800-999-3756, Monday
through Friday, 6 a.m. until 6 p.m. Mountain Time
(excluding holidays). To help us assist you, please
note the product model number and serial number
before calling. The model number is PFEL04900. The
serial number can be found on a decal attached to the
elliptical crosstrainer (see the front cover of this man-
ual for the location of the decal).
Before reading further, please look at the drawing
below and familiarize yourself with the parts that are
labeled.
Upper Body Arm
Resistance Control
Handlebar with Pulse Sensor
FRONT
BACK
RIGHT SIDE
Pedal Arm
Pedal Disk
Pedal
Console
Book
Rack
Incline Bracket
Incline Frame

ASSEMBLY
Assembly requires two persons. Place all parts of the elliptical crosstrainer in a cleared area and remove the
packing materials. Do not dispose of the packing materials until assembly is completed.
Assembly requires the following tools: the included allen wrench, a phillips screwdriver ,
an adjustable wrench , a rubber mallet , and pliers .
As you assemble the elliptical crosstrainer, use the drawings below to identify the small parts used in assembly.
The number in parenthesis below each drawing refers to the key number of the part, from the PART LIST on
page 18. The second number refers to the quantity used in assembly. Note: Some small parts may have been
pre-attached for shipping. If a part is not in the parts bag, check to see if it has been pre-assembled.
5
1. Hold the Rear Stabilizer (65) against the saddle on the
rear of the Frame (1). Make sure that the Stabilizer is
turned so the square holes are facing away from the
Frame. Attach the Stabilizer with two M10 x 105mm
Carriage Bolts (27) and two M10 Nylon Locknuts (26).
126
26
1
27
65
2
2. Turn the Resistance Control (57) counterclockwise to
the minimum setting.
If the Resistance Control (57) is attached to the Upright
(2), remove the M4 x 16mm Screw (35). Pull the bot-
tom of the Resistance Control away from the Upright
and then slide it down to remove it. 57
Tab
235
M1 0 x105mm C arr iage B olt ( 27 )Ð 2
Axle Screw (30)Ð2
M10 x 85mm Bolt (25)Ð1
Nylon Washer
(11)Ð2
M8 Split
Washer (58)Ð2 M8 Wa she r (81) Ð6
M4 x 16mm
Screw (35)Ð9
M4 x 16mm
Flange Screw
(43)Ñ6
M8 Nylon
Locknut (8 0) Ð2
M10 Nyl on
Locknut (2 6) Ð7
Spacer
(4 4) Ð4
M8 x 108mm Bolt (79)Ð2

6
5
4
84 84
57
Metal
Bracket
57
B
AC
84
57
3. Lay a cloth over the front of the Frame (1) to protect it.
Lay the Upright (2) in the position shown. Connect the
Extension Wire (51) to the Reed Switch Wire (50).
Next, connect the Resistance Cable (57) to the
Extension Cable (84) in the following way:
¥ Refer to drawing A. Pull up on the metal bracket, and
insert the tip of the Resistance Cable (57) into the
wire clip on the Extension Cable (84) as shown.
¥ Refer to drawing B. Firmly pull the Resistance Cable
(57) and slide it into the metal bracket on the
Extension Cable (84) as shown.
¥ Refer to drawing C. Using pliers, squeeze the prongs
on the upper end of the metal bracket together.
2
1
84
57
51
50
5. Attach the Incline Bracket (24) to the lower end of the
Upright (2) with the M10 x 85mm Bolt (25) and an M10
Nylon Locknut (26). Do not overtighten the Nylon
Locknut; the Incline Bracket must pivot easily.
24
25
26
2
4. Align the two holes in the front of the Upright (2) with
the two welded bolts on the front of the Frame (1).
Carefully push the Reed Switch Wire (not shown) into
the Upright until there is no slack.
Next, pivot the Upright (2) about halfway to the vertical
position while guiding the metal bracket on the
Extension Cable (not shown) into the Upright. Once
the top edge of the metal bracket is inside the Upright,
pivot the Upright to the vertical position so it rests on
the four welded bolts on the Frame (1). Be careful to
avoid pinching the wires. Tighten a M10 Nylon
Locknut (26) onto each welded bolt.
Refer to assembly step 2. Insert the tab on the Resis-
tance Control (57) into the Upright (2). Next, press the
bottom of the Resistance Control against the Upright.
Tighten the M4 x16mm Screw (35) into the Resistance
Control and the Upright.
2
1
Welded
Bolts
26
3

7
8. Connect the Extension Wire (51) to the corresponding
wire on the Console (87).
Next, connect the two Pulse Wires (86) to the two
remaining wires on the Console (87). Note: Either
Pulse Wire can be attached to either wire on the
Console.
Next, connect the ground wire to the indicated hole in
the Upright (2) with an M4 x 16mm Screw (35).
Carefully feed the wires down into the Upright (2).
Attach the Console Base (49) to the Upright with four
M4 x 16mm Screws (35). Be careful to avoid pinch-
ing the wires.
8
86
87
49
35
35
2
51
Console
Wires
35
Ground Wire
7. The Console (87) requires two ÒAAÓ batteries (not
included). Alkaline batteries are recommended. To
install batteries, turn the console over and insert two
batteries into the battery clip as shown in the inset
drawing. Make sure that the negative ends of the
batteries (marked ÒÑÓ) are touching the springs in
the battery clip.
Attach a Plastic Tie (53) to the battery clip as shown.
Attach the Console (87) to the Console Base (49) with
four M4 x 16mm Screws (35), making sure that the
indicated wires are extending from the Console Base
(49). Be careful not to pinch the wires.
7
35
Wires
Battery
Clip
Batteries
87
49
53
6
5
V-shaped Groove
29
Grease
81
81
30
30
58
58
1
Tubes
Tubes
6. Slide an M8 Split Washer (58) and an M8 Washer (81)
onto an Axle Screw (30). Tighten the Axle Screw into
one end of the Incline Axle (29). Next, apply a small
amount of the included grease to the Incline Axle.
Align the indicated tubes on the Incline Frame (5) with
the tubes on the Base (1). Make sure that the Incline
Frame is turned so the V-shaped grooves are on
top. Insert the Incline Axle (29) through the Incline
Frame and the Base. Note: It may be helpful to tap the
Incline Axle with a rubber mallet to insert it.
Slide an M8 Split Washer (58) and an M8 Washer (81)
onto the other Axle Screw (30). Tighten the Axle Screw
into the open end of the Incline Axle (29).

8
10. Apply grease to an M8 x 108mm Bolt (79). Slide an M8
Washer (81) onto the Bolt and insert the Bolt into the
indicated side of the Left Pedal Arm (3). Be careful not
to confuse the Left Pedal Arm with the Right Pedal
Arm (not shown); look at the position of the round
tube to identify the Left Pedal Arm. Next, slide a
Spacer (44), a Pedal Wheel (77), and another Spacer
(44) onto the Bolt and push the Bolt through the other
side of the Left Pedal Arm.
Next, slide a Tube Spacer (82), a Chrome Tube (21),
and an M8 Washer (81) onto the M8 x 108mm Bolt
(79). Tighten an M8 Nylon Locknut (80) onto the Bolt.
Attach the other Chrome Tube (not shown) to the Right
Pedal Arm (not shown) in the same way.
21
81
82
79
81
44
44
77
80
10
3
Grease
9. Identify the Left Pedal Arm (3), which has an ÒLÓ sticker
on it. Be careful not to confuse the Left Pedal Arm
with the Right Pedal Arm (not shown); look at the
position of the round tube in the inset drawing to
identify the Left Pedal Arm. Next, identify the Left
Pedal (41), which has the letter ÒLÓ molded onto the
bottom.
Turn over the Left Pedal Arm (3) as shown. Insert the
three plastic posts on the Left Pedal (41) into the three
indicated holes in the Left Pedal Arm. Make sure that
the Left Pedal is turned as shown. Attach the Left
Pedal with three M4 x 16mm Flange Screws (43).
Attach the Right Pedal (not shown) to the Right Pedal
Arm (not shown) in the same way.
943
3
41
Open Side
Plastic Posts
Round
Tube
Open Side
Round
Tube
10a
79
44
44
77
3
81
81
80 21
82 Front
View
3

9
13. Make sure that all parts of the elliptical crosstrainer are properly tightened. Note: Some hardware
may be left over after assembly is completed. To protect the floor or carpet from damage, place a mat
under the elliptical crosstrainer.
12. Refer to the inset drawing. Apply a small amount of
the included Teflon¨lubricant to a paper towel; rub a
thin film of the lubricant onto each of the Chrome
Tubes (21). Slide an Upper Body Arm (7) onto each
Chrome Tube. Make sure that the Upper Body Arms
are turned as shown.
Tap a 5/8Ó Axle Cap (85) onto one end of the Axle
(19). Insert the Axle through one of the Upper Body
Arms (7) and then through the Upright (2). Slide the
other Upper Body Arm (7) onto the Axle. Tap another
5/8Ó Axle Cap (85) onto the Axle.
19
2
12
21
Lube
4
7
85 7
7
85
11. Apply a small amount of grease to the axle on the left
Crank Arm (6).
Slide a Nylon Washer (11) and the Left Pedal Arm (3)
onto the axle on the left Crank Arm (6). Note: It may be
helpful to use a rubber mallet to tap these parts on. Be
careful not to confuse the Left Pedal Arm with the
Right Pedal Arm (not shown); look at the position
of the round tube to identify the Left Pedal Arm.
Next, tap a 3/4Ó Axle Cap (61) onto the axle.
Attach the Right Pedal Arm (not shown) in the same way.
6
Grease
11
61
3
11
Round Tube

10
HOW TO USE THE ELLIPTICAL CROSSTRAINER
EXERCISING ON THE ELLIPTICAL CROSSTRAINER
To mount the elliptical crosstrainer, hold the handlebar
and step onto the pedal that is in the lowest position.
Next, step onto the other pedal. Push the pedals until
they begin to move with a continuous motion. Note:
The pedal disks can turn in either direction. It is
recommended that you move the pedal disks in
the direction shown below; however, to give vari-
ety to your exercise, you may choose to turn the
pedal disks in the opposite direction.
To dismount the elliptical crosstrainer, wait until the
pedals come to a complete stop. Important: The
elliptical crosstrainer does not have a free wheel;
the pedals will continue to move until the flywheel
stops. When the pedals are stationary, step off the
highest pedal first. Then, step off the lowest pedal.
HOW TO ADJUST THE RESISTANCE
To adjust the
intensity of your
exercise, the
resistance of the
pedals can be
adjusted. To
increase the
resistance, turn
the resistance
control clockwise;
to decrease the
resistance, turn
the control coun-
terclockwise.
Pedal
Pedal Disk
Control