Pro-Form 831.28645.0 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. 831.28645.0
Serial No.
•Assembly
•Operation
•Maintenance
•Part List and Drawing
Sears, Roebuck and Co., Hoffman Estates, IL 60179

TABLE OF CONTENTS
IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HOW TO USE THE ELLIPTICAL EXERCISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
CONDITIONING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
PART LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
EXPLODED DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
LIMITED WARRANTY, REPAIR PARTS, AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
2

3
IMPORTANT PRECAUTIONS
WARNING:To reduce the risk of serious injury, read the following important precau-
tions before using the elliptical exerciser.
1. Read all instructions in this manual and all
warnings on the elliptical exerciser before
using the elliptical exerciser. Use the ellipti-
cal exercise only as described in this
manual.
2. It is the responsibility of the owner to ensure
that all users of the elliptical exerciser are
adequately informed of all precautions.
3. The elliptical exerciser is intended for
home use only. Do not use the elliptical
exerciser in a commercial, rental, or institu-
tional setting.
4. Keep the elliptical exerciser indoors, away
from moisture and dust. Place the 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 the elliptical exerciser to mount, dis-
mount, 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 the elliptical exerciser at all times.
7. The elliptical exerciser should not be used
by persons weighing more than 275 lbs.
(124 kg).
8. Wear appropriate exercise clothes while
using the elliptical exerciser. Always wear
athletic shoes for foot protection while exer-
cising.
9. Hold the handgrip pulse sensor or the han-
dlebars when mounting, dismounting, or
using the elliptical exerciser.
10. The pulse sensor is not a medical device.
Various factors may affect the accuracy of
heart rate readings. The pulse sensor is
intended only as an exercise aid in determin-
ing heart rate trends in general.
11. Keep your back straight while using the ellip-
tical exerciser; do not arch your back.
12. If you feel pain or dizziness while exercising,
stop immediately and cool down.
13. When you stop exercising, allow the pedals
to slowly come to a stop.
14. The decal shown below has been placed on
the elliptical exerciser.If the decal is miss-
ing or illegible, call the toll-free telephone
number on the front cover of this manual
and order a free replacement decal. Apply
the decal in the location shown.
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. Sears assumes no responsibility for personal injury or
property damage sustained by or through the use of this product.
246724 246723

4
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 front
cover of this manual. To help us assist you, note the
product model number and serial number before con-
tacting us. The model number is 831.28645.0. The
serial number can be found on a decal attached to the
elliptical exerciser (see the front cover of this manual
for the location of the decal).
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
Leveling Foot
Fan
*No water bottle is included

5
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 on pages 24 and 25. The number follow-
ing the parentheses is the quantity needed for assembly. Note: Some small parts may have been preassem-
bled. If a part is not in the parts bag, check to see if it has been preassembled.
M8 Split
Washer (72)–2
M8 x 48mm Button
Screw (78)–2
M4 x 16mm
Self-tapping
Screw (79)–10
M8 x 42mm Bolt
(71)–4
M10 x 20mm x
1mm Washer
(81)–2
M10 x 20mm x
1.5mm Washer
(84)–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)–8
M10 x 62mm Bolt (89)–4 M10 x 78mm Button Screw (90)–2
M10 x 20mm Button
Screw (91)–4
M10 x 20mm x
2mm Washer
(92)–4
M4 x 13mm
Washer (93)–2
M10 x 25mm
Washer (94)–4
M8 x 16mm Button
Screw (95)–3
M8 Nylon
Locknut (96)–4 M10 Nylon Locknut (97)–2
Wave Washer
(98)–8
Star Washer
(100)–3

6
1.
Orient the the Front Stabilizer (35) as shown.
Attach the two Wheels (25) to the Front Stabilizer
with two M10 x 62mm 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 Button Screws (90).
97
26
26
1
2
2
89
89
25
25
35
90
35
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 Bolts (89), two M10
Spacers (76), two M8 x 48mm Button Screws
(78), and two M8 Split Washers (72).
2
89
1
72
78
3
1
76
26
26

7
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
apiece 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 Button Screws
(95) and three Star Washers (100). Avoid pinch-
ing the Wire Harness (48) between the
Upright and the Frame.
6
4
95
95
100
2
95
100
48
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 23mm Shoulder Screw (80), an M10 x
20mm x 1.5mm Washer (84), and a Crank Axle
Cap (30).
Repeat this step to attach the Right Roller
Leg (21) to the right Crank Arm (not shown).
536
1
84 30 98
22
Grease
80 12
21
Grease

8
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
8
96
6
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).
7
19
18 79
79
8
93

9
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
86
65
17
17
2
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
x1mm Washer (81).
Repeat this step to attach the Right
Handlebar (9) to the Pivot Axle (65).
9
98
9
81
8
80
65
Grease

10
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).
10
88 88
13
14
87
87
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 (21).
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 23mm Shoulder Screws (80), two
M10 x 20mm x 2mm Washers (92), and two Axle
Caps (31).
Attach the Left Pedal Leg (14) to the left Roller
Leg (21) with two M10 x 20mm Button Screws
(91) and two M10 x 25mm Washers (94); do not
overtighten the Button Screws. The Legs (11,
14, 21) must be able to pivot freely.
Repeat this step for the Right Pedal Leg (not
shown).
92
91
14 94
80
31
32
31
11
80
21
94 91
92 32
11
Grease
98
Grease
98