Pro-Form XP THINLINE 480 User manual

CAUTION
Read all precautions and instruc-
tions in this manual before using
this equipment. Keep this manual
for future reference.
Serial
Number
Decal
odel No. 831.23844.0
Serial No.
Write the serial number in the
space above for reference.
• Assembly
• Operation
• aintenance
• Part List and Drawing
Sears, Roebuck and Co., Hoffman Estates, IL 60179
ELLIPTICAL EXERCISER
Userʼs anual

TABLE OF CONTENTS
WARNINGDECALPLACE ENT ..............................................................2
I PORTANTPRECAUTIONS ................................................................3
BEFOREYOUBEGIN ......................................................................4
ASSE BLY ...............................................................................5
HOWTOUSETHEELLIPTICALEXERCISER ..................................................12
AINTENANCEANDTROUBLESHOOTING ...................................................21
EXERCISEGUIDELINES ...................................................................22
PARTLIST ..............................................................................24
EXPLODEDDRAWING ....................................................................26
ORDERINGREPLACE ENTPARTS ..................................................BackCover
90DAYFULLWARRANTY ..........................................................BackCover
2
WARNING DECAL PLACE ENT
This drawing shows the location(s) of the
warning decal(s). If a 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(s) may not be shown at actual size.

3
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.
ake 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 userʼs 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.
I PORTANT PRECAUTIONS

4
BEFORE YOU BEGIN
Thank you for purchasing the revolutionary
PROFOR XP™ THINLINE 480 elliptical exerciser.
The THINLINE 480 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.
Pulse Sensor
Upper Body Arm
Pedal Disc
Wheel
Ramp Handle
Pedal
Water Bottle Holder*
Console
Fan
*Water bottle is not included

5
ASSE BLY
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.
Assembly requires the included tools and your own Phillips screwdriver , adjustable
wrench , and rubber mallet .
As you assemble the elliptical exerciser, use the drawings below to identify small parts. The number in parenthe-
ses 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. Note: Some small parts may have
been preassembled. If a part is not in the parts bag, check to see if it has been preassembled. If a part is
missing, call 1-888-533-1333.
M4 x 16mm
Screw (84)–14
M4 x 32mm Screw
(95)–2
M4 x 16mm Flat Head
Screw (94)–4
M10 Split
Washer (78)–10
M6 Nylon
Locknut (77)–4
M6 x 16mm Patch
Screw (80)–6
M10 x 20mm Patch
Screw (79)–4
M10 x 70mm Patch Screw (75)–6M10 x 41mm Shoulder
Patch Screw (63)–2
Wave Washer
(88)–6
M6 Large
Washer (90)–4
M6 x 38mm Button
Bolt (76)–4

6
2. Identify the Right Frame Cover (49), which is
marked with a “Right” sticker. Then, orient the
Right Frame Cover with the rounded side in the
indicated location. While another person lifts the
rear of the Frame (1), attach the Right Frame
Cover with two 4 x 16mm Screws (84).
Repeat this step for the Left Frame
Cover (48).
1.
Pull the ramp handle outward and lower the
Ramp (104) until it rests on the Frame (1).
Attach a Wheel (50) to the front of the Frame
(1) with an 10 x 41mm Shoulder Patch Screw
(63).
Attach the other Wheel (not shown) in the
same way.
1
To make assembly easier, read the
information on page 5 before you begin
assembling the elliptical exerciser.
1
63
50
Ramp
Handle
104
2
48
Rounded
Side
1
Rounded
Side
84
49

7
4. Orient the Water Bottle Holder (5) as shown
and slide it onto the Upright (2). Attach the
Water Bottle Holder with two 4 x 32mm
Screws (95).
Tip: Do not pinch the Wire Harness (100).
Slide the Console Cover (96) onto the Upright
(2) and move it downward to the Water Bottle
Holder. Then, insert the Console Bracket (3)
into the top of the Upright. Attach the Console
Bracket with four 4 x 16mm Screws (84).
4
3.Tip: Do not pinch the Wire Harness (100).
Start all screws before tightening any of
them.
Have another person hold the Upright (2) near
the Frame (1). Locate the wire tie in the Upright.
Tie the lower end of the wire tie to the Wire
Harness (100). Next, pull the upper end of the
wire tie upward out of the top of the Upright.
Then, untie and discard the wire tie. Tip: To
prevent the Wire Harness from falling inside
the Upright, secure the Wire Harness with a
rubber band.
Attach the Upright (2) to the Frame (1) with four
10 x 20mm Patch Screws (79), and four 10
Split Washers (78). Do not tighten the Patch
Screws yet.
3
Do not pinch the
Wire Harness (100)
Do not pinch the
Wire Harness (100)
2
1
100
78
78
78
79
79
84
84
95
100
96
3
5
Wire Tie
2
79

8
5. The Console (4) can use four 1.5V “D” batteries
(not included); alkaline batteries are recom-
mended. I PORTANT: If the Console has
been exposed to cold temperatures, allow it
to warm to room temperature before insert-
ing batteries. Otherwise, you may damage
the console displays or other electronic
components. Remove the screws, remove the
battery cover, insert the batteries into the bat-
tery compartment, and then reattach the battery
cover. ake sure to orient the batteries as
shown by the diagram inside the battery
compartment.
To purchase an optional AC adapter, contact
the store where you purchased this product
or call the telephone number on the cover of
this manual. To avoid damaging the console,
use only a manufacturer-supplied AC
adapter. Plug one end of the AC adapter into
the jack on the console; plug the other end into
an outlet installed in accordance with all local
codes and ordinances.
5
6. While a second person holds the Console (4)
near the Upright (2), connect the console wire
to the Wire Harness (100).
Tip: Do not pinch the wires. Attach the
Console (4) with four 4 x 16mm Flat Head
Screws (94).
6
4
4
2
94
96 94
100
Console Wire
Batteries
Batteries
Cover
Do not pinch
the wires during
this step
Screws

9
8
7
7. Slide the Console Cover (96) (see the drawing
in step 6) upward to the Console (4). Attach the
Console Cover with four 4 x 16mm Screws
(84).
96
84
84
4
8. Apply a generous amount of the included
grease to the Pivot Axle (16). Then, apply a
small amount of grease to two Wave Washers
(88).
Insert the Pivot Axle (16) into the Upright (2).
Slide a Wave Washer (88) onto each end of the
Pivot Axle.
Identify the Left Upper Body Leg (6), which is
marked with a “Left” sticker. Slide the Left
Upper Body Leg onto the Pivot Axle (16). Attach
the Left Upper Body Leg with an 6 x 16mm
Patch Screw (80) and a Large Axle Cover (20).
Attach the Right Upper Body Leg (31) in the
same way.
80
20
6
88
16
88
31
20
80
2
Grease

10
10
10. Apply a small amount of grease to two Wave
Washers (88) and to the axles on a Pedal Arm
Axle (21).
Identify an Upper Body Leg Spacer (113), which
has a curved side. Slide a Wave Washer (88)
and the Upper Body Leg Spacer onto the indi-
cated axle of the Pedal Arm Axle (21); make
sure that the curved side of the Upper Body
Leg Spacer is facing away from the Pedal
Arm Axle.
Identify a Pedal Leg Spacer (114), which has a
flat side. Slide a Wave Washer (88) and the
Pedal Leg Spacer onto the other axle of the
Pedal Arm Axle (21); make sure that the flat
side of the Pedal Leg Spacer is facing away
from the Pedal Arm Axle.
Repeat this step for the other Pedal Arm
Axle (not shown).
9
114
113
Grease
Grease
Curved Side
Flat Side
88
88
21
9. Attach the Left Pedal (12) to the left Pedal Arm
(14) with three 10 x 70mm Patch Screws (75),
three 10 Split Washers (78), and an 4 x
16mm Screw (84).
Repeat this step for the other side of the
elliptical exerciser.
14
75
78
78
12
84