CROSS TRAINER 95X-0XXX-01

Customer Support Services

PARTS MANUAL

rev 31 Jul 2008

CROSS TRAINER 95Xi

OPERATION MANUAL

SERVICE MANUAL

HARDWARE BAG

PLUG IN OPTION120/60

M051-00K62-A107

M051-00K62-A060

AK62-00152-0001

GK62-00002-0018

PLUG IN OPTION 240/50 UK

PLUG IN OPTION 240v AUS

GK62-00002-0019

GK62-00002-0020

PLUG IN OPTION 230/50 CONT. GK62-00002-0021

95X-0XXX-01

2

Page

CONSOLE SUPPORT & DEADSHAFT COVERS ............................................................4

HANDLEBARS AND BULLHORNS .................................................................................5

CONSOLE AND RELATED COMPONENTS....................................................................6

UPPER FRAME HARDWARE ..........................................................................................7

ROCKER ARMS AND PEDAL LEVERS ..........................................................................8

CRANK COVER AND LOWER CAPS ..............................................................................9

LOWER FRAME SHROUDS AND HARDWARE..............................................................10

PEDAL LEVER COMPONENTS .......................................................................................11

DRIVE MODULE COMPONENTS AND MAIN CABLE ....................................................12

DRIVE MODULE HARDWARE .........................................................................................13

CABLES ............................................................................................................................14

Note: The 95Xi comes with both Telemetry and

LifePulse Sensors.

3

CROSS TRAINER 95Xi

Console Support & Deadshaft Covers

Console Support

AK62-00123-0000

Console Support Cap

0K62-01030-0000

Console Support

Shroud

0K62-01023-0000

Console Support

Grommet

0017-00042-0754

95X-0XXX-01

S/N XTD100000

Right

Bullhorn Cover

0K62-01007-0001

Left

Bullhorn Cover

0K62-01008-0001

Right Inside

Deadshaft Cover

0K62-01010-0000

Left Inside

Deadshaft Cover

0K62-01011-0000

Front Inside

Deadshaft Covers (2)

0K62-01009-0000

2-Outside Front

Deadshaft Cover

0K62-01013-0000

2-Outside Rear

Deadshaft Cover

0K62-01012-0000

4

CROSS TRAINER 95Xi

Handlebars and Bullhorns

Right Handlebar

AK62-00086-0000

95X-0XXX-01

S/N XTD100000

*Right Bullhorn

AK62-00053-0000

Left Bullhorn

AK62-00054-0000

HR Sensor Kit

GK20-00002-0005

Left Handlebar

AK62-00087-0000

Heart Rate Cable

AK61-00051-0000

(one per handlebar)

*Right Bullhorn Assembly consists of: AK62-00057-0000 Bullhorn,

0K62-01136-0000 Grip and 0K62-01199-0000 Gasket

Left Bullhorn Assembly consists of: AK62-00058-0000 Bullhorn,

0K62-01136-0000 Grip and 0K62-01199-0000 Gasket

5

CROSS TRAINER 95Xi

Console & Related components

Console Case with decal

AK62-00142-0000

Programmed PCB

A084-92219-A032

A084-92221-A023 (JAP)

Console Case Screws

0017-00101-1242

Lower Display Cable

AK63-00038-0000

Polar Cable

AK39-00063-0000

95X-0XXX-01

S/N XTD100000

Battery Door

0K62-01026-0000

Upper and Lower

PCB mounting screws

0017-00101-1650 Polar PCB with receiver

AK39-00064-0000

Overlay/Bezel/Switch

(see chart below)

Lower PCB

B084-92222-B000

AK62-00149-0001 AK62-00191-0001

AK62-00149-0003

AK62-00149-0004

AK62-00191-0003

AK62-00191-0004

AK62-00149-0006 AK62-00191-0006

AK62-00149-0007 AK62-00191-0007

AK62-00149-0008 AK62-00191-0008

AK62-00149-0009

AK62-00149-0010

AK62-00191-0009

AK62-00191-0010

Eng + Met

Ger/Met

Spn/Met

Jap/Met

Frn/Met

Ital/Met

Dut/Met

Port/Met

6

CROSS TRAINER 95Xi

Upper Frame Hardware

4 - Console Mounting Screws

0017-00101-1796

95X-0XXX-01

S/N XTD100000

Handlebar Mounting Screws

0017-00101-1791

(3 per side)

6 - Console Support

Mounting Screws

0017-00101-1791

Console Support

Shroud Mounting

Screws

0017-00101-1796

Bullhorn Mounting

Screws

GK62-00002-0042

(kit includes 4 screws)

Inside Deadshaft

Cover Screws

0017-00101-1796

(2 per side)

Bullhorn Cover

Screws

0017-00101-1854

Outside Deadshaft

Cover Screws

0017-00101-1796

( 2 per side )

Items Not Shown:

Accessory Tray 0K62-01022-0000

Mounting Screws (2) 0017-00101-1846

7

CROSS TRAINER 95Xi

Rocker Arms & Pedal Levers contents:

Rocker Arms (2)

Hardened Spacers (2)

Oilite Washers (2)

Retaining Rings (2)

Loctite 620

Alcohol pad

Rocker Arms

AK62-00002-0070

Shaft Collar w/Screws

0K61-01259-0000

LF Bug

Medallion Assy.

AK58-00245-0000

Right Pedal

Lever Assembly

AK62-00236-0000

95X-0XXX-01

S/N XTD100000

Left Pedal Lever Assembly

AK62-00235-0000

8

CROSS TRAINER 95Xi

Crank Cover and Lower Caps

95X-0XXX-01

S/N XTD100000

Stabilizer Caps

4 - 0K62-01003-0000

Front frame Cap

0K62-01004-0000

Mounting Screws

(Located on front sides of Ladder Frame Cover)

2- 0017-00101-1795

9

Crank Cover

0K61-03100-0001

2 - Mounting screws

0017-00101-1837

CROSS TRAINER 95Xi

Lower Frame Shrouds & Hardware

95X-0XXX-01

S/N XTD100001

Rocker Cover Kit

(includes clip & screw)

GK62-00002-0066

Mounting screw

0017-00101-1796

Right Inside Rocker Cover

0K62-01038-0000

Right Inside Lever Joint Cover

0K62-01040-0000

Outside Pedal Joint Cover

0K62-01035-0000

Mounting screw

0017-00101-1836

Right Link Cover w/decal

AK62-00113-0000

Left Link Cover w/decal

AK62-00114-0000

Mounting screws

( 6 per cover)

0017-00101-1796

Rear Shroud Assembly

AK62-00223-0000

Mounting screws

(2 per side)

0017-00101-1796

Leg Levelers

AK62-00124-0000

Ladder Frame Cover w/decal

AK62-00106-0000

4 - Mounting screws

0017-00101-1795

Rocker Cover Kit

(includes clip & screw)

GK62-00002-0066

Mounting screw

0017-00101-1796

Left Inside Rocker Cover

0K62-01037-0000

Left Inside Lever Joint Cover

0K62-01039-0000

Outside Pedal Joint Cover

0K62-01035-0000

Mounting Screw

0017-00101-1836

Shroud Panel

0K62-01002-0002

Mounting screws

(2 per side)

0017-00101-1795

Wheel/Bracket Assy.

AK62-00102-0000

Mounting Screws

( 3 per assy.)

0017-00101-1789

10

CROSS TRAINER 95Xi 95X-0XXX-01

Control Link Kit

GK62-00002-0071

(contains 2 control links, part nos. AK62-00384-0000)

Control Links (2)

AK62-00384-0000

Left Pedal

0K62-01005-0000

Right Pedal

0K62-01006-0000 Hex nut

0017-00103-0333

Right Inside

Pedal Cover

0K62-01015-0000

Left Inside

Pedal Cover

0K62-01016-0000

5 - Mounting screws

0017-00101-1796

Washer

0017-00104-0479

Nut

0017-00103-0333

Crank Extension

Mounting Bolt

0017-00101-1907

Pedal Mounting Hardware

4 - Screw - 0017-00101-1805

4 - Washer-0017-00104-0469

Pedal/Rocker Shaft & Bearings

Order Kit GK62-00002-0001

E-Ring

0017-00100-0107

Thrust Washer

0K47-01105-0000

Brass Washer

0K47-01104-0000

Roller w/bearing

AK62-00196-0001

Shaft Collar

0K62-01065-0000

Washer

0017-00104-0474

Brass Washer

0K47-01104-0000

Anti-Lift Roller

0K62-01191-0000

Setscrew

0017-00101-1803

Anti-Lift Track

Roller Extrusion

AK62-00197-0000

2 - Screws

0017-00101-1789

0K62-01208-0000

2 - Screws

0017-00101-1836

Note: If replacing the Tie Rod Assembly or Crank Extension for the first time, order kit GK62-00002-0015. Both sides must be replaced simultaneously in this situation.

11

CROSS TRAINER 95Xi

Drive Module components & Cable

Resistor with harness assembly

AK62-00171-0000

Flexonic Belt J8

0K62-01134-0000

95X-0XXX-01

S/N XTD100000

Power Control Board

B084-92218-D002

Metric Poly-V pulley

0K35-01186-0007

Reed Switch

118E-00001-0140

Right Crankarm

AK62-00204-0000 Battery

0017-00003-0685

Poly-V Crank Pulley

0K61-02409-0000

Left Crankarm with plate weldment and Bearings

Order Kit

GK62-00002-0003

Magnet/Standoff

Assembly

AK62-00186-0000

Crankshaft Plate

0K61-02302-0001

Crossover Shaft and Bearings

Order Kit GK62-00002-0002

12

Flexonic Belt J10

0K62-01135-0000

Alternator

Flywheel Assembly

AK61-00250-0002

Main Cable

Connects to

Power Control Board

(not shown)

AK62-00093-0000

CROSS TRAINER 95Xi

Drive Module Hardware

Alternator mounting bolt

0017-00101-0986

95X-0XXX-01

S/N XTD100000

Alternator mounting bolt and nut

0017-00101-1793

0017-00103-0332

Plastic Grommet (4)

0017-00042-0754

PCB Grommet (4)

0017-00042-0821

PCB Mounting Screw (4)

0017-00101-1838

Resistor mounting rod

0K63-01166-0000

Cable mounting screws

0017-00101-1839

Cable mounting nuts

0017-00103-0159

Screw

0017-00101-1836

Washer

0017-00104-0465

Machine Key

0K53-01183-0000

Set Screws

0017-00101-1833

Thrust Washer

0K47-01104-0000

Crankarm nut

0017-00103-0334

Crankarm mounting bolt

0017-00101-1849

Retaining Ring

0017-00100-0107

Magnet mounting screw

0017-00101-1835

Crankshaft plate mounting screws

0017-00101-1834

Reed Switch/cable mounting screws

0017-00101-1794

Battery mounting screws

0017-00101-1797

Hex key

0K53-01122-0000

Set screw

0017-00101-1833

13

CROSS TRAINER 95Xi 95X-0XXX-01

Power Control Cable

AK62-00092-0000

ORANGE

AC TAP

FIELD

EXC

Valt

FIELD

RTN

GND

RED/BLK

RED/BLK

RED/BLK

BLK

BLK

BLK

BLK/WHT

YELLOW

User Arm HR Cables

AK61-00051-0001

POWER RES.

2 x .75 OHM

240W

P2

12POS.MNL

GREEN

GREEN

GREEN

RPM_ALT

VoltR

VoltR

VoltR

Volt

Volt

GND

GND

GND

GND

FIELD

BLK/PURPLE

6V

RED

Console HR

WHITE

BLACK

BLACK

WHITE

Cable

AK61-00052-0002

P9

RJ45

CSAFE

P10

RJ45

CARDIO

TH.

P11

10POS.

BACKGROUND

DEBUG

HOR.

4POS. MINI FIT JR.

P4

RT SIGNAL

GND

GND

LT SIGNAL

NC

NC

RXD

TXD

Vcardio

CTS

GND

Vsysc

NC

NC

RXD

TXD

Vcardio

CTS

GND

Vsysc

DS

BERR

GND

BKPT

GND

FREEZE

RESET

Dsi

Vcc

Dsc

GND

IO

St2

I3

I1

St2

I2

St3

I4

St1

I5

St3

I6

St1

START

GND

Power Control Board

B084-92218-D000

Upper Console Board

A084-92219-A016

P1

17POS.

LOWER KEYPAD

St8

I6

St5

START

GND

I1

St6

GND

P12

19 POS.

UPPER KEYPAD

I2

St6

I4

I5

GND

St4

I3

St5

St6

IO

St4

GND

Vbat

RPM_REED

3 POS. MINI FIT

P3

P1

13POS.KK-156

N.C.

N.C.

COM

REED SWITCH

MAGNET

Main Cable

AK62-00093-0000

Lower Console Cable

AK63-00038-0000

S98

S108

S118

S128

S138

S148

S158

LWR-CNSL

D08

D18

D28

D38

D48

D58

D68

D78

D88

D98

D108

D118

D128

D138

D148

D158

P5

24POS. MICROFIT

RED

BLUE

YELLOW

GREEN

WHITE

BLACK

BROWN

ORANGE

GREY

RED

BLUE

YELLOW

GREEN

WHITE

BLACK

BROWN

ORANGE

GREY

RED

BLUE

YELLOW

GREEN

WHITE

BLACK

P1

24POS. MICROFIT

D4

D5

D6

D7

D8

D9

D10

D11

D12

D13

D14

D15

S15

S15

D0

D1

D2

D3

S9

S10

S11

S12

S13

S14

Lower

Console Board

B084-92222-B000

Vce

GND

RED

WHITE

BLACK

P7

3POS.

MINI FIT JR.

POLAR RECEIVER

Polar w/latch Conn.Cable

AK39-00063-0000

PolarPCB w/header Cable

AK39-00064-0000

14