Assembly Manual Cross-Trainer „CONDOR”
Item # 07859-190
Environmentaly friendly: printed on 100% recycled paper
Assembly must be carried out by an adult!
Thank you for purchasing our high quality KETTLER product.
If you have any questions or concerns regarding this product, please contact us:
KETTLER International, Inc. E-mail parts@KETTLERUSA.COM
Parts & Service Department Tel: 757-427-2400 ext. 26
P. O.Box 2747 Fax: 757-563-9273
Virginia Beach, Virginia 23450 USA
Please have this owner’s manual with you when you call.
DO NOT CONTACT YOUR RETAILER.
USA
Handling the equipment
■ Before using the equipment for exercise, check carefully to en-
sure that it has been correctly assembled.
■ Before beginning your first training session, familiarize yourself
thoroughly with all the functions and settings of the unit.
■ It is not recommended to use or store the apparatus in a damp
room as this may cause it to rust. Please ensure that no part of
the machine comes in contact with liquids (drinks, perspiration
etc.). This may cause corrosion.
■ The machine is designed for use by adults and children should
not be allowed to play with it. Children at play behave unpredictably and dangerous situations may occur for which the manufacturer cannot be held liable. If, in spite of this, children are
allowed to use the equipment, ensure that they are instructed in
its proper use and supervised accordingly.
■ The crosstrainer complies with the DIN EN 957 - 9, class HB.
It is therefore unsuitable for therapeutic use.
■ A slight production of noise at the bearing of the centrifugal
mass is due to the construction and has no negative effect upon
operation. Possibly occurring noise during reverse pedalling result from engineering and are absolutely safe.
■ Do not use corrosive or abrasive materials to clean the equip-
ment. Ensure that such materials are not allowed to pollute the
environment.
■ The crosstrainer has a magnetic brake system.
■ To operate correctly, the pulse function requires a minimum vol-
tage of 2,7 volts (only for computers working with batteries).
■ The equipment is dependent of revolutions per minute.
■ Please ensure that liquids or perspiration never enter the ma-
chine or the electronics.
■ Before use, always check all screws and plug-in connections as
well as respective safety devices fit correctly.
■ Always wear suitable shoes when using.
■ All electric appliances emit electromagnetic radiation when in
operation. Please do not leave especially radiation-intensive
appliances (e.g. mobile telephones) directly next to the cockpit
or the electronic controlsystem as otherwise values displayed
might be distorted (e.g. pulse measurement
Instructions for Assembly
■ Ensure that you have received all the parts required (see check
list) and that they are undamaged. Should you have any cause
for complaint, please contact your KETTLER dealer.
■ Before assembling the equipment, study the drawings carefully
and carry out the operations in the order shown by the diagrams. The correct sequence is given in capital letters.
■ The equipment must be assembled with due care by an adult
person. If in doubt call upon the help of a second person, if
possible technically talented.
■ Please note that there is always a danger of injury when wor-
king with tools or doing manual work. Therefore please be careful when assembling this machine.
■ Ensure that your working area is free of possible sources of
danger, for example don’t leave any tools lying around. Always dispose packaging material in such a way that it may not
cause any danger. There is always a risk of suffocation if children play with plastic bags!
■ The fastening material required for each assembly step is sho-
2
Important Instructions
For Your Safety
■ The crosstrainer should be used only for its intended purpose,
i.e. for physical exercise by adult persons.
■ Any other use of the equipment is prohibited and may be dan-
gerous. The manufacturer cannot be held liable for damage or
injury caused by improper use of the equipment.
■ The crosstrainer has been designed in accordance with the la-
test standards of safety. Any features which may have been a
possible cause of injury have been avoided or made as safe as
possible.
■ Incorrect repairs and structural modifications (e.g. removal or
replacement of original parts) may endanger the safety of the
user.
■ Damaged components may endanger your safety or reduce the
lifetime of the equipment. For this reason, worn or damaged
parts should be replaced immediately and the equipment taken
out of use until this has been done. Use only original KETTLER
spare parts.
■ If the equipment is in regular use, check all its components
thoroughly every 1 -2 months. Pay particular attention to the
tightness of bolts and nuts. This is particularly true for the
attachment of grip strap and running plate.
■ To ensure that the safety level is kept to the highest possible
standard, determined by its construction, this product should
be serviced regulary (once a year) by specialist retailers.
■ Instruct persons using the equipment (in particular children) on
possible sources of danger during exercising.
■ Before beginning your program of exercise, consult your doc-
tor to ensure that you are fit enough to use the equipment. Base
your program of exercise on the advice given by your doctor.
Incorrect or excessive exercise may damage your health!
■ Any interference with parts of the product that are not descri-
bed within the manual may cause damage, or endanger the
person using this machine. Extensive repairs must only be carried out by KETTLER service staff or qualified personnel trained
by KETTLER.
Please read these instructions carefully prior to carrying out assembly and using for the first time.
They contain information which is important for your safety as well as for the use and maintenance of the appliance. Keep these instructions in a safe place for reference purposes, maintenance
work and to assist you when ordering spare parts.
3
List of spare parts page 10-12
When ordering spare parts, always state the full article number,
spare-part number, the quantity required and the inspection number stamped on the back.
Example order: Art. no. 07859-190 / spare-part no. 70128562
/ 2 pieces / inspection no .................... Please keep original
packaging of this article, so that it may be used for transport at
a later date, if necessary.
Important: spare part prices do not include fastening material; if
fastening material (bolts, nuts, washers etc.) is required, this
should be clearly stated on the order by adding the words „with
fastening material“.
KETTLER International, Inc.
P. O.Box 2747
Virginia Beach, Virginia 23450 USA
Tel: 757-427-2400 ext. 26
Fax: 757-563-9273
E-mail parts@KETTLERUSA.COM
wn in the diagram inset. Use the fastening material exactly as
instructed. The required tools are supplied with the equipment.
■ Bolt all the parts together loosely at first, and check that they
have been assembled correctly. Tighten the locknuts by hand
until resistance is felt, then use spanner to finally tighten nuts
completely against resistance (locking device). Then check that
all screw connections have been tightened firmly. Attention:
once locknuts have been unscrewed they no longer function
correctly (the locking device is destroyed), and must be replaced.
■ For technical reasons, we reserve the right to carry out preli-
minary assembly work (e.g. addition of tubing plugs).
4
1
1
2
1/1
2/2
1
✓
Checklist (contents of packaging)
1/1
2
M10x105
6
M8x16
4
M5x45
2
M10
4
M5
4
ø10
2
ø21x8.4
4
ø25x10.5
4
ø25x8.4
8
2
2
2
M5x20
1
5
1
A
B
C
E
D
F
E
2x
F
2x
E
F
!1. „E“ 2. „F“!
The screwed connections must be controled at regular
intervals.
!
AACCTTUUAALL SSIIZZEE
AACCTTUUAALL SSIIZZEE
6
3
2
1.
2.
3.
A
B
AACCTTUUAALL SSIIZZEE
AACCTTUUAALL SSIIZZEE
2x
AACCTTUUAALL SSIIZZEE
AACCTTUUAALL SSIIZZEE
2x
AACCTTUUAALL SSIIZZEE
AACCTTUUAALL SSIIZZEE
7
4
8x
ab
c
5
4x
AACCTTUUAALL SSIIZZEE
AACCTTUUAALL SSIIZZEE
8
6
2x
Battery change
A weak or an extinguished computer display makes a battery
change necessary. The computer is equipped with two batteries.
Perform the battery change as described below:
■ Remove the lid of the battery compartment and replace the bat-
teries by two new batteries of type AA 1,5V.
■ When inserting the batteries pay attention to the designation
an the bottom of the battery compartment.
■ Should there be any misoperation after switching on the com-
puter again, shortly disconnect the batteries once again and reinsert them.
IImportant: The guarantee does not cover worn-out batteries.
You should no longer put used batteries in domestic waste. Please do your bit for the environment and return your batteries to the
trade or to the local authority pick-up point so that the collected
C
B
A
batteries can be properly disposed of or recycled in an environment-friendly way.
AACCTTUUAALL SSIIZZEE
AACCTTUUAALL SSIIZZEE
9
B
A
Handling
!
!
10
Spare Parts Drawing
532728 29
91
55 89 56 58
51
59
72
52
84
83
74
85
54
64
87
42
44-50
63
43
57
32
80
81
60
22
61
347778
39
9
93
31
30
37
82
69
86
24
92
18
2
19
1
8
6
7
3
952675
36
66
65
41
71
41
62
73
63
33
70
76
4
5
39
21
75
20
40
25
23
68 35
2
88
11
List of Spare Parts
Condor Cross-Trainer 7859-190
Pos.
No. Description Qty. Spare Parts
1 Base Frame 1 94313995
2 Bearing for Drive Axle 6203-ZZ C3 2 33100017
3 Drive Axle 17x114 mm 1 11300055
4Magnetic P/U Wire 375 mm 1 67000662
5Magnetic P/U 1 17013990
6 Fly Wheel Resistance Magnet 1 94313567
7Fly Wheel Magnet Segment 3 67000170
8 Guide Piece for Magnet (2803) 1 70128340
9 Lower Tension Rod & Block 1 94313568
10 Cable Rerouter & P/U (2804) 1 70126725
11 Push Bar (4-6014) 1 25006014
12 Spacer 8x1x24 mm 1 97200485
13 Roller 1 10121057
14 Cable 1, 2x900 mm 1 43004053
15 Spiral 2, 5x580 mm 1 43004052
16 Set Screw 1 43004111
17 Bolt Cap 1 43004018
18 Set Spindle 1 97201389
19 Spring For Magnet Tension (4-5891) 1, 6mm 1 25605891
20 Idler Pulley w/ Bearings 6300-ZZ 1 94313101
21 Spring for Belt Tension 1 25635052
22 Flywheel 1 91140379
23 Drive Belt 1651 PJ6 1 67005127
24 Right Drive Disc 1 94313542
25 Left Drive Disc 1 94313544
26 Right Drive Disc Shaft ø20x120,5mm 1 10900091
27 Right Side Main Shroud 1 70128552
28 Left Side Main Shroud 1 70128553
29 Drive Disc Cap 2 70128562
30 Right Lower Mast Cover 1 70128559
31 Left Lower Mast Cover 1 70128560
32 Right Front Ski Cover 2 70128421
33 Left Front Ski Cover 2 70128422
34 Rivets 6x9, 5 mm 8 10418503
35 Frame Cross Members 291111287-20
36 Floor Levelers 2 91170389
37 Right Transport Castor 1 91170387
38 Left Transport Castor 1 91170388
39 Skis w/ Bearings 2203-2RS 2 94315158
40 Left Drive Disc Shaft ø20x120,5mm 1 10900092
41 Ski Pole Bearing 6203-ZZ 8 33100038
42 Mast 1 94313998
43 Upper Tension Rod 1 97201823
44 Tension Assembly 1 70127070
45 Tension Assembly 1 70127080
46 Tension Assembly 1 70127500
47 Tension Assembly 1 97200358
48 Tension Assembly 2 10100079
49 Tension Assembly 1 97201443
50 Tension Assembly 1 97200553
51 Center Handlebar 1 94314013
52 Grip for Center Handlebar 750 mm 1 10118074
53 Main Shroud Top Cover 1 70128563
54 Rear Plate for Tension Assembly 1 91170207
55 Computer ST2207-8 1 67000543
56 Rear Computer Housing 3547 1 70128555
57 Top Lead Wire 1 67000549
58 Ear Lobe Clip Heart Rate Monitor 1 67000653
59 Hand Pulse Sensors WP 1007-5C 1 67000658
60 Mast Cover 3089 1 70128475
docu 1121a/ 02.04
12
List of Spare Parts
Condor Cross-Trainer 7859-190
Pos.
No. Description Qty. Spare Parts
61 Right Ski Pole 1 94313569
62 Left Ski Pole 1 94313576
63 Lower Ski Pole Bearing 6200-ZZ 4 33100036
64 Lower Ski Pole Sleeve 20x4.5x59 mm 2 97201447
65 Ski Pole Grips 680 mm 2 10118034
66 Ski Pole Top Cap 28 mm 2 10100018
67 Fly Wheel Bearing 6203-ZZ 2 33100023
68 Underside Plate for Frame Cross Member 2 97200256
69 Right Foot Plate 1 70128398
70 Left Foot Plate 1 70128399
71 Rear Center Ski Pole Pivot Covers w/ Screw Holes 2 70128411
72 Front Center Ski Pole Pivot Covers 2 70128412
73 Rear Bottom Ski Pole Cover 2 70128413
74 Front Bottom Ski Pole Cover 2 70128414
75 Spacer 2 70133275
76 Tension Assembly 2 10100079
77 Wavy Washer A5 4 10601001
78 Foot Plate Adjuster Caps M5 4 10104000
79 Hardware Bags 1 94313723
80 Water Bottle Holder 1 70190051
81 Water Bottle 1 70190041
82 Guide for Tension Cable 1 67000088
83 Center Handlebar 1 9720036
84 Left Upper Mast Cover 1 70128558
85 Right Upper Mast Cover 1 70128557
86 Sleeve ø22,2x2x27,5 mm 2 97201463
87 Plastic Side Insertion Piece for Computer Housing (3550) 1 70128556
88 Adaptor Ring 3322 1 70128492
89 Front Computer Housing 1 70128554
90 Computer Cover 1 10206111
91 Shroud Screws 6 10224072
92 Sleeve for Tension Cable 10x1.9x13 mm 1 97200445
93 Connector Pin (3295) 3 70128446
94 Sheet Film Buffer for Cross Member 2 34010120
95 Bearing 2203-2RS 1 33100047
In case of complaint, please state this control number.
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