1
CROSS-TRAINER 91X-0XXX-01
Customer Support Services
PARTS MANUAL revised 26 Feb 2008
2
91X CROSS-TRAINER
91X-0XXX-01
REFERENCES S/N XTF100000 and UP
MANUAL: OPER; 91X; ENG X M051-00K61-A093
MANUAL: SERVICE; 91X M051-00K61-A097
ARCTIC SILVER TOUCH UP PAINT:
SPRAY CAN
.5 OZ BOTTLE W/APPLICATOR
.33 OZ PEN
0017-00008-0204
0017-00008-0205
0017-00008-0206
STEALTH GRAY TOUCH UP PAINT
( FOR ROCKER ARMS):
SPRAY CAN
.5 OZ BOTTLE W/APPLICATOR
0017-00008-0199
0017-00008-0198
HARDWARE BAG AK61-00181-0000
UNLABELED PARTS
DESCRIPTION PART NO.
BATTERY: 6V; 2.5AH C 0017-00003-0685
1/4 -20X 5 HXL NO L CUP ST BO B 0017-00101-0333
SHAFT: PEDAL-LEVER; CLEVIS B OK61-01076-0000
KIT: SERV; POLAR-RCVR; TESTED BM SK40-00045-0001
The 91X-0XXX-01 has both Telemetry and LifePulse sensors for Heart Rate.
3
91X CROSS-TRAINER
91X-0XXX-01
CONTENTS S/N XTF100000 and UP
Page
DRIVE BELTS AND ALTERNATOR.................................................................................4
CONSOLE SUPPORT ASSEMBLY..................................................................................5
CONSOLE ASSEMBLY....................................................................................................6
ROLLER ASSEMBLY.......................................................................................................7
CRANKSHAFT ASSEMBLY.............................................................................................8
DRIVE LINKAGE ASSEMBLY..........................................................................................9
ANTI-LIFT BRACKET AND OUTER PEDAL COVERS....................................................10
FRAME ASSEMBLY.........................................................................................................11
CLEVIS AND FRONT FRAME COVERS .........................................................................12
PEDAL LEVER ASSEMBLY.............................................................................................13
ROCKER ARM COVERS .................................................................................................14
ROCKER ARM ASSEMBLY.............................................................................................15
REAR DRIVE SHROUDS W/DECALS..............................................................................16
UPPER ARM / HEART RATE ASSEMBLY......................................................................17
CABLES............................................................................................................................18
4
91X CROSS-TRAINER
91X-0XXX-01
DRIVE BELTS AND ALTERNATOR S/N XTF100000 and UP
Drive Belt
0K61-02701-0000
Intermediate Bracket
0K61-02400-0001
A
lternator Pivot Bolt
0017-00101-0964
A
lternator Strap Bolt-2
0017-00101-0986
Flange Lock Nut
0017-00103-0188
Alternator Strap
w/Insert
0K61-02601-0000
Intermediate
Pulley Bolt
0017-00101-1651
Alternator Belt
0K53-01184-0000
Intermediate Pulley Assy
A
K61-00061-0000
Lock Nut
0017-00103-0117
A
lternator
0017-00009-0841
Alternator w/Flywheel
Assembly
AK61-00250-0001
Alternator Flywheel
0K61-02500-0001
5
91X CROSS-TRAINER
91X-0XXX-01
CONSOLE SUPPORT ASSEMBLY S/N XTF100000 and UP
Bolt-2
0017-00101-1645
Flat Washer-2
0017-00104-0192
Console Support
Assembly
AK61-00500-0015
Polar Cable
AK36-00021-0003
Mounting Screws (8)
(not shown for accessory
tray and console)
0017-00101-1744
Accessory Tray Kit
GK63-00002-0062
Main Cable
AK61-00136-0000
Console Cap
0K61-01283-0001
Bullhorn Grip 11.75” (2)
0K62-01136-0002
6
91X CROSS-TRAINER
91X-0XXX-01
CONSOLE ASSEMBLY S/N XTF100000 and UP
Console Board - Upper
A084-92219-A022
Console Case Assembly
AK63-00121-0001
Battery Door
0K63-01029-0001
Phillips Pan Screws(13)
0017-00101-1650
Upper Overlay
Lower Overlay
Console Assembly Overlay/Bezel/
Switch Assembly
AK61-00203-0001 Eng/Eng AK61-00183-0001
AK61-00203-0002 Eng/Met AK61-00183-0001
AK61-00203-0004 Spn/Met AK61-00183-0004
AK61-00203-0007 Frn/Met AK61-00183-0007
AK61-00203-0010 Por/Met AK61-00183-0010
7
91X CROSS-TRAINER
91X-0XXX-01
ROLLER ASSEMBLY S/N XTF100000 and UP
Crank Arm
AK61-00064-0001
Set Screw
1/4-20x5
0017-00101-0333
Bolt
0017-00101-1606
Locking Nut
0017-00103-0025
Crank Cover
0K61-03100-0002
Square Key
0K53-01122-0000
Allen-Head
Cap Screw
0017-00101-1645
Arm Extension
0K61-03004-0000
Shaft Collar
0K61-01260-0000
Roller Bearing Assembly
GK61-00002-0026
Flat Washer
0017-00104-0417
Snap Ring
0017-00100-0152
Set Screws
0017-00101-0314
8
91X CROSS-TRAINER
91X-0XXX-01
CRANKSHAFT ASSEMBLY – AK61-00157-0002 S/N XTF100000 and UP
1.00” Dia. Pillow Block (2)
0K53-01181-0000
Hex Bolts (4)
0017-00101-1551
Magnet-Standoff Assy.
A
K62-00186-0000
Crankshaft Plate
0K61-02302-0001
Locking Nut (4)
0017-00103-0019
Torx screw
0017-00101-1282
Flat Washer
0017-00104-0144
Crankshaft w/plate
0K61-01360-0002
Retaining Ring (2)
0017-00100-0152
Poly-V Crank Pulley
0K61-02409-0000
9
91X CROSS-TRAINER
91X-0XXX-01
Tie Rod Kit – GK61-00002-0020 S/N XTF100000 and UP
Spherical Washer
0017-00009-1085
Spherical
End Sleeve
0K61-01066-0000
Control Link
Sleeve
0K61-01261-0000
Wave Washer
Spring
0017-00009-1084
Silver Bearing
Back Side
Black Bearing
Front Side
Flat Washer
0017-00104-0164
Flat Washer
0017-00104-0164
Locking Nut
0017-00103-0286
Control Link
w/Bearing Assembly
AK61-00073-0001
10
91X CROSS-TRAINER
91X-0XXX-01
ANTI LIFT BRACKET & OUTER PEDAL COVERS S/N XTF100000 and UP
Left Link Cover w/decal
AK61-00175-0002
Decal
0K61-01367-0000
White (used on 91X-0006-01 only)
0K61-06310-000
3
Phillips Pan Screw
0017-00101-1646
Allen Head Bolt
0017-00101-1645
Roller Retainer Plate
0K61-04114-0000
Right Link Cover w/decal
AK61-00175-0001
Decal
0K61-01367-0000
White Link Cover
(used on 91X-0006-01 only)
0K61-06330-0003
11
91X CROSS-TRAINER
91X-0XXX-01
FRAME ASSEMBLY S/N XTF100000 and UP
Control PCB
A
K61-00145-0000
Resistor Bracket
assy. W/cable
AK61-00127-0000
Screw (14)
0017-00101-1282
Screw (14)
0017-00101-1282
Pillow Block
Bearing Nuts
0017-00103-0025
Pillow Block
Bearing Washers
0017-00104-0192
Pillow Block
Bearing Bolts
0017-00101-1635
Extrusion Cover
0K61-06121-0008
White Extrusion Cover
(used on 91X-0006-01 only)
0K61-06121-0005
12
91X CROSS-TRAINER
91X-0XXX-01
CLEVIS & FRONT FRAME COVERS S/N XTF100000 and UP
Clevis Cover Screw-2
0017-00101-1242
Clevis Cover-2
AK61-00062-0001
Stabilizer Cap-4
0K61-01284-0001
Wheel Shaft
0K61-01300-0000
Leg Leveler-4
AK61-00035-0000
Wheel Cap-2
0017-00042-1066
Grommets-14
0017-00042-0754
Phillips Screw-18
0017-00101-1242
Front Cover-RT
0K61-06250-0002
Righ
5
White Cover - t
(used on 91X-0006-01 only)
0K61-062 0-0001
Front Cover-LT
0K61-06240-0002
White Cover - Left
(used on 91X-0006-01 only)
0K61-06240-0001
Wheel-2
0017-00042-0674
Wheel & Cap Kit
GK61-00002-0011
13
91X CROSS-TRAINER
91X-0XXX-01
PEDAL LEVER ASSEMBLY S/N XTF100000 and UP
Tape-4 pieces
0K61-04115-0002
Pedal Kit
GK61-00002-0054
Screw
0017-00101-1242
Inside Cover-LT
0K61-06300-0004
Inside Cover-RT
0K61-06320-0004
White Inside Cover, Left
0K61-06300-0003
White Inside Cover, Right
0K61-06320-0003
(white covers used on
91X-0006-01 only)
Locking Nut-2
0017-00103-0137
Pedal Lever
Clevis Shaft-2
0K61-01076-0000
Bolt-2
0017-00101-1646
Left Pedal Assembly AK61-00172-0002
Right Pedal Assembly AK61-00172-0001
Push-On Clip-4
0017-00009-1143
BEVELED WASHER
OK61-01356-0000
O-Ring
0017-00041-0053
Rocker Seal, Stealth
0K61-01359-0003
14
91X CROSS-TRAINER
91X-0XXX-01
ROCKER ARM COVERS S/N XTF100000 and UP
Phillips Pan Screw-18
0017-00101-1242
Rear Rocker
Arm Cover
0K61-06340-0003
Front Rocker
Arm Cover
0K61-06341-0003
Front Deadshaft Cover
0K61-06350-0003
Rear Deadshaft Cover
0K61-06351-0003
Polar Receiver
AK40-00045-0001
Insulator Receiver Tube
0K36-01059-0002
Front Rocker
Arm Cover
0K61-06340-0003
Rear Rocker
Arm Cover
0K61-06341-0003
15
91X CROSS-TRAINER
91X-0XXX-01
ROCKER ARM ASSEMBLY S/N XTF100000 and UP
Flat Washer
0017-00104-0454
Rocker Arm
A
K61-00094-0003
Hex Bolt
0017-00101-1635
Shaft Split Collar
0K61-01259-0000
16
91X CROSS-TRAINER
91X-0XXX-01
REAR DRIVE SHROUDS W/DECALS S/N XTF100000 and UP
Phillips Pan Screw-22
0017-00101-1242
Left Rear Cover w/Decal
AK61-00176-0002
Lef
7
White t Rear Cover
(used on 91X-0006-01 only)
AK61-00060-000
Right Rear Cover w/Decal
AK61-00176-0001
White Right Rear Cover
(used on 91X-0006-01 only)
AK61-00060-0008
Plug-2
0K14-01384-0000
17
91X CROSS-TRAINER
91X-0XXX-01
UPPER ARM/HEART RATE ASSEMBLY S/N XTF100000 and UP
Upper Arm - RT
Assembly
AK61-00178-0001
Upper Arm - LT
Assembly
A
K61-00178-0002
Life Pulse Cable
AK61-00051-0000
Flat Washer
0017-00104-0450
Bolt
0017-00101-1645
Electrode Kit
GK20-00002-0005
Strain Relief Bushing
0017-00042-1078
18
91X CROSS-TRAINER
91X-0XXX-01
CABLES S/N XTF100000 and UP
3
4
GND
Vsysc
2
1
TDO
RDI
RIGHT
PALM
FINGER
PALM
CLEAR
FINGER
LEFT
WHITE
BLK
WHITE
BLK
2 1
2 1
1
1
BLK
2
2
CLEAR
BLK
LIFEPULSE
RT SIGNAL
2
4
3
1
SIGNAL
LT
GND
GND
13
I6
GND
START
ST5
15
16
14
ST6
I4
I5
ST6
ST4
I2
10
11
12
7
8
9
ST6
I0
ST5
ST4
I3
GND
4
5
6
2
3
1
V
cc
9
2
GND
7
8
6
RESET
Dsi
FREEZE
4
5
3
BKPT
GND
BERR
1
DS
BLACK
WHITE
1
V
cc
GND
SIGNAL
3
2
RED
POLAR RECEIVER
ST6
GND
I1
18
19
17
10
Dso
#RED/BLK
#RED/BLK
#RED/BLK
*BLK/WHT
*YELLOW
GND
ACTAP
*ORANGE
Valt
ValtR
8
6V
RED
#BLK
#BLK
*RED
#BLK
BLK/PURPLE
Valt
Valt
GND
GND
GND
GND
FIELD
1
6
3
2
11
10
5
16
Vsys
RPM_ALT
Vbat
RPM_REED
Vbat
A_START
Va lt
GND
FIELD
FIELD KICK
RED
4
BLUE
YELLOW
PINK
12 65
BLK
GREEN
WHITE
7 811
BROWN
ORANGE
PURP LE
1413
GND
Vsysc
LOAD_CMD
RELAY_c
GND
WHI TE/BLK
GREY
N.C.
N.C.
153 2
N.C.
N.C.
10 91
Vsys
Va lt
GND
Vbat
RPM_REED
RPM_ALT
A_START
REED CONTROL
FIELD
11 78 131 9 10 46
GND
KEY
LOAD_CMD
RELAY_C
2 35 12
RPM_REED
Vbat
GND
#GREEN
#GREEN
#GREEN
ValtR
ValtR
ValtR
RPM_ALT
12
7
9
4
3
2
1
REED SWTCH
N.O.
N.C.
COM
MAGNET
CONTROL PCB
B084-92218-*000
B084-92218-*002
UPPER CONSOLE
B084-92219-*005
P2
12POS.MNL
P3
3POS.MINI FIT
P1
13POS. KK-156
P2
16-POS.MINI FIT JR.
P12
19POS.LIF
UPPER KEYPAD
P4
4POS.MINI FIT JR.
P6
4POS. MICROFIT
TESTER
COM
P11
10POS.
BACKGROUND DEBUG HDR.
P7
3POS. MINI FIT JR.
FIELD EXC FIELD RTN
POWER RES.
2 x .75
OHM
240W
Main Cable
AK61-00136-0000
HR Console Cable
AK61-00052-0002
Polar Cable
AK36-00021-0003
Power Control Board Cable
AK61-00135-0000
Reed Switch
Assembly
118E-00001-0140
/