CROSS-TRAINER 91XW-0XXX-01
Customer Support Services
PARTS MANUAL
rev. 04 May 2007
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91X CROSS-TRAINER
CONTENTS
91XW-0XXX-01
S/N XTG100000 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
BRACKETS AND 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
3
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91XW CROSS-TRAINER
91XW-0XXX-01
DRIVE BELTS AND ALTERNATOR
S/N XTG100000 and UP
Alternator Pivot Bolt
0017-00101-0964
Alternator
Intermediate Bracket
0K61-02400-0001
0017-00009-0841
Alternator w/Flywheel
Assembly
Alternator Strap
Bolt-2
0017-00101-0986
AK61-00250-0001
Alternator Flywheel
0K61-02500-0001
Flange Lock Nut
0017-00103-0188
Lock Nut
0017-00103-0117
Alternator Strap
w/Insert
0K61-02601-0000
Alternator Belt
0K53-01184-0000
Drive Belt
0K61-02701-0000
Intermediate
Pulley Bolt
0017-00101-1651
Intermediate Pulley Assy
AK61-00061-0000
4
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91XW CROSS-TRAINER
91XW-0XXX-01
CONSOLE SUPPORT ASSEMBLY
S/N XTG100000 and UP
Mounting Screws (8)
(not shown for accessory
tray and console)
0017-00101-1744
Accessory Tray Kit
GK63-00002-0062
Main Cable
AK61-00136-0000
Bullhorn Grip 11.75” (2)
0K62-01136-0002
Console Cap
0K61-01283-0001
Console Support
Assembly
AK61-00500-0015
Polar Cable
AK36-00021-0003
Bolt-2
0017-00101-1645
Flat Washer-2
0017-00104-0192
5
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91XW CROSS-TRAINER
CONSOLE ASSEMBLY
91XW-0XXX-01
S/N XTG100000 and UP
Upper Overlay
Console Board - Upper
A084-92219-A006
Console Case Assembly
AK63-00121-0001
Lower Overlay
Phillips Pan Screws(13)
0017-00101-1650
Battery Door
0K63-01029-0001
Console Assembly
Overlay/Bezel/
Switch Assembly
AK61-00183-0001
AK61-00203-0001 Eng/Eng
AK61-00203-0002 Eng/Met
AK61-00203-0003 Ger/Met
AK61-00203-0004 Spn/Met
AK61-00203-0007 Frn/Met
AK61-00203-0008 Itl/Met
AK61-00203-0009 Dut/Met
AK61-00203-00010 Por/Met
AK61-00183-0001
AK61-00183-0003
AK61-00183-0004
AK61-00183-0007
AK61-00183-0008
AK61-00183-0009
AK61-00183-0010
6
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91XW CROSS-TRAINER
ROLLER ASSEMBLY
91XW-0XXX-01
S/N XTG100000 and UP
Roller Bearing Assembly
GK26-00002-0026
Shaft Collar
0K61-01260-0000
Allen-Head
Cap Screw
0017-00101-1645
Set Screws
0017-00101-0314
Arm Extension
0K61-03004-0000
Crank Cover
0K61-03100-0002
Locking Nut
0017-00103-0025
Bolt
0017-00101-1606
Crank Arm & Spindle assy.
AK61-00064-0001
Set Screw
1/4-20x5
0017-00101-0333
Square Key
0K53-01122-0000
7
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91XW CROSS-TRAINER
91XW-0XXX-01
CRANKSHAFT ASSEMBLY – AK61-00157-0002
S/N XTG100000 and UP
Hex Bolts (4)
Poly-V Crank Pulley
0017-00101-1551
1.00” Dia. Pillow Block (2)
0K53-01181-0000
0K61-02409-0000
Crankshaft Plate
0K61-02302-0001
Torx screw
0017-00101-1282
Flat Washer
0017-00104-0168
Crankshaft w/plate
0K61-01360-0002
Locking Nut (4)
0017-00103-0019
Retaining Ring (2)
0017-00100-0152
Magnet-Standoff Assy.
AK62-00186-0000
8
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91XW CROSS-TRAINER
91XW-0XXX-01
DRIVE LINKAGE ASSEMBLY
S/N XTG100000 and UP
Control Link
w/Bearing Assembly
AK61-00073-0001
Black Bearing
Front Side
Control Link
Sleeve
Spherical Washer
0017-00009-1085
0K61-01261-0000
Spherical
End Sleeve
0K61-01066-0000
Flat Washer
0017-00104-0164
Wave Washer
Spring
0017-00009-1084
Locking Nut
0017-00103-0286
Flat Washer
0017-00104-0164
Silver Bearing
Back Side
9
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91XW CROSS-TRAINER
91XW-0XXX-01
ANTI LIFT BRACKET & OUTER PEDAL COVERS
S/N XTG100000 and UP
Right Link Cover w/decal
AK61-00175-0001
Decal
0K61-01367-0000
Allen Head Bolt
0017-00101-1645
Phillips Pan Screw
0017-00101-1646
Roller Retainer Plate
0K61-04114-0000
Left Link Cover w/decal
AK61-00175-0002
Decal
0K61-01367-0000
10
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91XW CROSS-TRAINER
FRAME ASSEMBLY
91XW-0XXX-01
S/N XTG100000 and UP
Pillow Block
Bearing Washers
0017-00104-0192
Pillow Block
Bearing Nuts
0017-00103-0025
Extrusion Cover
0K61-06121-0006
Pillow Block
Bearing Bolts
0017-00101-1635
Screw (14)
0017-00101-1282
Resistor Bracket
w/cable assy.
AK61-00127-0000
Control PCB
AK61-00145-0000
Screw (14)
0017-00101-1282
11
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91XW CROSS-TRAINER
91XW-0XXX-01
CLEVIS & FRONT FRAME COVERS
S/N XTG100000 and UP
Grommets-14
0017-00042-0754
Clevis Cover Screw-2
0017-00101-1242
Stabilizer Cap-4
0K61-01284-0001
Leg Leveler-4
AK61-00035-0000
Wheel Shaft
0K61-01300-0000
Clevis Cover-2
AK61-00062-0001
Wheel-2
0017-00042-0674
Wheel & Cap Kit
GK61-00002-0011
Wheel Cap-2
0017-00042-1066
Front Cover-LT
0K61-06240-0002
Phillips Screw-18
0017-00101-1242
Front Cover-RT
0K61-06250-0002
12
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91XW CROSS-TRAINER
91XW-0XXX-01
PEDAL LEVER ASSEMBLY
S/N XTG100000 and UP
Pedal Kit
GK61-00002-0054
Screw
0017-00101-1242
Tape-4 pieces
0K61-04115-0002
Locking Nut-2
0017-00103-0137
Pedal Lever
Clevis Shaft-2
0K61-01076-0000
Inside Cover-LT
0K61-06300-0004
Inside Cover-RT
0K61-06320-0004
Push-On Clip-4
0017-00009-1143
Bolt-2
0017-00101-1646
Left Pedal Assembly AK61-00172-0002
Right Pedal Assembly AK61-00172-0001
O-Ring
0017-00041-0053
Rocker Seal
0K61-01359-0003
BEVELED WASHER
OK61-01356-0000
13
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91XW CROSS-TRAINER
ROCKER ARM COVERS
91XW-0XXX-01
S/N XTG100000 and UP
Rear Rocker
Arm Cover
0K61-06341-0003
Polar Receiver
SK40-00045-0001
Insulator Receiver Tube
0K36-01059-0002
Front Rocker
Arm Cover
0K61-06340-0003
Front Deadshaft Cover
0K61-06350-0003
Rear Deadshaft Cover
0K61-06351-0003
Front Rocker
Arm Cover
0K61-06341-0003
Rear Rocker
Arm Cover
0K61-06340-0003
Phillips Pan Screw-18
0017-00101-1242
14
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91XW CROSS-TRAINER
91XW-0XXX-01
ROCKER ARM ASSEMBLY
S/N XTG100000 and UP
Flat Washer
0017-00104-0454
Shaft Split Collar
0K61-01259-0000
Hex Bolt
0017-00101-1635
Rocker Arm
AK61-00094-0003
15
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91XW CROSS-TRAINER
91XW-0XXX-01
REAR DRIVE SHROUDS W/DECALS
S/N XTG100000 and UP
Right Rear Cover
w/Decal
AK61-00176-0001
Left Rear Cover
w/Decal
AK61-00176-0002
Phillips Pan Screw-22
0017-00101-1242
Plug-2
0k14-01384-0000
16
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91XW CROSS-TRAINER
91XW-0XXX-01
UPPER ARM/HEART RATE ASSEMBLY
S/N XTG100000 and UP
Upper Arm - RT
Assembly
AK61-00178-0001
Upper Arm - LT
Assembly
AK61-00178-0002
Electrode Kit
GK20-00002-0005
Flat Washer
0017-00104-0450
Bolt
0017-00101-1645
Life Pulse Cable
AK61-00051-0000
Strain Relief Bushing
0017-00042-1078
17
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91XW CROSS-TRAINER
CABLES
91XW-0XXX-01
S/N XTG100000 and UP
Power Control Board Cable
AK61-00135-0000
*ORANGE
CONTROL PCB
B084-92218-*000
P2
POWER RES.
12POS.MNL
2 x .75
OHM
B084-92218-*002
#RED/BLK
#RED/BLK
240W
4
7
RPM_ALT
ValtR
#GREEN
#GREEN
#GREEN
#RED/BLK
ACTAP
Reed Switch
Assembly
118E-00001-0140
Valt
9
ValtR
ValtR
12
8
ValtR
Valt
*RED
GND
10
P3
Valt
11
5
FIELD EXC
FIELD RTN
3POS.MINI FIT
#BLK
#BLK
#BLK
GND
GND
2
GND
1
2
N.C.
Vbat
N.O.
3
1
GND
GND
3
RPM_REED
COM
FIELD
6
MAGNET
*BLK/WHT
*YELLOW
REED SWTCH
P1
13POS. KK-156
11
8
7
1
9
13
10
6
4
2
5
3
12
BLK/PURPLE
LIFEPULSE
Main Cable
PALM
PALM
BLK
BLK
6V
AK61-00136-0000
LEFT
RIGHT
CLEAR
CLEAR
RED
FINGER
FINGER
2
2
1
1
1
1
2
2
P2
16-POS.MINI FIT JR.
P12
19POS.LIF
P4
UPPER KEYPAD
4POS.MINI FIT JR.
4
12
5
6
7
8
11 13 14
16
3
15
2
10
9
1
WHITE
4
2
RT SIGNAL
GND
1
2
GND
ST4
I3
BLK
BLK
GND
1
3
3
4
WHITE
LT
ST5
ST6
SIGNAL
5
6
I0
ST4
I2
7
8
9
P6
ST6
4POS. MICROFIT
TESTER
COM
HR Console Cable
AK61-00052-0002
10
11
I4
I5
1
TDO
RDI
12
ST6
I6
2
13
14
3
4
GND
ST5
Vsysc
15
16
START
GND
UPPER CONSOLE
B084-92219-*005
I1
ST6
17
18
GND
19
P11
10POS.
BACKGROUND DEBUG HDR.
P7
3POS. MINI FIT JR.
1
2
DS
1
Vcc
RED
BERR
2
3
WHITE
SIGNAL
GND
3
4
GND
BLACK
BKPT
GND
5
6
POLAR RECEIVER
FREEZE
7
8
9
RESET
Dsi
Vcc
Polar Cable
10
Dso
AK36-00021-0003
18
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