Owner’s Manual
IRONMAN 120e ELLIPTICAL
Customer Service
1.800.750.IRON
1.800.750.4766
Ironman Fitness
4009 Distribution Drive
Suite 250
Garland, TX 75041
315-00033
Rev A 06/05
Important Safety Information
WARNING! Before using this unit or starting any exercise program, consult your physician. This is especially
important for persons over the age of 35 and/or persons with pre-existing health problems. The manufacturer
or distributor assumes no responsibility for personal injury or property damage sustained by or through the use
of this product.
WARNING! To reduce the risk of electrical shock, burns, fire, or other possible injuries to the user, it is
important to review this manual and the following precautions before operation.
SAFETY PRECAUTIONS AND TIPS
1. It is the owner's responsibility to ensure that all users of this unit have read the Owner's Manual and are
familiar with warnings and safety precautions.
2. This unit has a user maximum capacity of 250 pounds.
3. The unit should only be used on a level surface and is intended for indoor use only. The unit should not be
placed in a garage, patio. Ironman Fitness recommends a mat be placed under the unit to protect floor or car-
pet and for easier cleaning.
4. Wear comfortable, good-quality walking or running shoes and appropriate clothing. Do not use the unit with
bare feet, sandals, socks or stockings.
5. Always examine your unit before using to ensure all parts are in working order.
6. Allow the unit to fully stop before dismounting.
7. Pets should never be allowed near the unit.
8. Do not leave children unsupervised near or on the unit.
9. Never operate the unit where oxygen is being administered, or where aerosol products are being used.
10. For safety and to prevent damage to your unit, no more than one person should use the unit at a time.
11. Service to your unit should only be performed by an authorized service representative, unless authorized
and/or instructed by the manufacturer.
12. Failure to follow these instructions will void the unit warranty.
3
Before You Start
Thank you for purchasing the Ironman 120e Elliptical! This quality product you have chosen was designed
to meet your needs for cardiovascular exercise. Before you start, please read the Owner's Manual and become
familiar with the operation of your new unit.
Remember to take the time to perform the stretching exercises provided to avoid injury.
If you are taking medication, consult your physician to see if the medication will affect your exercise heart rate.
If you have heart problems, you are not active, and/or are over the age of 35 years, do not use the pre-set pro-
grams or start an exercise program without first contacting and receiving approval from your physician.
Do not spill liquids on the console. Ironman Fitness recommends a sealed water bottle for beverages consumed
while using the unit.
Please review the following drawing below to familiarize yourself with the listed parts.
CONSOLE
HANDLEBAR
W/PULSE
HANDLEBARS
TENSION KNOB
SLEEVE
ASSEMBLY
SLEEVE
ASSEMBLY
MAIN FRAME
HANDLEBAR
POST
PLASTIC
BELLOWS
FRONT
PEDAL TUBE
STABILIZER
PEDAL
REAR STABILIZER
4
Assembly
INSTRUCTIONS FOR ASSEMBLY:
Unpack the box in a clear area. Check to make sure all components are present and in good condition.
Do not dispose of the packing material until the assembly is completed. Tools have been provided for you
to use when assembling this product.
Locate the hardware pack and identify the following parts required for assembly.
Tools:
1. Allen Wrench, M5 and M6
2. Phillips Screw Driver
3. Wrench
Main Components:
1. Owner’s Manual
2. Main Frame
3. Front Stabilizer Assembly
4. Handlebar w/Pulse Assembly
5. Upper Handlebar Assembly, Left and Right
6. Handle bar Post
7. Tension Knob
8. Sleeve Assembly Left and Right
9. Pedal Tube Assembly Left and Right
10. Console Assembly
11. Rear Stabilizer Assembly
12. Pedals Left and Right
13. Plastic Bellows
Hardware:
1. M8 Cap Nut (28) - Qty. 4
2. Arc Washer, M8 * 15 (27) - Qty. 12
3. Carriage Bolt, M8 * 70 (26) - Qty. 4
4. Screw, Button Head , M8 * 15 (52) - Qty. 8
5. Washer, M6 * 13 (70) - Qty. 4
6. Nylon Locknut, M6 (71) - Qty. 4
7. Carriage Bolt, M6 * 40 (69) - Qty. 4
8. Bolt, Hex Head, 3/8 * 45 (15) - Qty. 4
9. Washer, 10 * 26 * 2.0 (16) - Qty 4
10. End Cap, #19 (73) - Qty 6
11. End Cap #13 (83) - Qty 2
5
Assembly
Figure 1
FIGURE 1
Step 1:
Using Two Carriage Bolts (26), Cap
Nuts (28) and Arc Washers (24), Attach
the Front Stabilizer Assembly to the
Main Frame.
Figure 2
FIGURE 2
Step 2:
Using Two Carriage Bolts (26), Cap
Nuts (28) and Arc Washers (27) Attach
Rear Stabilizer Assembly to Main
Frame.
FIGURE 3
Step 3:
Using Two Hex Head Bolts (15), Nylon
Lock Nuts (17) and Washers (16)
Attach Left Foot Pedal (12) to the Pedal
Tube Assembly.
Figure 3
Step 4:
Using One Bolt (77), Lock Nuts (17)
and Washers (16), Attach the Pedal
Tube Assembly to the Pedal Attachment
point (8).
Step 5:
Repeat Pedal Assembly for Right side.
6
Assembly
FIGURE 4:
Step 1:
Slide the Plastic Bellows (38) onto the
Upright Post (38).
Step 2:
Connect the Console Cable (51) to Sensor
Wires (49). Slide the Resistance Cable
(53) thru the Upright Post (38) and out
the large hole on the side of the Upright
Post (38).
Step 3:
Using Two Washers (27) and Screws (52),
Attach the Upright Post (38) to the Main
Frame. Slide the Plastic Bellows down
until it meets the Main. Assembly.
FIGURE 5
Step 1:
Insert the Pulse Wires (50) into the bigger
hole on the Upright Post Assembly. Pull
the Pulse Wires out thru the top of the
Upright Post Assembly (38). Using Two
Screws (52) and Arc Washers (27), Attach
the Pulse Handlebar to the Upright Post
Assembly.
FIGURE 6
Step 1:
Connect Tension Knob (54) to Resistance
Cable (53). Refer to Figure 6a,6b,and 6c
for detailed instructions. Using one Screw
(55) and Washer (72), Attach Tension
Knob to Upright Post Assembly (38).
Step 2:
Connect the Console Cables (51) and the
Pulse Cable (50) to wires coming from
Console (57).
Step 3:
Slide the Console (57) onto the Upright
Post Assembly.
7
Assembly
FIGURE 6a: Connect the Tension Knob to the Resistance Cable. Fit the Resistance Control Cable into the
slot of the Tension Knob. Pull the brass end of the Resistance Control Cable over the lip of the Tension Knob
Bracket. The connection should look like Figure 6c when completed.
6c
6a
6b
FIGURE 7:
Step 1:
Stud
Using two Bolts (69), Washers (70) and
Cap Nuts (71), Attach the Left Upper
Handlebar Assembly (65L) to the Lower
Sleeve Assembly (67L).
Step 2:
Slide Lower Sleeve Assembly onto the
two Studs. Connect Lower Sleeve
Assembly with two Bolts (6), Washers
(72) and Cap Nuts (73).
Step 3:
Using Cap Nuts (73, 83), cover bolt
heads.
Step 4:
Stud
Repeat for Left side.
CONGRATULATIONS!!!!!!
You have completed Assembly of your New Ironman 120 e Elliptical.
8
Console Overview
CONSOLE BUTTONS:
ENTER/RESET:
Press to begin workout or change console settings.
PULSE/RECOVERY:
Press to run Pulse program.
DOWN:
Press to set or change TIME, DISTANCE or CALORIES.
UP:
Press to set or change TIME, DISTANCE or CALORIES.
GENERAL INFORMATION:
1. The console will shut off after it detects 4 minutes no activity.
2. Battery Specifications: Two 1.5V AA Batteries
3. If display is illegible or only partial segments appear, remove batteries, wait for 15 seconds and reinstall
batteries. If display is still illegible, you may need new batteries.
FUNCTIONS:
TIME:
This will count up from 00:00 up to 99:50 if you do not enter a preset time.
If you do enter a preset time the console will count down from the time you set to 0:00.
SPEED:
Displays the current exercise speed on the console screen.
DISTANCE:
This will count the accumulated distance during a workout.
If you enter a preset target the console will count from that distance set down to zero.
CALORIE:
This will count the accumulated calorie consumption during a workout.
If you enter a preset target the console will count from the amount set down to zero.
Note: This data is an estimate only and should be used as a comparison over several exercise sessions.
PULSE:
This will display your current heart rate within 5 seconds of holding the handgrip.
Note: To obtain an accurate reading, hold the handgrips with both hands.
PULSE RECOVERY:
To monitor your improvement after each exercise the console is equipped with a special function known as
RECOVERY. Before ending an exercise press the RECOVERY button. The console will stop all function dis-
plays except TIME, which will count down from 00:60 to 00:00. Once the time reaches 00:00 the console
will show a Recovery Status with a grade of F1 to F6, F1 being the best and F6 being the worst. Press the
PULSE RECOVERY button again to return to the main display.
9
Moving Instructions
CAUTION! TO REDUCE THE POSSIBILITY OF INJURY WHILE LIFTING, BEND YOUR LEGS AND
KEEP YOUR BACK STRAIGHT. AS YOU LEAN THE UNIT, LIFT USING YOUR LEGS, NOT YOUR
BACK.
Stand at the front of the unit and using the small handlebar, carefully tilt the machine until the weight is trans-
ferred to the transport wheels. Using extreme caution, move the unit to the desired location. To set the unit
down, carefully lower unit onto rear foot tube assembly in a resting position. Do not attempt to move the unit
over an uneven or rough surface.
10
Monitoring Your Heart Rate
Monitoring Your Heart Rate
To obtain the greatest cardiovascular benefits from your exercise workout, it is important to work within your
target heart rate zone. The American Heart Association (AHA) defines this target as 60%-75% percent of your
maximum heart rate.
Your maximum heart rate may be roughly calculated by subtracting your age from 220. Your maximum heart
rate and aerobic capacity naturally decreases as you age. This may vary from one person to another, but use
this number to find your approximate effective target zone. For example, the maximum heart rate for an aver-
age 40 year-old is 180 bpm. The target heart rate zone is 60%-75% of 180 or 108-135 bpm. See Fitness Safety
below.
Before beginning your workout, check your normal resting heart rate. Place your fingers lightly against your
neck, or against your wrist over the main artery. After finding your pulse, count the number of beats in 10 sec-
onds. Multiply the number of beats by six to determine your pulse rate per minute. We recommend taking your
heart rate at these times; at rest, after warming up, during your workout and two minutes into your cool down,
to accurately track your progress as it relates to better fitness.
During your first several months of exercising, the AHA recommends aiming for the lower part of the target
heart rate zone-60%, then gradually progressing up to 75%.
According to the AHA, exercising above 75% of your maximum heart rate may be too strenuous unless you
are in top physical condition. Exercising below 60% of your maximum will result in minimal cardiovascular
conditioning.
Check your pulse recovery rate – If your pulse is over 100 bpm five minutes after you stop exercising, or if
it’s higher than normal the morning after exercising, your exertion may have been too strenuous for your cur-
rent fitness level. Rest and reduce the intensity next time.
Fitness Safety The target heart rate chart indicates average rate zones for different ages. A variety of different
factors (including medication, emotional state, temperature and other conditions) can affect the target heart
rate zone that is best for you. Your physician or health care professional can help you determine the exercise
intensity that is appropriate for your age and condition.
(MHR) = Maximum Heart Rate
(THR) = Target Heart Rate
220 - age = maximum heart rate (MHZ)
MHZ x .60 = 60% of your maximum heart rate.
MHZ x .75 = 75% of your maximum heart rate.
For example, if you are 30 years old, your calculations will be as follows:
220 - 30 = 190
190 x .60 = 114 (low end or 60% of MHZ)
190 x .75 = 142 (high end or 75% of MHZ)
30 year-old (THR) Target Heart Rate would be 114-142
See Heart Rate Table (on page 14) for additional calculations.
11
Monitoring Your Heart Rate
TARGET HEART RATE ZONE
200
100%
195
190
185
180
175
Serious
athletic
170
165
160
training range
155
132
85%
170
150
166
146
162
143
157
139
153
135
Cardiovascular
conditioning
range
149
131
105
145
128
102
140
124
99
136
120
96
75%
Fat burning
range
116
93
60%
120
117
114
111
108
20 25 30 35
40 45 50 55 60 65
AGE
12
Warm Up Exercises
EXERCISE GUIDELINES
WARNING! Before beginning this or any exercise program, you should consult your physician. This is espe-
cially important for individuals over the age of 35 or individuals with pre-existing health problems.
Warming up prepares the body for the exercise by increasing circulation, supplying more oxygen to the mus-
cles and raising body temperature. Begin each workout with 5 to 10 minutes of stretching and light exercise
to warm up. The photos on this page show several forms of basic stretching you may perform before your
workouts. In order to achieve an adequate warm-up, perform each stretch three times.
TOE TOUCH STRETCH
Stand bending your knees slightly and slowly bend forward from your hips.
Allow your back and shoulders to relax as you reach down toward your toes
as far as possible. Hold for 15 counts, then relax. This will stretch your ham-
strings, back of knees, and back.
HAMSTRING STRETCH
Sit with one leg extended. Bring the sole of the opposite foot toward you and
rest it against the inner thigh of your extended leg. Reach toward your toes as
far as possible. Hold for 15 counts, then relax. This will stretch your ham-
strings, lower back, and groin.
CALF/ACHILLES STRETCH
With one leg in front of the other, reach forward and place your hands against
a wall. Keep your back leg straight and your back foot flat on the floor. Bend
your front leg, lean forward and move your hips toward the wall. Hold for 15
counts, then relax. To cause further stretching of the Achilles tendon, bend
your back leg as well. This will stretch your calves, Achilles tendons, and
ankles.
QUADRICEPS STRETCH
With one hand against a wall for balance, reach back and grasp one foot with
your other hand. Bring your heel as close to your buttocks as possible. Hold
for 15 counts, then relax. This will stretch your quadriceps and hip muscles.
INNER THIGH STRETCH
Sit with the soles of your feet together and your knees outward. Pull your
feet toward your groin area as far as possible. Hold for 15 counts, then relax.
This will stretch your quadriceps and hip muscles.
13
Exploded View
14
Exploded View
15
Parts List
Ironman 120E Ellipticall Parts List Rev A
REF# KEYS PART#
DESCRIPTION
QTY. REF# KEYS PART#
DESCRIPTION
QTY.
1
323-00320
MAIN FRAME, 120E
1
1set
1set
1
45 302-00711
46 302-00712
47 302-00704
48 304-00005
49 313-00056
50 313-00195
51 313-00023
52 302-00715
53 310-00084
54 310-00047
55 302-00716
56 323-00325
57 307-00086
58 306-00615
59 306-00616
60 310-00168
61 302-01130
62 302-00719
63 306-00455
64L 323-00323
64R 323-00324
65 328-00037
66 306-00456
67L 306-00617
67R 306-00618
68 306-00199
69 302-00720
70 302-01122
71 302-00722
72 302-00723
73 302-00724
74L 323-00326
74R 323-00327
75 302-00032
76 302-00725
77 302-01116
78 302-00727
79 319-00132
80 319-00203
81 302-01104
82 302-01187
83 302-01094
84 315-00033
SCREW, #45
2
2a 331-00075
2b 331-00076
BALL BEARINGS #2A
MAGNETIC SPRING#46
CAP NUT, M8
1
1
1
1
2
1
8
1
1
1
1
1
1
1
2
5
5
1
1
1
2
4
1
1
2
4
4
4
8
6
1
1
8
4
2
1
1
2
2
2
2
1
BALL BEARINGS #2B
3
4
5
6
7
8
9
302-01145
311-00056
330-00077
302-00691
330-00078
319-00200
331-00086
MAGNET, 12.5 * 5
BELT, J6 440
PULLEY 270MM, DCS & 120E
PULLEY AXLE DCV5.2EL/120e
NYLON LOCK NUT, 1/2" * 20T
CRANK DCV5.2EL/120e
U BRACKET FOR PEDAL TUBE, 120E
BEARING, GREASED, 15.8 X 22.2
PEDAL TUBE, 120E
1
SPEED SENSOR
1
PULSE WIRE, 120E
4
EXTENSION WIRE #51
SCREW, M8X15#52
2
2
RESISTANCE CABLE #53
RESISTANCE KNOB DCV5.2EL/120e
SCREW #55
4
10 319-00201
11 306-00197
12 302-00728
13 311-00029
14 306-00461
15 302-00695
16 302-00696
17 302-00697
18 319-00118
19 331-00011
20 302-01186
21 302-00699
22 302-00700
23 302-00701
24 319-00202
25 319-00120
26 302-00702
27 302-00703
28 302-00704
29 323-00321
30 306-00451
31 306-00452
32 302-00705
33 306-00566
34 331-00078
35 330-00076
36 331-00079
37 302-00706
38 323-00322
39 302-00707
40 302-00031
41 302-00708
42 302-00709
43 302-00710
44 319-00121
2
PLASTIC SPACER #11 DCV5.2/120e
IDLER WHEEL SPACER
IDLER WHEEL ALL INNOFIT UNITS
PEDAL, DCV5.2EL/120e
HEX HEAD BOLT, 3/8" X 45
WASHER, 10 X 26 X2
2
PULSE HANDLEBAR ASSEMBLY, 120E
CONSOLE, 120E
1
1
LEFT COVER, 120E
2
RIGHT COVER, 120E
4
ADJUSTABLE KNOB DCV5.2EL/120e
SCREW, M4*16
8
NYLOCK NUT, 3/8"
7
SCREW, M5X75#62
PU WHEEL #18
2
PLASTIC BELLOW, DCV5.2EL/120e
UPPER HANDLEBAR, LEFT, 120E
UPPER HANDLEBAR, RIGHT, 120E
FOAM GRIP #65
BEARING 608ZZ
4
SPACER, 8.5 X 12.7 X 10
WASHER, 8X19X1.5
6
9
SCREW, 8X33.5
2
BAR CAP, DCV5.2EL/120e
SLEEVE, LEFT, 120E
HEX HEAD SCREW M6 #23
FRONT STABILIZER, 120E
FRONT STABILIZER CAP #25
CARRIAGE BOLT M8X70 #26
ARC WASHER 8X19X1.5 #27
CAP NUT, M8
2
1
SLEEVE, RIGHT, 120E
PLASTIC NUT CAP DCV5.2E/H/120e
CARRIAGE BOLT M6X40 #69
WASHER 6*13*1 TRI-5.3E
NUT M6#71
2
4
12
4
TUBE RAIL, 120E
1
WASHER 13X26X2#72
NYLON LOCK NUT, #19
CONNECT TUBE LEFT, 120E
CONNECT TUBE RIGHT, 120E
BEARING, 12.7X25.1
REAR STABILIZER CAP, DCV5.2EL/120e
RAIL TUBE CAP, DCV5.2EL
HEX HEAD BOLT 3/8 * 25
WHEEL, DCV5.2EL/120e
BEARING #34
2
2
1
1
3
BEARING,10X15
WHEEL AXLE DCV5.2EL/120e
BEARING, 8 * 13 * 7, #36
SPRING #37
1
HEX HEAD BOLT, 3/8"*50
NYLOCK NUT#78
5
1
IDLER ARM DCV5.2EL/120e
U BRACKET, CONNECT TUBE,120E
HEX HEAD BOLT M8*40
SCREW, M8 * 55
UPRIGHT POST, 50.8, 120E
NYLON LOCK NUT M8 #39
WHEEL SPACER DISCOVERY 5.2
BC NUT 3/8"#41
1
10
1
1
NYLOCK NUT M8
WASHER 10X19X1.5#42
NUT, #43
1
OWNER'S MANUAL, 120E
1
MAGNETIC PLATE #44
1
16
Warranty Information
IRONMAN FITNESS 120e LIMITED WARRANTY
Residential Warranty
Frame: Lifetime
Parts: 1 Year
Labor: None
This Limited Warranty applies in the United States and Canada to products manufactured or distributed by Ironman Fitness
(“Ironman”) under the Ironman brand name. The warranty period to the original purchaser is listed above in the table.
Ironman warrants that the Product you have purchased for use from Ironman or from an authorized Ironman reseller is free from
defects in materials or workmanship under normal use during the warranty period. Your sales receipt, showing the date of purchase
of the Product, is your proof of purchase. This warranty only extends to you, the original purchaser. It is not transferable to anyone
who subsequently purchases the Product from you. It excludes expendable parts (wear items). Wear items pertain to components
that might need to be replaced due to normal wear and tear. These items vary per product but will include pedal straps, seats, grips,
chains, bottom bracket assemblies, pads, etc. Please contact an Ironman customer service representative for specifics on wear
items. This Limited Warranty becomes VALID ONLY if the product is purchased through an Ironman Fitness authorized dealer
unless otherwise authorized by Ironman Fitness in writing.
During the warranty period Ironman will repair or replace (at Ironman’s option) the product if it becomes defective, malfunctions,
or otherwise fails to conform with this Limited Warranty under normal use. In repairing the Product, Ironman may replace defec-
tive parts, or at the option of Ironman, serviceable used parts that are equivalent to new parts in performance. All exchanged parts
and Products replaced under this warranty will become the property of Ironman. Ironman reserves the right to change manufactur-
ers of any part to cover any existing warranty.
This warranty DOES NOT COVER shipping charges, export taxes, custom duties and taxes, or any other charges associated with
transportation of the parts or Product.
To obtain warranty service, you must contact an Ironman authorized retailer, service technician or Ironman Fitness at our phone
number located in this manual. Any parts determined to be defective must be returned to Ironman to obtain warranty service. You
must prepay any shipping charges, export taxes, custom duties and taxes, or any other charges associated with transportation of the
parts or Product. In addition, you are responsible for insuring any parts or Product shipped or returned. You assume the risk of loss
during shipment. You must present Ironman with proof-of-purchase documents (including the date of purchase). Any evidence of
alteration, erasing or forgery of proof-of-purchase documents will be cause to void this Limited Warranty.
This warranty does not extend to any product not purchased from Ironman or from an authorized Ironman reseller. This Limited
Warranty does not extend to any Product that has been damaged or rendered defective; (a) as a result of accident, misuse, or abuse;
(b) by the use of parts not manufactured or sold by Ironman; (c) by modification of the Product or normal wear and tear; (d) opera-
tion on incorrect power supplies; or (e) as a result of service by anyone other than Ironman, or an authorized Ironman warranty
service provider. Product on which the serial number has been defaced or removed is not eligible for warranty service. Should any
Product submitted for warranty service be found ineligible, an estimate of repair cost will be furnished and the repair will be made
if requested by you upon Ironman’s receipt of payment or acceptable arrangements for payment.
EXCEPT AS EXPRESSLY SET FORTH IN THIS WARRANTY, IRONMAN MAKES NO OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MER
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IRONMAN EXPRESSLY DIS
CLAIMS ALL WARRANTIES NOT STATED IN THIS LIMITED WARRANTY. ANY IMPLIED WAR
RANTIES THAT MAY BE IMPOSED BY LAW ARE LIMITED TO THE TERMS OF THIS LIMITED
WARRANTY. NEITHER IRONMAN NOR ANY OF ITS AFFILIATES SHALL BE RESPONSIBLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WAR-
RANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE LIMITATIONS OR EXCLUSION MAY NOT APPLY TO YOU. This Limited Warranty gives you specific legal rights
and you may also have other rights that may vary from state to state. This is the only expressed warranty applicable to Ironman-
branded products. Ironman neither assumes nor authorizes anyone to assume for it any other express warranty.
PLEASE SEND IN THE ATTACHED WARRANTY CARD WITHIN TEN (10) DAYS OF PURCHASE TO
REGISTER YOUR UNIT WITH IRONMAN FITNESS.
17
Customer Service
1.800.750.IRON
1.800.750.4766
Ironman Fitness
4009 Distribution Drive
Suite 250
Garland, TX 75041
Ironman and M-dot are registered trademarks of the World Triathlon Corp., used here by permission.
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