120r
Owner’s Manual
IRONMAN 120r RECUMBENT
Customer Service
1.800.750.IRON
1.800.750.4766
Ironman Fitness
4009 Distribution Drive
Suite 250
Garland, TX 75041
315-00049
07/05 Rev A
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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.
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3
Before You Start
Thank you for purchasing the Ironman 120r Recumbent ! 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
HANDLEBARS
TENSION KNOB
HANDLEBAR
POST
FRONT
STABILIZER
PEDAL
ADJUSTMENT KNOB
MAIN FRAME
REAR STABILIZER
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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
6. HANDLE BAR POST
7. TENSION KNOB
10. CONSOLE ASSEMBLY
11. REAR STABILIZER ASSEMBLY
12. PEDALS LEFT AND RIGHT
Hardware:
1. SCREW M8X1 (49) - Qty 8
2. WASHER (63) - Qty 9
3. CARRIAGE SCREW M8X70 (35) - Qty 2
4. NUT M8 (37) - Qty 2
5. ARC WASHER (36) - Qty 6
6. CARRIAGE SCREW M8X40 (48) - Qty 4
7. NYLOCK NUT M8 (60) - Qty 6
8. HEX HEAD SCREW M6X40 (50) - Qty 8
9. WASHER (62) - Qty 8
10. SCREW M8X15 (49) - Qty 8
11. SCREW M5X10 (65) - Qty 1
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5
Assembly
35
Figure 1
FIGURE 1
Step 1:
Loosen the adjustment knob (41) on
the front frame (1). Slide the rear frame
backward and secure with the adjust-
ment knob (41).
34
36
37
Step 2:
Attach the rear stabilizer (3) onto the
rear frame with screws (49) and washers
(63).
1
41
49
63
Step 3:
63
49
Attach the front stabilizer (34) onto the
main frame with carriage bolts (35), cap
nuts (37) and washers (36).
3
48
Figure 2
FIGURE 2
4
Step 1:
Connect Cables (76) to Cables (42).
Step 2:
Attach the seat frame (4) onto the rear
frame with carriage bolts (48), nylon
lock nuts (60) and washers (63).
Note: Be careful not to pinch cables.
42
76
63
63
60
41
63
60
60
FIGURE 3
Step 1:
Figure 3
6
5
Attach the seat (5) onto the seat frame
(4) with bolts (50) and washers (62).
Step 2:
Attach the back cushion (6) onto the
seat frame (4) with bolts (50) and wash-
ers (62).
4
62
50
50
62
50
62
50
50
1
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6
Assembly
FIGURE 4:
Step 1:
Figure 4
Thread the right pedal (39) onto the right
side of the crank (8) as shown. Tighten the
pedal securely. Select the right pedal strap
which has “R” marked on the bottom side
of the strap. Snap the three hole end onto
the inside edge of the right pedal (39).
Snap the other three hole end onto the
outside edge of the right pedal (39). Select
adjustment holes which allow your foot to
be easily removed from the pedals.
Step 2:
38
8
1
Repeat with the left pedal and strap.
39
Figure 5
75
FIGURE 5
Step 1:
Insert the sensor wire (packed with ten-
sion controller) from the top of the han-
dlebar post (75). Connect the wires per
Figure 5.
Step 2:
Fix the handlebar post (75) onto the main
frame (1) with screws (49) and arc wash-
ers (36).
Figure 6
FIGURE 6
Step 1:
Connect Tension Knob (30) to Resistance
Cable (58). Refer to Figure 6a,6b,and 6c
for detailed instructions. Using one Screw
(65) attach Tension Knob to Upright Post
Assembly (77).
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7
Assembly
FIGURE 6a, 6b,6c: 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:
Figure 7
Connect Sensor and Tension Cables to
Console as shown is Figure 7.
Step 2:
Attach Console (33) to Upright using
four Screws. Note: The four Screws
will already be installed into the back of
Console(33) when you remove it from the
box.
CONGRATULATIONS!!!!!!
You have completed Assembly of your New Ironman 120r Recumbent.
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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
displays 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.
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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.
First, kneel down and grasp the rear support tube with both hands as shown in Figure 1. Next, with a
firm grasp on rear support tube stand up bringing the rear of the bike up in the air and tilt the unit until it rolls
freely on the transport wheels. Using extreme caution, move the unit to the desired location as shown in Figure
2. Do not attempt to move the unit over an uneven or rough surface.
Note: The unit you purchased may not be identical to the one pictured.
Figure 2
Figure 1
Note: This unit may not be identical to your unit.
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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 current
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.
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11
Monitoring Your Heart Rate
TARGET HEART RATE ZONE
200
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
Fat burning
range
116
93
120
60%
117
114
111
108
20 25 30 35
40 45 50 55 60 65
AGE
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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
hamstrings, 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
hamstrings, 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 (not pictured)
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.
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13
Exploded View
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14
Parts List
Ironman 120r Recumbent Parts List Rev A
Ref #
1
Part #
Description
Qty
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
6
2
1
1
1
1
2
2
2
2
4
2
4
8
8
1
1
2
1
4
5
2
1
1
6
1
8
9
1
1
1
1
2
1
2
2
2
2
1
1
1
1
1
1
1
323-00334 MAIN FRAME, 120R
323-00335 RAIL TUBE,120R
2
3
323-00336 REAR STABILIZER 60X600, 120R
323-00338 REAR FRAME, 120R
4
5
328-00059 SEAT PAD, 120R
6
328-00060 BACK PAD, 120R
7
311-00056 PULLEY 270MM, DCV/120E/R
330-00075 CRANK 1/2" ONE PC DCV5.2R/120R
331-00071 BALLBEARING HOUSING, DCV5.2R/120R
331-00070 BALLBEARING, DCV5.2R/120R
331-00074 OUTSIDE BEARING COLLAR, DCV5.2R/120R
331-00073 INSIDE BEARING COLLAR, DCV5.2R/120R
302-00667 WASHER,24X40X2.4
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
#
302-00659 CURVE WASHER, 23X35X2
302-00660 HEX HEAD SCREW #15
304-00002 BELT, J6 430
311-00055 FLY WHEEL #17
331-00072 BEARING 6000ZZ
330-00074 AXLE OF FLY WHEEL 9.98X143, D5.2U/R/120R
302-00662 SPACER OF FLY WHEEL 10X13X10
302-00005 GREASED WHEEL 8X13X7, DCV5.2R/120R
319-00104 IDLER WHEEL PLATE #22
311-00029 IDLER WHEEL ALL INNOFIT UNITS
302-00663 SPACER OF IDLER WHEEL #24
313-00028 PULSE WIRE (1)
313-00064 PULSE WIRE(2)
302-00665 SPRING OF IDLER WHEEL #27
319-00099 ARC MAGNET PLATE #28
302-00664 SPRING OF ARC MAGNET #29
310-00165 TENSION KNOB DCV5.2R
313-00057 SPEED SENSOR
302-01145 MAGNET, 12.5 * 5
307-00086 CONSOLE, 120E/120R
323-00337 FRONT STABILIZER 60X350, 120R
302-00658 CARRIAGE SCREW M8X70
302-00657 ARC WASHER 8X19X1.5
302-00515 NUT M8
306-00633 LEFT PEDAL, 120R
306-00634 RIGHT PEDAL, 120R
306-00200 BUSHING OF MAIN FRAME
310-00001 ADJUSTABLE KNOB U/R/H CM520/530/580 DCV5
313-00028 PULSE WIRE (1)
306-00565 FRONT STABILIZER ENDCAP, DCV5.2EL
306-00564 REAR STABILIZER ENDCAP, DCV5.2R
306-00459 HANDLEBAR TUBE CAP, DCV5.2R
306-00201 SEAT FRAME TUBE CAP
306-00445 CAP 38.1, DCV5.2R/120R
306-00460 CARRIAGE SCREW M8X40, DCV5.2R/120R
302-00670 SCREW M8X15
302-00671 HEX HEAD SCREW M6X40
302-00672 SCREW M8
302-00673 HEX HEAD SCREW 3/8"X26
302-00674 HEX HEAD SCREW M8X60
302-00675 SCREW M3X8
302-00676 SCREW#55
302-00677 SCREW#56
302-00678 SCREW M5X10
313-00027 EXTENSION WIRE
302-00679 NYLOCK NUT M10
302-00680 NYLOCK NUT M8
306-00245 RAIL TUBE CAP, DCV5.2R
302-00687 WASHER 6X13X1.0
302-00681 WASHER 8X19X1.5
302-00682 SCREW 3/8"
302-00683 SCREW M5X10
302-00684 BC NUT 3/8"
302-00685 NYLOCK NUT 3/8"
302-00686 WASHER 10X26X2.0
302-00690 WASHER 10X19X1.5
302-00688 SCREW M4X16
302-00689 SCREW M4/8
306-00203 HANDLEBAR TUBE CAP
310-00166 FOAM GRIP DCV5.2R
305-00096 LEFT COVER, 120R
305-00097 RIGHT COVER, 120R
313-00147 PULSE WIRE (3)
323-00333 CONSOLE TUBE, 120R
302-01148 BOLT PACK DCV5.2R/120R
315-00049 OWNER'S MANUAL 120R
310-00192 TENSION KNOB ASSEMBLY, 120R
#
#
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15
Warranty Information
IRONMAN FITNESS 120r 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
WARRANTY 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.
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16
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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