Schwinn 438 Elliptical Service Manual SCH 430 431 450 SM Rev C Web

User Manual: Schwinn 438 Elliptical Service Manual Troubleshoot Schwinn 438 Elliptical |

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SERVICE MANUAL PN 001-6987 REV B (03/07)

SCHWINN RETAIL ELLIPTICALS

Service Manual

This manual applies to the following models:

426

430 431

450

CONTENTS

Table of Contents

Reading the Serial Number ................................................2

Troubleshooting .................................................................3

Important Contact Numbers ..............................................16

READING THE SERIAL NUMBER

SCHWINN ELLIPTICAL SERIAL NUMBERS

The serial number can be located on the underside of the

machine base. The below instructions show how to decode

the information contained in the serial number:

Serial Number Scheme as Follows:

AAAAAA: KIT NUMBER MODEL

CC: COUNTRY CODE (ELECTRONIC REFERENCE DOES NOT APPLY TO STRENGTH PRODUCTS)

00-DOMESTIC, 110V, 60 HZ, US UNITS ENGLISH OVERLAYS

01-DOMESTIC, 220V, 60HZ, US UNITS ENGLISH OVERLAYS

02-INTERNATIONAL, 230V, 50HZ, METRIC UNITS ENGLISH OVERLAYS

03-INTERNATIONAL, 230V, 50HZ, METRIC UNITS GERMAN OVERLAYS

H CONTACT HEART RATE

0-NO CONTACT HEART RATE

3-WITH CONTACT HEART RATE

XXX MANUFACTURER/VENDOR (3 DIGIT CODE)

SRS-SRS

YY YEAR

MM MONTH

DD DAY

ZZZ MACHINE NUMBER BUILT THAT PRODUCTION RUN

Example serial number (Domestic 110V 430 Elliptical shown):

TROUBLESHOOTING

No display/partial display/unit will not turn on

BASIC TROUBLESHOOTING

1. Problem:

Solution:

A. Make sure the unit is plugged into a functioning wall

outlet.

B. Check the power connection at the front of the unit.

Connection should be secure and undamaged. Replace

the unit adapter or connection if either are damaged.

C. Check data cable integrity. All cable wires should

be intact. If any are visibly crimped or cut, replace the

cable.

D. Check data cable connections/orientation. Insure the

cable is connected securely and oriented properly. The

small latch on the connector should line up and snap

into place.

E. Check console display for damage. Check for

any visual sign that the console display is cracked or

otherwise damaged. Replace the console if damaged.

F. Check console display. If the console only has a

partial display and all connections are OK, replace the

computer.

Advanced Troubleshooting

If any steps above do not resolve problems, proceed to

ADVANCED TROUBLESHOOTING, problem A1.

TROUBLESHOOTING

Unit operates but Contact HR not displayed

BASIC TROUBLESHOOTING

2. Problem:

Solution:

Note: Sensors may have difﬁculty with dried out or

calloused hands. A conductive electrode cream such as

“Signa Crème” or “Buh-Bump” can help make better

conduct. These are available on the Web or at medical

or some larger ﬁtness stores.

A. Insure hands are centered on the HR sensors.

Hands must be kept still with relatively equal pressure

applied to each side.

B. Check the HR cable connection at the console.

Insure the cable is connected securely to console.

If the above tests reveal no problems, replace

the console handle assembly.

TROUBLESHOOTING

Unit operates but Telemetric HR not displayed

BASIC TROUBLESHOOTING

3. Problem:

Solution:

A. Check for interference. Try moving the unit away

from sources of interference (TV, Microwave, etc.). If

interference is eliminated and HR still does not function,

replace the strap. If the problem persists, replace the

console.

Console displays “E2” error code

4. Problem:

Solution:

A. Check data cable integrity. All wires in the cable

should be intact. If any are crimped or cut, replace the

cable.

B. Check data cable connections/orientation. Insure the

cable is connected securely and oriented properly. The

small latch on the connector should line up and snap

into place.

If the above tests reveal no problems, Motor,

DC Servo should be replaced.

TROUBLESHOOTING

No speed/RPM reading

BASIC TROUBLESHOOTING

5. Problem:

Solution:

A. Check data cable integrity. All wires in the cable

should be intact. If any are crimped or cut, replace the

cable.

B. Check data cable connections/orientation. Insure the

cable is connected securely and oriented properly. The

small latch on connector should line up and snap into

place.

C. Check magnet position (requires shroud removal;

see Advanced Troubleshooting, A6). The magnet should

be in place on the ﬂywheel. If no magnet is present,

replace the ﬂywheel magnet.

D. Check RPM Sensor (requires shroud removal; see

Advanced Troubleshooting, A6). The RPM sensor

should be aligned with the magnet and connected

to the data cable. Re-align the sensor if necessary;

replace if there is any damage to the sensor or to the

connecting wire.

TROUBLESHOOTING

Console shuts off (enters sleep mode) while in use

BASIC TROUBLESHOOTING

6. Problem:

Solution:

A. Check data cable integrity. All cable wires should be

intact. If any are crimped or cut, replace the cable.

B. Check data cable connections/orientation. Insure the

cable is connected securely and oriented properly. The

small latch on the connector should line up and snap

into place.

C. Reset Machine (if equipped with reset button).

Unplug the unit from the electrical outlet for three

minutes. Reconnect to the outlet, and after the console

powers up, press “reset”.

D. Check magnet position (requires shroud removal;

see Advanced Troubleshooting, A6). The magnet should

be in place on the ﬂywheel. If no magnet is present,

replace the ﬂywheel magnet.

E. Check RPM Sensor (requires shroud removal; see

Advanced Troubleshooting, A6). The RPM sensor

should be aligned with the magnet and connected

to the data cable. Re-align the sensor if necessary;

replace if there is any damage to the sensor or to the

connecting wire.

TROUBLESHOOTING

BASIC TROUBLESHOOTING

Fan (if equipped) will not turn on or will not turn off

7. Problem:

Solution:

A. Check data cable integrity. All wires in the cable

should be intact. If any are crimped or cut, replace the

cable.

B. Check data cable connections/orientation. Insure the

cable is connected securely and oriented properly. The

small latch on the connector should line up and snap

into place.

C. Reset Machine (if equipped with reset button).

Unplug the unit from the electrical outlet for three

minutes. Reconnect to the outlet, and after the console

powers up, press “reset”.

D. If the fan still does not function properly, replace the

fan. If the problem persists, replace the console.

TROUBLESHOOTING

Unit rocks/does not sit level

BASIC TROUBLESHOOTING

8. Problem:

Solution:

A. Check leveler adjustment. Leveling feet may be

turned in or out to level the elliptical.

B. Check surface under unit. Adjustment may not be

able to compensate for extremely uneven surfaces.

Move the elliptical to a level area.

C. If the problem is not resolved by performing tasks

A. and B., re-assemble the machine per Step 2, Install

Front Stabilizer and Extrusion Assembly, in the 430

Elliptical Assembly Guide.

Pedals loose/unit difﬁcult to pedal

9. Problem:

Solution:

A. Check pedal arm to crank connection. The pedal arm

should be tightened securely to the crank. Insure the

connection is not cross-threaded.

B. Check crank to axle connection. The crank nut (found

under the dust cap) should be tightened securely to the

axle. Be sure the cranks are connected at 180 degrees

from each other.

TROUBLESHOOTING

ADVANCED TROUBLESHOOTING

No display/Unit will not turn on

A1. Problem:

Solution:

A. Check A/C adapter (assumes electrical outlet is OK).

Use a volt meter to check the voltage output from the

adapter. With the positive lead on the inside of the

connector and negative lead on the outside, voltage

should be within 9-14VDC. If the voltage is outside this

range, replace the adapter. If the voltage is OK, check

the computer.

B. Check computer (assumes A/C adapter output is OK).

Disconnect the upper wiring harness from the back of

the computer. While power is supplied to the machine,

use a volt meter to check that voltage is reaching the

computer. Voltage between pins 1 (purple) and 3 (pink),

(Figure A), should be within 9-14VDC. If the voltage is

within range, replace the computer. If not, replace the

upper wiring harness.

Figure A

TROUBLESHOOTING

C. Check upper wiring harness (assumes A/C adapter

is OK, and no voltage is present at the end of the

upper wiring harness). Remove the console mast and

disconnect the upper wiring harness from the lower

wiring harness. Test the output voltage at the lower

harness using pins 1 and 3, as above. If the voltage is

present is now between 9-14VDC, replace the upper

wiring harness. If not, check the power plug wire.

D. Check power plug wire (requires shroud removal;

see Advanced Troubleshooting, A6). Note, this step

assumes the AC Adapter is OK, and no voltage is

present at the end of the lower wiring harness).

Remove the shroud half that has the power plug

mounted into it. Disconnect the power plug wire from

the resistance motor wiring harness. Test the voltage

output of the power plug wire. If no voltage is present,

replace the power plug wire. If the voltage is within

9-14VDC, replace the Motor, DC Servo (includes lower

wiring).

ADVANCED TROUBLESHOOTING

TROUBLESHOOTING

ADVANCED TROUBLESHOOTING

Resistance does not change (assumes unit powers up

and otherwise functions normally)

A2. Problem:

Solution:

A. Check computer wire connections and continuity.

Replace any damaged wires. If wire is OK, check servo

motor.

B. Check servo motor (requires shroud removal; see

Advanced Troubleshooting, A6). Power up the unit and

adjust the resistance level at the console, watching

for movement at the servo motor. If the motor turns

but the magnet arm assembly does not move, check

and secure the mechanical components. Replace

any damaged components. If the motor does not

turn, check wire continuity and the integrity between

the console and the DC motor. If all cables are good,

replace the Motor, DC Servo.

TROUBLESHOOTING

ADVANCED TROUBLESHOOTING

Drive train click/tick noise once per full crank revolution

A3. Problem:

Solution:

A. Check crank/pulley assembly. Disconnect left and

right foot assemblies and rotate the crank. If sound

persists, replace the crank/pulley assembly. If sound

does not come from rotating crank, check the foot

assemblies and the upper/lower handlebars.

B. Check foot assemblies, leg assemblies, handlebar

assemblies. Manually manipulate the foot, leg, and

handlebar assemblies to isolate the sound. Tighten any

loose joints that are making noise, or replace any noisy

assemblies if the sound persists.

TROUBLESHOOTING

Noise multiple times per revolution or once per 1.5 revo-

lution.

A4. Problem:

Solution:

A. Check belt. Remove shrouds (see A6). Visually

inspect the belt for irregularity while slowly rotating the

pedals. Replace the belt if damaged.

B. Check tensioner spring, pulley. Check that the

belt tensioner spring is in place and functional. If the

tensioner is in place but is not providing enough tension

to prevent the belt from slipping, adjust or replace the

tension spring.

C. Check ﬂywheel assembly. Slowly rotate the crank

arms and listen closely for any sound from the ﬂywheel

hub. If sound is present, replace the ﬂywheel bearings.

ADVANCED TROUBLESHOOTING

TROUBLESHOOTING

ADVANCED TROUBLESHOOTING

A5. Problem:

Refer to Figures B and C to locate the four pivots (two

on each side of the machine).

A. Loosen hardware ¼ turn at a time until the unit no

longer makes noise. The bolts all have a sufﬁcient

amount of loc-tite applied to them, so further loosening

should not occur while the unit is in use.

B. However, if three complete turn revolutions of

the hardware are made, and there is still noise, the

hardware should not be backed out any further, and

other troubleshooting should be performed.

Note: A petroleum-based lubricant may also need to be

applied to the pivots shown above after prolonged use

(suggested every three years).

Solution:

Certain pivots may make a squeaking noise while the

machine is in use, and while addressing the problem,

the user tightens the pivots too tight.

Figure B Figure C

TROUBLESHOOTING

ADVANCED TROUBLESHOOTING

Something wrong with the motor, ﬂywheel, RPM sensor,

or other internal components

A6. Problem:

Solution:

Access motor, ﬂywheel, RPM sensor, or other internal

components.

- First, remove shrouds

(Figure D): remove Phillips

head screws securing right

and left shrouds.

- As needed, remove either

right or left crank, or both,

using a crank puller to

remove covers for accessing

internal components.

- Disconnect left and right

foot assemblies and all

movement arms.

- Detach power plug wire

from front of shrouds and lift

off shrouds.

Internal components can now be inspected or replaced

as needed (Figure E).

Flywheel

Magnet Pack Assy

Motor, DC Servo

Flywheel Magnet

RPM Sensor

Crank Bearings

Crank Pulley

Figure D

Figure E

IMPORTANT CONTACT NUMBERS

OFFICES IN THE UNITED STATES:

E-mail: cstech@nautilus.com

• NAUTILUS INNOVATION CENTER

Nautilus, Inc.

1886 Prairie Way

Louisville, Colorado, USA 80027

Phone: 800-NAUTILUS (800-628-

8458)

Fax: 800-898-9410

• TECHNICAL/CUSTOMER SERVICE

Nautilus, Inc.

World Headquarters

16400 SE Nautilus Drive

Vancouver, Washington, USA

98683

Phone: 800-NAUTILUS (800-628-

8458)

Fax: 877-686-6466

• CORPORATE HEADQUARTERS

Nautilus, Inc.

World Headquarters

16400 SE Nautilus Drive

Vancouver, Washington, USA

98683

Phone: 800-NAUTILUS (800-628-

8458)

INTERNATIONAL OFFICES:

For technical assistance and a list of

distributors in your area, please call or fax

one of the following numbers.

• INTERNATIONAL CUSTOMER

SERVICE:

Nautilus International S.A.

Rue Jean Prouvé 6

1762 Givisiez / Switzerland

Tel: + 41-26-460-77-77

Fax: + 41-26-460-77-70

Email: technics@nautilus.com

INTERNATIONAL OFFICES:

• SWITZERLAND OFFICE

Nautilus Switzerland S.A.

Tel: + 41-26-460-77-66

Fax: + 41-26-460-77-60

• GERMANY and AUSTRIA OFFICE

Nautilus GmbH

Tel: +49 2203/20 20-0

Fax: +49 2203/20 20-45 45

• ITALY OFFICE

Nautilus Italy s.r.l.

Tel: +39-051-664-6201

Fax: +39-051-664-7461

• UNITED KINGDOM OFFICE

Nautilus UK Ltd.

Tel: +44-1908-267-345

Fax: +44-1908-267-346

• CHINA OFFICE

Nautilus Representative Ofﬁce

Tel: +86-21-523-707-00

Fax: +86-21-523-707-09

If you need assistance, please have both the serial number of your

machine and the date of purchase available when you contact the

appropriate Nautilus ofﬁce listed below.

IMPORTANT CONTACT NUMBERS

Schwinn 438 Elliptical Service Manual SCH 430 431 450 SM Rev C Web

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