Schwinn 430 User manual

Schwinn®430 and Journey 4.0 Elliptical

Fitness Machine Service Manual 8006854.021518.C

Service Manual

Section Code Section Page Number

1 Important Safety Instructions 2

1 Safety Warning Labels and Serial Number 3

1 Speciﬁcations 3

1 Maintenance 4

1 Moving the Machine 5

1 Leveling the Machine 5

1 Troubleshooting 6

1 Console Service Mode 8

1 Maintenance Parts Exploded View 10

1 Replacement Procedure Skill Level 11

Mechanical Procedures 12

2 Adjust the Belt Tension 12

3 Set the Brake Tension 15

Part Replacement 18

4 Brake Assembly 18

5 Console 21

6 Console Mast 23

7 Crank Arms 26

8 Data Cable in the Mast 30

9 Drive Belt and Flywheel Assembly 34

10 Front Stabilizer 37

11 Lift Assembly and Rail Assembly 39

12 Pedals and Legs 44

13 Power Inlet 46

14 Roller Wheel Disc (older models only) 48

15 RPM Sensor (Speed Sensor) 50

16 Servo Motor 52

17 Shrouds 55

18 Static Handlebar and Water Bottle Holder 60

19 Tensioner Assembly (Idler Assembly) 62

20 Upper and Lower Handlebar Arms 64

Table of Contents

Nautilus, Inc., www.NautilusInc.com - Customer Service: North America (800) 605-3369, [email protected] | outside U.S. www.nautilusinternational.com | © 2013 Nautilus, Inc. | ® indicates trademarks regis-

tered in the United States. These marks may be registered in other nations or otherwise protected by common law. Schwinn is a trademark licensed to Nautilus, Inc.

8018293.021518.A

8007200.021518.B

Service Procedures

Important Safety Instructions

This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and

understand all Warnings on this machine.

Before servicing or using this equipment, obey the following warnings:

Read and understand the Service Manual before working on the machine. Failure to obey the instructions and safety

warnings could cause injury to the service technician or bystanders.

• Keep bystanders and children away from the product being serviced at all times.

• Make sure that the repair is done in an appropriate work space away from foot trafﬁc and exposure to bystanders.

• Some components of the equipment can be heavy or awkward. Enlist the service of a second person when you do maintenance

steps involving these components. Do not try to do heavy or awkward steps on your own.

• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine replacement

parts can cause a risk to users, keep the machine from operating correctly and void the warranty.

• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing

maintenance or replacing components. If necessary, request replacement warning stickers or placards from Nautilus customer

service.

• Do not try to change the design or functionality of the machine being serviced as this can adversely affect user safety.

• Do not put the machine back in service until all shrouds, instructions, warning labels and correct functionality have been veriﬁed

and tested for correct performance.

United States. These marks may be registered in other nations or otherwise protected by common law. Schwinn is a trademark licensed to Nautilus, Inc.

NOTICE: This document provides important safety instructions, adjustments, and general troubleshooting information for the maintenance of the

Schwinn®430 and Journey 4.0 Elliptical Fitness Machines.

If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.

This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and

understand all Warnings on this machine.

Important Safety Instructions and General Troubleshooting

Information for the Schwinn®430 and Journey 4.0 Elliptical

Fitness Machines

Safety Warning Labels and Serial Numbers

Speciﬁcations

Product specification

Serial Number

REVISIONS

ECO

REVISION

REV DESCRIPTION

APPROVED

DATE

TITLE.

PART NO.

REV.

SHEET 1 OF 1

SCALE: 1:1

DO NOT SCALE DRAWING

1. ALL ITEMS MUST BE RoHS COMPLIANT

2. ALL DIMENSIONS APPLY BEFORE PLATING OR COATING.

3. REMOVE ALL BURRS, BREAK SHARP EDGES 0.5 MM MAX.

4. ALL MACHINES SURFACES Ra 3.2 uM.

5. ALL APPLICABLE NAUTILUS STANDARDS AND

SPECIFICATIONS APPLY.

6. ALL DIMENSIONS ARE IN MILLIMETERS

7. ALL DUAL DIMENSIONS ARE IN INCH

UNLESS OTHERWISE SPECIFIED:

METRIC

THIRD ANGLE

PROJECTION

INTERPRET DIMENSIONS AND TOLERANCES

PER ASME Y14.5M - 1994

2.5

1.5

0.75

0.25

1°

X.X

X.XX

X.XXX

ANGULAR

SIZE

This document is the property of Nautilus, Inc. It may not be reproduced in whole or part, provided to third parties, or used for any purposes other than the performance of work for Nautilus, Inc. without written authorization. All rights are reserved, including copyrights.

TOLERANCES.

DRAWN

DESIGNED

DATE

METRIC_C_REV G

NAUTILUS, INC.

16400 SE NAUTILUS DRIVE, VANCOUVER, WA 98683

LIFECYCLE

7-22-10

APPROVALS

- -

- - - -

WARRANTY ITEM:

A RELEASED

NPI 13149 DLOVELY 7-22-10

D.LOVELY

07 /22 / 2010

D.LOVELY

004-0930

CRUSH WARNING

21.78mm

54.8mm

MATERIAL.

COLOR.

DIE LINE

PMS 152

PMS 109

BLACK

WHITE

Labels must be created from an agency approved tamper proof labeling system

such as "UL Recognized component marking and labeling system (example: UL PGGU2) or equivalent.

Label and adhesive must be rated for surface it is applied to (painted metal or ABS plastic),

Label and adhesive must be rated for 60 degrees C minimum. Labels must meet UL 1647 Permanence of Marking Test.

•

Maximum User Weight: 300 lbs. (136 kg)

Max pedal height at full incline: 26.0” (66.1 cm)

Power Requirements:

Operational Voltage: 9VDC

Operating Current: 1500 mA

Regulatory Approvals:

 ACPowerAdapter: ULlisted,CSAcertied(orequivalent),

Rated 120V 60Hz Input, 9VDC, 1500mA

Output. Class 2.

This product, its packaging, and components contain chemicals known to the State of California to cause cancer, birth defects,

or reproductive harm. This Notice is provided in accordance with California’s Proposition 65. If you would like additional

information, please refer to our website at www.nautilus.com/prop65.

63.2”

(160.5 cm)

70.1”

(178.1 cm)

28.2”

(71.5 cm)

WARNING!

• Injury or death is possible if caution is not used while

using this machine.

• Keep children and pets away.

• Read and follow all warnings on this machine.

• Refer to the Owner’s Manual for additional warnings and

safety information.

• The heart rate displayed is an approximation and should

be used for reference only.

• Not intended for use by anyone under 14 years of

age.

• The maximum user weight for this machine is 300 lbs

(136 kg).

• This machine is for home use only.

• Consult a physician prior to using any exercise

equipment.

Maintenance

Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is neces-

sary to do the necessary tasks.

Equipment must be regularly examined for damage and repairs. The owner is responsible to make sure

that regular maintenance is done. Worn, damaged or loose components must be repaired or replaced

immediately. Only manufacturer supplied components can be used to maintain and repair the equip-

ment.

WARNING

ATTENTION

DANGER

IMMEDIATE ACTION REQUIRED

CAUTION

To reduce the risk of electrical shock or unsupervised usage of the equipment, always

unplug the power cord from the wall outlet and wait 5 minutes before cleaning, maintaining

or repairing this machine. Place the power cord in a secure location.

Whendisposingofoldparts,obeytheapplicablelocalandprovincialrequirements.

Daily: Before each use, examine the exercise machine for loose, broken, damaged,

or worn parts. Do not use if found in this condition. Repair or replace all parts at

therstsignofwearordamage.Aftereachworkout,useadampclothtowipe

your machine and Console free of moisture.

Note:AvoidexcessivemoistureontheConsole.

Weekly: Checkforsmoothrolleroperation.Wipethemachinetoremovedust,dirt,or

grime. Clean the rails and surface of the rollers with a damp cloth.

Apply silicone lubricant to a dry cloth and wipe the rails to eliminate roller noise.

Silicone lubricant is not intended for human consumption. Keep out

of reach of children. Store in a safe place.

Note: Do not use petroleum based products.

Monthly

or after 20 hours:

Make sure all bolts and screws are tight. Tighten as necessary.

NOTICE: Do not clean with a petroleum based solvent or an automotive cleaner. Be sure to keep the Console free

of moisture.

FCC Compliance

Changes or modications to this unit not expressly approved by the party responsible for compliance could

void the user’s authority to operate the equipment.

The machine and power supply comply with part 15 of the FCC rules. Operation is subject to the following two conditions:

(1)Thisdevicemaynotcauseharmfulinterference,and(2)thisdevicemustacceptanyinterferencereceived,including

interference that may cause undesired operation.

Note:ThismachineandpowersupplyhavebeentestedandfoundtocomplywiththelimitsforaClassBdigital

device,pursuanttoPart15oftheFCCRules.Theselimitsaredesignedtoprovidereasonableprotectionagainst

harmfulinterferenceinaresidentialinstallation.Thisequipmentgenerates,usesandcanradiateradiofrequency

energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio

communications.

However,thereisnoguaranteethatinterferencewillnotoccurinaparticularinstallation.Ifthisequipmentdoescause

harmfulinterferencetoradioortelevisionreception,whichcanbedeterminedbyturningtheequipmentoffandon,the

user is encouraged to try to correct the interference by one or more of the following measures:

•Reorientorrelocatethereceivingantenna.

•Increasetheseparationbetweentheequipmentandreceiver.

•Connecttheequipmentintoanoutletonacircuitdifferentfromthattowhichthereceiverisconnected.

• Consult the dealer or an experienced radio/TV technician for help.

Moving the Machine

The machine may be moved by one or more persons depending on their physical abilities and capacities.

Make sure that you and others are all physically fit and able to move the machine safely.

1. Remove the power cord.

2. Use the Transport Handle to carefully lift the machine onto the transport rollers.

3. Push the machine into position.

4. Carefully lower the machine into position.

NOTICE: Be careful when you move the elliptical. All abrupt motions can

affect the computer operation.

Leveling the Machine

The machine needs to be leveled if your workout area is uneven or if the Rail Assembly is slightly off the ﬂoor. To adjust:

1. Place the machine in your workout area.

2. Safely stand on the back of the Rail Assembly for approximately 20 seconds.

3. Step off the machine.

4. Loosen the locking wing nuts and adjust the

levelers until they all contact the ﬂoor.

Do not adjust the levelers to such a

height that they detach or unscrew from

the machine. Injury to you or damage to

the machine can occur.

5. Adjust until the machine is level. Tighten the

locking wing nuts.

Make sure the machine is level and stable before

you exercise.

USB Charging

IfaUSBDeviceisattachedtotheUSBPort,thePortwillattempttochargetheDevice.ThepowersuppliedfromtheUSB

PortmaynotbeenoughtooperatetheDeviceandchargeitatthesametime.

Troubleshooting

No display/partial display/

unit will not turn on

Check electrical (wall)

outlet

Make sure unit is plugged into a functioning wall outlet.

Check connection at front

of unit

Connection should be secure and undamaged. Replace

adapter or connection at unit if either are damaged.

Check data cable integrity Allwiresincableshouldbeintact.Ifanyarevisiblycrimpedor

cut, replace cable.

Check data cable

connections/orientation

Be sure cable is connected securely and oriented properly.

Small latch on connector should line up and snap into place.

Check console display for

damage

Checkforvisualsignthatconsoledisplayiscrackedorother-

wise damaged. Replace Console if damaged.

Console Display IfConsoleonlyhaspartialdisplayandallconnectionsarene,

replace the Console.

Iftheabovestepsdonotresolvetheproblem,contactCus-

tomer Care for further assistance.

Unit operates but Contact

HR not displayed

HR cable connection at

Console

Be sure cable is connected securely to Console.

HR cable box connection Be sure cables from handlebars and cable to Console are

secure and undamaged.

Sensor grip Be sure hands are centered on HR sensors. Hands must be

keptstillwithrelativelyequalpressureappliedtoeachside.

Dry or calloused hands Sensorsmayhavedifcultywithdriedoutorcallousedhands.

Aconductiveelectrodecream(heartratecream)canhelp

makebetterconduct.Theseareavailableontheweborat

medicalorsomelargertnessstores.

Static Handlebar Iftestsrevealnootherissues,StaticHandlebarshouldbe

replaced.

No speed/RPM reading,

Console displays “Please

Stride” error code

Check data cable integrity All wires in cable should be intact. If any are cut or crimped,

replace cable.

Check data cable

connections/orientation

Be sure cable is connected securely and oriented properly.

Small latch on connector should line up and snap into place.

Check magnet position

(requiresshroudremoval)

Magnet should be in place on pulley.

Check Speed Sensor

(requiresshroudremoval)

Speed sensor should be aligned with magnet and connected to

data cable. Realign sensor if necessary. Replace if there is any

damage to the sensor or the connecting wire.

Resistance does not

change (machine turns on

and operates)

Check Console CheckforvisualsignthatConsoleisdamaged.ReplaceCon-

sole if damaged.

Check data cable integrity Allwiresincableshouldbeintact.Ifanyarevisiblycrimpedor

cut, replace cable.

Check data cable

connections/orientation

Be sure cable is connected securely and oriented properly.

Reseat all connections. Small latch on connector should line up

and snap into place.

CheckServoMotor

(requiresshroudremoval)

Ifmagnetsmove,adjustuntiltheyarewithintheproperrange.

ReplaceServoMotorifnotfunctioningproperly.

MCB(requiresshroud

removal)

Replace MCB.

Iftheabovestepsdonotresolvetheproblem,contactCus-

tomer Care for further assistance.

Console shuts off (enters

sleep mode) while in use

Check electrical (wall)

outlet

Make sure unit is plugged into a functioning wall outlet.

Check connection at front

of unit

Connection should be secure and undamaged. Replace

adapter or connection at unit if either are damaged.

Check data cable integrity All wires in the cable should be intact. If any are cut or crimped,

replace cable.

Check data cable

connections/orientation

Be sure cable is connected securely and oriented properly.

Small latch on connector should line up and snap into place.

Reset machine Unplug unit from electrical outlet for 3 minutes. Reconnect to

outlet.

Check magnet position

(requiresshroudremoval)

Magnet should be in place on pulley.

Check Speed Sensor

(requiresshroudremoval)

Speed sensor should be aligned with magnet and connected to

data cable. Realign sensor if necessary. Replace if there is any

damage to the sensor or the connecting wire.

Fan will not turn on or will

not turn off

Check data cable integrity All wires in cable should be intact. If any are cut or crimped,

replace cable.

Check data cable

connections/orientation

Be sure cable is connected securely and oriented properly.

Small latch on connector should line up and snap into place.

Reset machine Unplug unit from electrical outlet for 3 minutes. Reconnect to

outlet.

Fan will not turn on, but

Console operates

Check for blockage of fan Unplugunitfromelectricaloutletfor5minutes.Removemate-

rial from fan. If necessary, detach the Console to help with

removal.ReplacetheConsoleifunabletoremoveblockage.

Unit rocks/does not sit

level

Checkleveleradjustment Adjustlevelersuntilmachineislevel.

Check surface under unit Adjustment may not be able to compensate for extremely un-

evensurfaces.Movemachinetolevelarea.

Foot pedals loose/unit

difculttooperate

Hardware Tightly secure all hardware on the Pedal Arms and Handlebar

Arms.

Drivetrainclick/tick

noise once per full crank

revolution

Check crank/pulley

assembly

Disconnect left and right foot assemblies and rotate crank. If

sound persists, replace crank/pulley assembly. If sound does

not come from rotating crank, check foot assemblies and up-

per/lower handlebars.

Check foot assemblies,

leg assemblies, handlebar

assemblies

Manuallymovefoot,leg,andhandlebarassembliestoisolate

sound. Replace part making sound.

Squeakingnoise

that appears a few

minutes into a workout

and normally will get

progressivelyworseas

the workout continues

Bolt that connects the

swing arms to the axle

running through the

console mast

Loosenpivotrodboltslightlyuntilnoisegoesaway.White

lithiumgreasecanalsobeappliedforatemporaryx.Contact

Customer Care for assistance.

Rollersqueakingonrail Apply silicone lubricant to a dry cloth and wipe the rails to

eliminate roller noise.

Incline assembly sticks/

difculttoadjust

Check position of incline

assembly

Adjustlevelerstoraisethefrontofrailassemblyuntilthere

is 0.6cm - 1.25cm (1/4” - 1/2”) space between the top of the

incline assembly and the main unit shroud.

Console Service Mode

The Console Setup Mode lets you input the date and time, set the units of measurement to either English or Metric,

change the machine type, control the sound settings ( on/ off), or see maintenance statistics (Total Run Hours – for

servicetechnicianuseonly).

1. Hold down the PAUSE/END button and Right button together for 3 seconds while in the Power-Up Mode to go into

the Console Setup Mode.

Note: Push PAUSE/END to exit the Console Setup Mode and return to the Power-Up Mode screen.

2. The Console display shows the Date prompt with the current setting. To change, use the Increase/Decrease buttons

toadjustthecurrentlyactivevalue(ashing).PushtheLeft/Rightbuttonstochangewhichsegmentisthecurrently

activevalue(month/day/year).

3. Push OK to set.

4. The Console display shows the Time prompt with the current setting. Push the Increase/Decrease buttons to adjust

thecurrentlyactivevalue(ashing).PushtheLeft/Rightbuttonstochangewhichsegmentisthecurrentlyactivevalue

(hour / minute / AM or PM).

5. Push OK to set.

6. The Console display shows the Units prompt with the current setting. To change, push OK to start the Units option.

Push the Increase/Decrease buttons to change between “MILES” (Imperial English units) and “KM” (metric units).

Note:IftheunitschangewhenthereisdatainUserStatistics,thestatisticsconverttothenewunits.

7. Push OK to set.

8. The Console display shows the Machine Type prompt with the current setting. Push the Increase/Decrease buttons to

change between “BIKE” and Elliptical (“ELIP”).

9. Push OK to set.

10. The Console display shows the Sound Settings prompt with the current setting. Push the Increase/Decrease buttons

to change between “ON” and “OFF”.

11. Push OK to set.

12. The Console display shows the TOTAL RUN HOURS for the machine.

To go to the next Console Setup Mode prompt, push the OK button.

To enter the Manufacturing Menu (MFG Menu), hold down the PAUSE/END button and Down button together for 3

seconds.TheConsoledisplayshowstheFirmwareVersionstring.PushtheUp/Downbuttonstomovethroughthe

MFG Menu options. Push OK to make a selection.

a. ENTER MFG TEST – This option is intended for use on the manufacturing production line only. It is a chained

series of tests similar to the tests listed below, but optimized to be run on the production line. Use of this chained

test should not be necessary anywhere but on the production line.

b. DEBUG TERMINAL – Not used.

 c. MOVELIFT–Notused.Ifselected,thisoptionshouldnotdamagetheconsole,butalsoshouldnothaveany

noticeable effect.

 d. RESETMFGNVM–Notused.Ifselected,thisoptionshouldnotdamagetheconsole,butalsoshouldnothave

any noticeable effect.

 e. RUNBEEPTEST–Soundseachsystembeep/tone/sequenceinorder.Pressanykeytoexit

f. RUN BUTTON TEST – The Console display shows the function of each button as buttons are pressed. If the

displayshowsanincorrectfunction,theoverlayontheConsolemaybeincorrectforthatmodel.Ifthedisplay

doesnotshowafunction,thermwareversionmaybeincorrect.Nobeepsaresoundedduringthistest.

  Toexitthetest,pushandholdoneofthelongkeysequences(i.e.longPause/End+RightorlongPause/End+

Down).

 g. RUNLEDTEST–DrivesLEDstothefollowingstates:

1. All LEDs On 1 second

2. All LEDs Off 1 second

  3. SequenceSegments1atatime–on1second,off1second

Press any key to exit test

 h. RUNLCDTEST–Drives3x5and1x5LCDdisplayswiththefollowingpatterns:

1. All segments on

2. All segments off

  3. Setindividualsegmentsoneatatimeuntilallsegmentsareilluminated.

Press any key to exit.

i. RESET CONSOLE – Resets the data from user inputs. The Console setup, user records and workout records will

beresettodefaults.ThisoptiondoesnotresetMFGNVM(nonvolatilememory).

13. The Console display shows the Software Version prompt.

14. For the next prompt, push the OK button.

15 . The Console will display the Power-Up Mode screen.

Maintenance Parts Exploded View

Your machine may differ. Use only as a guide.

A Console O Mast Boot CC Speed Sensor Magnet

B Heart Rate Cable P Shroud, Top DD RPM (Speed) Sensor

C Handlebar, Static Q Data Cable, Lower EE Pedal Arm, Left

D Data Cable, Upper R Incline Assembly FF Transport Wheel

E Arm Pivot Rod S Manual Main Shroud GG Front Stabilizer

F Console Mast T Frame Assembly HH Leg, Left

G Water Bottle Holder U Rail Assembly II Power Inlet

H Handlebar Arm, Lower Right V Shroud, Left JJ AC Adapter

I Handlebar Arm, Upper Right W Crank Assembly, Left KK MP3 Cable

J Pedal Arm, Right X Servo Motor LL Handlebar Arm, Lower Left

K Crank Assembly, Right Y Brake Assembly MM Handlebar Arm, Upper Left

L Shroud, Right Z Fly Wheel NN Plate, Roller (older models only)

M Roller AA Drive Belt OO Silicone Lubricant, Bottle

N Leg, Right BB Drive Pulley

REPLACEMENT PROCEDURE SKILL LEVEL

LevelI: Low-verylittlemechanicalknowledgeorexposure.

LevelII: Intermediate-someexperiencewithmechanicalprocedures

LevelIII: Advanced-knowledgeableaboutmechanicalprocedures

WARNING

ATTENTION

DANGER

IMMEDIATE ACTION REQUIRED

CAUTION

To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug

the power cord from the wall outlet and wait 5 minutes before cleaning, maintaining or repairing

this machine. Place the power cord in a secure location.

When disposing of old parts, obey the applicable local and provincial requirements.

For instructions to replace the following parts, please refer to the Assembly Manual for your machine:

• Power Adapter

• Water Bottle Holder

Adjust the Belt Tension on the Schwinn®430/470

and Journey 4.0/4.5 Elliptical Fitness Machines Skill Level: II

8007603.021518.B

Replacement Procedure

United States. These marks may be registered in other nations or otherwise protected by common law. Schwinn is a trademark licensed to Nautilus, Inc.

NOTICE: This document provides instructions for the adjustment of the Drive Belt tension on the Schwinn®430/470 and Journey 4.0/4.5 Elliptical ﬁtness machines.

If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.

This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and

understand all Warnings on this machine.

Important Safety Instructions - Before servicing or using this equipment, obey the following warnings:

This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand

all Warnings on this machine.

WARNING

ATTENTION

DANGER

IMMEDIATE ACTION REQUIRED

CAUTION

To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the

wall outlet and wait 5 minutes before cleaning, maintaining or repairing this machine. Place the power cord in a secure

location.

• Read and understand the Part Replacement Procedure before working on the machine. Failure to obey the instructions and safety warnings

could cause injury to the service technician or bystanders.

• Keep bystanders and children away from the product being serviced at all times.

• Make sure that the repair is done in an appropriate work space away from foot trafﬁc and exposure to bystanders.

• Some components of the equipment can be heavy or awkward. Enlist the service of a second person when you do maintenance steps

involving these components. Do not try to do heavy or awkward steps on your own.

• If replacement parts are necessary, use only genuine Nautilus replacement parts and hardware. Failure to use genuine replacement parts

can cause a risk to users, keep the machine from operating correctly and void the warranty.

• Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing

maintenance or replacing components. If necessary request replacement warning stickers or placards from Nautilus customer service.

• Do not try to change the design or functionality of the machine being serviced as this can adversely affect user safety.

• Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been verified and tested for correct

performance.

Tools Required (not included)

#2 Phillips screwdriver 10mm open end wrench (2)

13mm open end wrench

Small ﬂathead screwdriver 14mm socket and wrench

Crank puller

Note: Your machine may not match the image. For reference only.

1. Remove the Left Shroud from the Main Unit. Refer to the

“Replace the Shrouds” procedure.

2. To test the Drive Belt tension:

• Push the Drive Belt downward at the midpoint (M) between the

pulleys and measure the distance. The Drive Belt should have

only 0.25” (0.64 cm) of give. See Figure 1.

Or:

• Hold the edges of the Drive Belt at the midpoint (M) and twist it

(see Figure 2). It should turn only 90 degrees

(1/4 turn, to vertical).

If the tension is correct, go to Step 6.

If the tension is too loose or too tight, adjust the nuts and bolt on

the Tensioner Assembly (Idler Assembly). Continue to Step 3.

!To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall

outlet and wait 5 minutes before cleaning, maintaining or repairing this machine. Place the power cord in a secure location.

NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure.

Figure 1

Figure 2

0.25”

0.64 cm }

3. To adjust the nuts (C) on the Tensioner Assembly (A), use a

10mm open end wrench to hold the bolt (B) steady and turn the

nuts with a second 10mm open end wrench.

4. When the tension is correct, tighten the nuts (C) against

the Tensioner Bracket (D) to hold the bolt (B) and the Tensioner

Assembly (A) in position.

Note: This step may require two people.

5. Carefully turn the crank arm and check the movement of the

drive belt. The Crank Arms and Flywheel should move as one.

!Be sure to keep ﬁngers clear of all pinch hazards when you

turn the Drive Pulley.

Adjust the belt tension again if necessary.

6. Reassembly is the reverse procedure.

NOTICE: Be sure not to crimp any cables.

7. Final Inspection

Inspect your machine to ensure that all hardware is tight and components

are properly assembled.

!Do not use until the machine has been fully assembled and

inspected for correct performance in accordance with the

Owner’s Manual.

Set the Brake Tension (Calibration) on the

Schwinn®430/470 and Journey 4.0/4.5 Elliptical Fitness Machines Skill Level: III

8007604.021518.B

Replacement Procedure

United States. These marks may be registered in other nations or otherwise protected by common law. Schwinn is a trademark licensed to Nautilus, Inc.

NOTICE: This document provides instructions for the calibration of the Brake tension on the Schwinn®430/470 and Journey 4.0/4.5 Elliptical Fitness Machines.

If you need assistance, please call Schwinn Customer Service at 1-800-605-3369.

This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and

understand all Warnings on this machine.

Important Safety Instructions - Before servicing or using this equipment, obey the following warnings:

This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and under-

stand all Warnings on this machine.