Schwinn 438 User manual

CongratuJations
Thank you tbr making the Schwinn _ Elliptical Trainer Model 438 a part of your
exercise program. For many years to come, you will be able to rely on the quality
of Schwinn's _'craftsmanship and durability. We have included some general fitness
guidelines tbr your use and hope you will find the inlbrmation valuable in assisting
you in your pursuit of a healthy lifestyle.
The Schwinn _ 438 elliptical trainer will enable you to customize and monitor your
workouts to:
A Increase your energy level
A Increase cardiovascular and aerobic fitness
A Increase lower and upper body muscle strength
_' Decrease your overall percentage of body t:at
Whether you are just getting started in an exercise program or are already
physically fit, the Schwinn _ 438 elliptical trainer is designed to be an efficient,
easy, and enjoyable way to achieve an improved level of fitness. You can exercise
your way to a more fit and healthy body. The on-board digital computer enables
you to accurately monitor your progress by tracking time, distance, speed, calories,
and strides per minute.
This Assembly Guide and Owner's Manual contains all the inlbrmation you need
to operate and enjoy your Schwinn _ elliptical trainer. Please read the manual in
its entirety belbre attempting to exercise on the Schwinn _ 438 elliptical trainer.
Pay special attention to the satL'ty notices at the beginning of the owner's manual
to avoid serious iniury to yoursetf or damage to the equipment. Take a moment to
thoroughly review the parts and hardware lists and required tools before getting
started with the assembly process.
If you find any parts or hardware missing, or should you need assistance with
assembling your Schwinn _ Elliptical Trainer Model 438, contact Customer Service
at 800-864-1270 or write to:
Nautilus, Inc.
World Headquarters
16400 SE Nautilus Drive
Vancouver, Washington 98683
USA

Assembly Guide
Parts Diagram ....................................... 3
Parts List .............................................. 4
Hardware List ....................................... 5
Assembly Instructions .......................... 6
Owner's Manual
Safeguards .......................................... 17
Features .............................................. 19
Operation ............................................ 20
Maintenance ....................................... 46
Fitness Guide ..................................... 48
Workout Log ...................................... 57
Warranty ............................................. 58
FOR DETAILED INSTRUCTIONS AND INFORMATION ON
HOW TO USE AND CARE FOR YOUR SCHWINN _'_ELLIPTICAL
TRAINER MODEL 438, REFER TO THE OWNER'S MANUAL
SECTION STARTING ON PAGE 17.

l

ToolsRequired
The tools below are required during the assembly of your Schwinn _ 438 ettipitcal
trainer. They are included with the product.
4ramAllen Wrench
6ramAllen Wrench
5ramAllen Wrench
OpenEndWrench
<1
Philips Screwdriver
Complete Parts Diagram
Q

Console#2
Handlebar Jct CoverSet #5
FanAssv #3
Lower Left Handlebar Assv #6
Front Stabilizer Assv #4
Left PedalArm Assv #7
Left Upper Handlebar #8 Lower Handlebar Cover Set#9 Lower Right Handlebar Assy #10
Left Mast Cover #12 Right Mast Cover #13 Complete Rear RailAssv #14
:l
Right Pedal Arm Assv #15 Right Upper Handlebar #16 Sub Pedal Arm Assv #17
Console Mast Assv #18 Complete Static Handlebar #19 Right Crank Cover #20
Left Crank Cover #21 AC Adaptor #23 Shroud Plug #25

Step #1
8.2x18x1.STCurveWasher
#35(Qty 6)
Step #3
8x25 Button Head Bolt #36
(Qty.6)
Step #4, #5, and #10
8x15Socket Cap Head Bolt 8.2x15x1.2TArcWasher#43 5x8 PanHead Screw#11
#26(Qty 4) (Qty4) (Qty 11)
Step #6 Step #7 and #8
10.2x25x1.STFlatWasher
#33(Qty 2)
12.Sx25x1.0TArc Washer
#32(Qty 4)
10xl.5Nylon FlexNut #34 4x16Self-Tap RoundHead
20.Sx29x1.STWave Washer
#27(Qty4)
Step #8
10.3x35x2TFlatWasher #28
(Qty2)
Step#8 and #9
NylonFlexNut #29(Qty 4)
Screw#41(Qty2)
Step#9
(Qty 2)
8x10Set Screw #30 (Qty4) 8x50Carriage Bolt#37 (Qty 2)
4)<16Self-Tapping Round
Head Screw #41(Qty4)

introduction
Read and [bttow each step carefully and in proper order to avoid missing any
steps. Be sure to have all parts and tools on hand {'ora particular step belbre
beginning assembly {'or that step. If you discover parts are missing, contact
Customer Service at 800-864-1270.
Step 1--Assemble the FrontStabilizer and Rear Rail Assembly
Parts
N/A Main Frame (Qty l)
#4 Front Stabilizer (Qty 1)
#14 Rear Rail Assembly (Qty 1)
Hardware
#35 8.2xl8xl.5T Curve Washer
(Qty 6)
#36 8x25 Button Head Bolt
(Qty 6)
1-1
1-2
Attach the Front Stablizer (#4)
to the Main Frame with two (2)
Button Head Bolts (#36) and
two (2) Curve Washers (#35).
Attach the Rear Rail Assembly
(#14) to the Main Frame with
[bur (4)Button Head Bolts (#36)
and tbur (4) Curve Washers
(#35).
Main Frame
36
Figure A-1

Step 2--Assemble the Console
Parts
#2 Console (Qty l)
#3 Fan Assembly (Qty 1)
#19 Static Handlebar (Qty 1)
2-1
2-2
Remove the six (6) Round Head
Machine Screws (#1)from the
Console (#2).
Attach the Console (#2) to the
Static Handlebar (#19) with the
six (6)Round Head Machine
Screws (#1) you removed in the
previous step.
2-3 Separate the two halves of the
Fan Assembly (#3) by removing
the five (5) screws.
2-4 Place the rear half of the Fan
Assembly (#3) on the back of
the Static Handlebar (#19).
2-5 Place the front half of the Fan
Assembly (#3) on the front of
the Static Handlebar (#19), and
reinstall the five (5) screws you
removed from the Fan Assembly
(#3) in step 23.
2-6 Plug the Fan Assembly (#3) into
the Console (#2).
Fan Screw
Figure A-2
//
\
19

IStep 3--Attach the Console Mast to the Main Frame
Parts
N/A Main Frame (Qty l)
#18 Console Mast (Qty 1)
#25 Shroud Plug (Qty 4)
Hardware
#26 8xl 5 Socket Cap Head Bolt
(Qty 4)
#43 8.2xl 5x 1.2T Arc Washer
(Qty 4)
3-1
3-2
3-3
Securely attach the "zip tie" at
the bottom of the Console Mast
(#18) to the computer cable from
the Main Frame, and pull the
"zip tie" and attached computer
cable through the Console Mast
(#18) from the top.
Insert the Console Mast (#l 8)
into the Main Frame, and attach
with {bur (4) Socket Cap Head
Bolts (#26) and {bur (4) Arc
Washers (#43).
Place Shroud Plugs (#25) in the
holes in the Main Frame.
_18
25 26 Main Frame
43
26
Figure A-3

Step 4--Attach the Consoleto the Console Mast
Parts
#2 Console (Qty 1)
#3 Fan Assembly (Qty 1)
#18 Console Mast (Qty l)
#19 Static Handlebar (Qty 1)
Hardware
#11 5x8 Pan Head Screw (Qty 4)
4-1 Attach the Console/Fan/Static
Handlebar Assembly (#2, #3,
and #19) to the Console Mast
(#18) with four (4) Pan Head
Screws (#11).
19
Figure A-4

Step 5--Attach Mast Covers
Parts
#12 Left Mast Cover (Qty 1)
#13 Right Mast Cover (Qty 1)
#18 Console Mast (Qty 1)
Hardware
#11 5x8 Pan Head Screw (Qty 5)
5-1
5-2
Slide the Leti Mast Cover (#12)
over the Console Mast Pivot,
and attach with two (2)Pan
Head Screws (#11).
Slide the Right Mast Cover
(#13) over the Console Mast
Pivot, and attach with 3 Pan
Head Screws (#11).
12
Console Mast Pivots
18
13
11
Figure A-5
10

Step 6--Attach the Sub Pedal Arm Assemblies and Crank Covers
Parts
#17 Sub Pedal Arm Assy (Qty 2)
#20 Right Crank Cover (Qty 1)
#21 Let1 Crank Cover (Qty 1)
Hardware
#32 12.5x25x1.0T Arc Washer
(Qty 4)
#33 10.2x25x1.5T Flat Washer
(Qty 2)
#34 10xl.5 Nylon Hex Nut (Qty 2)
#41 4xl 6 Self-Tapping Round Head
Screw (Qty 2)
6-1 Place the Sub Pedal Arm
Assembly (#17), two (2)Arc
Washers (#32), and one (1)Flat
Washer (#33) on the right Pivot
Tube (#22), as shown in the
figure close-up below:
6-2
6-3
6-4
6-5
6-6
Install the Nylon Hex Nut (#34)
on the right Pivot Tube bolt.
Align the Wheel on the Sub
Pedal Arln Assembly (#17)
in the track on the Rear Rail
Assembly.
Place the Right Crank Cover
(#20) on the right Pivot Tube
(#22).
Secure the Right Crank Cover
(#20) with the Self-Tapping
Round Head Screw (#41).
Repeat steps 6-1 through 6-5
{'orthe let1Pivot Tube using the
Let1 Crank Cover (#21).
41
17
21
17 ............... 34
32
22
//
//
2O
22
Figure A-6
17
11

IStep 7--Attach the Pedal Arm Assemblies
Parts 7-1 Remove the two (2) 8xl.25x10
#7 Button Head Bolts (#39), a
8xl.25x20 Button Head Bolt
(#40), and a Pedal Arm Bracket
#15 (#42) from the Right Pedal Arm
Assembly (#15).
#17
Let1 Pedal Arm Assembly
(Qty l)
Right Pedal Arm Assembly
(Qty l)
Sub Pedal Arln Assy (Qty 2)
Hardware
#27 20.5x29xl.5TWave Washer
(Qty 2)
7-2 Attach the Right Pedal Arm
Assembly (#15) to the Sub
Pedal Arm Assembly (#17) with
a Wave Washer (#27), a Pedal
Arm Bracket (#42), two (2)
8x1.25xl 0 Button Head Bolts
(#39), and a 8x1.25x20 Button
Head Bolt (#40).
7-3 Repeat steps7 1 and 7 2tbrthe
Let1 Pedal Arm Assembly (#7).
27
42 39
40/ 17
Figure A- 7
J
27
39 42
15
12

Step 8--Attach the Upper Handlebar Assemblies
Parts
#8 Left Upper ltandlebar (Qty 1)
#16 Right Upper ltandlebar
(Qty l)
#18 Console Mast (Qty l)
Hardware
#27 20.5x29xl.5T Wave Washer
(Qty 2)
#28 10.3x35x2T Washer Flat
(Qty 2)
#29 Nylon HexNut (Qty 2)
8-1 Attach the Right Upper
Handlebar (#16) to the Console
8-2
Mast (#18) with a Flat Washer
(#28), a Wave Washer (#27), and
a Nylon llex Nut (#29).
Repeat step 81 tbr the Left
Upper llandlebar (#8).
29
Figure A-8
27 /
18 ._
27
13

Step 9--Attach the Lower Handlebar Assemblies
Parts
#6 Lower Left Handlebar Assembly
(Qty 1)
#7 Left Pedal Arm Assembly
(Qty 1)
#8 Left Upper Handlebar (Qty 1)
#9 Lower Handlebar Cover Set
(Qty 2)
#10 Lower Right Handlebar
Assembly (Qty l)
# 15 Right Pedal Arm Assembly
(Qty l)
#16 Right Upper Handlebar
(Qty l)
Hardware
#29 Nylon llexNut (Qty 2)
#30 8x10 Set Screw (Qty 4)
#37 8x50 Carriage Bolt (Qty 2)
#41 4xl 6 Self-Tapping Round Head
Screw (Qty 4)
9-1
9-2
Attach the Lower Right
Handlebar Assembly (#10) to
the Right Upper Handlebar
(#16) using the two (2) Set
Screws (#30).
Attach the Lower Right
Handlebar (#10) to the Right
Pedal Arm Assembly (#15)
using a Nylon ltex Nut (#29),
and a Carriage Bolt (#37).
9-3 Secure the Lower Handlebar
Cover Set (#9) to the Lower
Right Handlebar Assembly
(#10) with two (2) Self-Tapping
Round Head Screws (#41).
9-4 Repeat steps 91 through 93
tbr the Lower Left Handlebar
Assembly (#6).
1,1

6
4_
Figure A-9
15

Stop lO--Attach the Handlebar Junction Cover Set
Parts
#5 Handlebar Junction Cover Set
(Qty 2)
#8 Left Upper Handlebar (Qty 1)
#16 Right Upper Handlebar
(Qty l)
Hardware
#11 5x8 Pan Head Screw (Qty 4)
10-1
10-2
Attach the Handlebar Junction
Cover Set (#5) to the Right
Upper Handlebar (#16) with two
(2) Pan Head Screws (#11) and
the Cap.
Repeat step 101 tbr the Left
Upper llandlebar (#8).
ll
16
Cap 5
Figure A-10
\
Cap
16

important Safety information
Do not discard this Owner's Manual. It contains important inlbrmation on the
proper and safe operation of your Schwinn _ Elliptical Trainer Model 438.
The tbltowing is a list of warning labels used throughout this manual:
Warning: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious iniury.
ALWAYS DISCONNECT POWER TO THE
ELLiPTiCAL BEFORE SERViCiNG THiS
EQUIPMENT!
SERViCiNG THE UNiT WiTH POWER
CONNECTED MAY CAUSE ELECTRICAL
SHOCKS, ELECTROCUTION OR
MECHANICAL INJURY.
Fitness Safeguards and Warnings
Belbre starting any exercise program, obtain a medical exam to confirm your
fitness level and ability to perlbrm the planned program. See your physician; he
or she can help establish the correct exercise frequency, intensity (target heart rate
zone), and time appropriate tbr your particular age and condition.
The tbllowing five warnings listed below are located on the warning label affixed
to the computer console mast of the machine:
o Read and understand the "Owner's Manual" betbre using this equipment.
o If you tL'elunusual pain, dizziness, shortness of breath, chest tightness or
discomtbrt, STOP all use, and consult your physician immediately.
o Misuse or abuse of this equipment may lead to serious iniury.
o Keep children away t?om this equipment, and supervise teenagers using it.
o Replace this or any other warning label if damaged, illegible, or missing.
17

Other important Safeguards and Warnings
, The equipment is not designed fbr, and is not safe fbr, use by people weighing
more than 300 pounds (136 kilograms).
"Follow all instructions in the Schwinn _'_Elliptical Trainer Model 438Assembly
Guide al_d Owl_er ;' Mal_ual. Use the machine only as outlined in the manual's
operating instructions.
, The owner must ensure that all users of this equipment are adequately intbrmed
of all warnings, precautions, and instructions.
, Keep the area within 39 inches (100 centimeters) of the equipment on all sides
clear of all obstructions, children, bystanders, and pets.
, Warn bystanders to keep a safe distance from the equipment, especially t?om the
moving pedals.
.Use the equipment only on a solid, level surfiace. Cover the floor or carpeting
beneath the equipment tbr protection.
, Keep fingers and other objects away from moving parts of the equipment.
.Always wear athletic shoes tbr tbot protection. Do not wear loose clothing that
could become entangled in the drive mechanism.
.Do not allow anyone other than the user to touch the machine while it is in
operation.
.Care should be taken when mounting or dismounting the machine.
, Do not operate in damp or wet conditions.
.Belbre each use, inspect the equipment tbr loose, broken, or worn parts. If any
are present, do not use the equipment.
,The safety of the equipment can only be ensured if it is regularly examined and
maintained. (See the maintenance section of the Schwilm _'_'Elliptical Yrail_er
Model 438 Assembly Guide al_d Owl_er _'Mul_ual.)
.Service the equipment only in accordance with the maintenance section in the
Schwim_:'_Elliptical Yruiner Model 438 Assembly Guide al_d Owner :s'Mulmal.
Always disconnect the power supply betbre servicing the machine.
.This elliptical is tbr home use only. Do not use in a commercial, institutional, or
rental setting.
18