Schwinn 490e User manual

1
8030508.071523.A
8030507.071523.A
Service Manual
Table of Contents
Schwinn™490 / 590e Ellipticals
Service Manual
Section Code Section Page Number
Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America [phone], [email protected] |
outside U.S. www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc.,
registered or otherwise protected by common law in the United States and other nations. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
1 Important Safety Instructions 2
1 Safety Warning Labels and Serial
Number 3
 1 Specications 4
1 Grounding Instructions 5
1 Moving and Storing the Machine 6
1 Leveling the Machine 6
1 Using the JRNY™ app with
your machine 7
1 USB Charging 7
1 Bluetooth®Audio (Input) 7
1 Bluetooth®Heart Rate Monitor
(not supplied) 7
1 Maintenance 9
1 Cleaning 9
1 Maintenance Parts 10
1 Troubleshooting 12
1 Console Setup Mode 15
1 Electrical Wiring 17
1 Replacement Procedure Skill Level 18
 Mechanical/ModicationProcedures
2 Calibrating the Resistance 19
Part Replacement
3 Replace the Cables 22
4 Replace the Console 35
5 Replace the Console Mast 39
6 Replace the Resistance Sensor 45
7 Replace the Sensor Hub 50
8 Replace the Servo Motor 57
9 Replace the Shrouds 61
10 Replace the Speed Sensor 76
11 Replace the Upper Handlebars 82
™

2
8030509.071523.A
Service Procedures
Important Safety Instructions and General Troubleshooting
Information for the Schwinn™490 / 590e Ellipticals
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.
!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.
• 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tra󰀩c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.
• Use only replacement parts and hardware that are supplied or approved by Nautilus. Failure to use Nautilus-approved
replacementpartscanadverselya󰀨ectthesafetyandfunctionalityoftheequipmentcreatingarisktousersandwill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 at any time the Warning labels become loose, unreadable or dislodged,
replace the labels. If purchased in US/Canada, contact Customer Service for replacement labels. If purchased outside US/
Canada, contact your local distributor for them.
•Donottrytochangethedesignorfunctionalityofthemachinebeingservicedasthiscanadverselya󰀨ectusersafetyand
will void the warranty.
• Do not put the machine back in service until all shrouds, instructions, warning labels and correct functionality have been
veriedandtestedforcorrectperformance.
•SAVE THESE INSTRUCTIONS
NOTICE: This document provides important safety instructions, adjustments, and general troubleshooting information for the maintenance of the
Schwinn™ 490 / 590e Ellipticals.
If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside
US/Canada). To nd your local distributor, go to: www.nautilusinternational.com
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.
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America [phone], [email protected] | outside U.S.
www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise
protected by common law in the United States and other nations. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY

3
SAFETY WARNING LABELS AND SERIAL NUMBER
ProductSpecicationandSerialNumber
WARNING!
Read, understand and obey all warnings on this machine.
Keep children away. Not intended for use by anyone
under 14 years of age. Prior to use, read and understand
the owners manual. Injury or death is possible if caution
isnotusedwhileusingthismachine.Themaximum
user weight for this machine is 330 lbs (150 kg). Care
should be taken when mounting and dismounting the
stationaryexerciseequipment.Beforedismounting,bring
the machine to a complete stop. The heart rate displayed
isanapproximationandshouldbeusedforreference
only.Thisexerciseunitdoesnothaveafreewheeland
pedal speed must be reduced in a controlled manner. For
Consumer Use Only. Consult a physician prior to using
anyexerciseequipment.
(Label on Schwinn™490 machine is available in
English and French Canadian only.)

4
SPECIFICATIONS
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o󰀨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di󰀨erentfromthattowhichthereceiverisconnected.
•Consultthedealeroranexperiencedradio/TVtechnicianforhelp.
This product complies with the European Radio Equipment Directive 2014/53/EU
Power Requirements: 120V 220V
Operational Voltage: 110-127V AC, 60Hz 220V - 240V AC, 50Hz
Operating Current: 2A 2A
Maximum User Weight: 150 kg (330 lb)
Total Surface Area (footprint) of equipment: 12,723 cm2
Maximum Pedal Height - with full incline: 28.3 in ( 72 cm)
Machine Weight:    approx.84.8kg(187lb)
This product complies with the European Radio Equipment Directive
2014/53/EU
DO NOT dispose of this product as refuse. This product is to be
recycled. For proper disposal of this product, please follow the
prescribed methods at an approved waste center.
172.6 cm
( 68 in )
86.2 cm
( 33.9 in )
147.6 cm ( 58.1 in )
2.1 m (82.1 in)
1.5 m
(57.9
in)
0.6 m
( 24 in )
0.6 m
( 24 in )
For safe operation, the location must be on a hard, level surface.
Allowaminimumworkoutareaof82.1inx57.9in(208.5cmx
147.1 cm). Keep the workout area clear 0.6 m (24 in) along the side
used to access the machine and to the rear of the machine. Be
sure that the workout space you are utilizing has adequate height
clearance, taking into consideration the height of the user and the
maximuminclineoftheellipticalmachine.

5
Safety Warning Labels and Serial Number
Grounding Instructions
This product must be grounded. If it should malfunction or break down, grounding provides a path of least resistance for
electric current to reduce the risk of electric shock. This product is equipped with a cord having an equipment-grounding
conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
Improper connection of the equipment-grounding conductor can result in a risk of
electric shock. Check with a qualied electrician or serviceman if you are in doubt as
to whether the product is properly grounded. Do not modify the plug provided with the
product – if it will not t the outlet, have a proper outlet installed by a qualied
electrician.
If you connect the machine to an outlet with GFI (ground fault interrupt) or AFI (arc fault interrupt), machine operation can
cause the circuit to trip.
This machine is for use on a nominal 120-V circuit, and has a grounding plug that looks like the plug
illustrated below. A temporary adapter that looks like the adapter illustrated may be used to connect this
plug to a 2-pole receptacle as shown if a properly grounded outlet is not available.
Thetemporaryadaptershouldbeusedonlyuntilaproperlygroundedoutletcanbeinstalledbyaqualiedelectrician.
Thetabforthegroundingscrewmustbeconnectedtoapermanentgroundsuchasaproperlygroundedoutletboxcover.
Whenever the adapter is used, it must be held in place by a metal screw.
Earthing Instructions (for a 220-240V AC system)
This product must be electrically earthed. If a malfunction occurs, correct earthing decreases the risk of electric shock.
The power cord is equipped with an equipment-earthing conductor, and must be connected to an outlet that is properly
installed and earthed.
The electrical wiring must comply with all applicable local and provincial standards
and requirements. Incorrect connection of the equipment-earthing conductor can
result in a risk of electric shock. Consult a licensed electrician if you are not sure that
the machine is correctly earthed. Do not change the plug on the machine – if it does
not t the outlet, have a correct outlet installed by a licensed electrician.
If you connect the machine to an outlet with RCBO (Residual-Current circuit Breaker with Overload protection), machine
operation can cause the circuit to trip. A Surge Protector Device is recommended to protect the machine.
!If a Surge Protector Device (SPD) is used with this machine, be sure that it matches the power rating of this
equipment (220-240V AC). Do not connect other appliances or devices to the surge protector in combination
with this machine.
Metal Screw
Tab for
Grounding
Screw
Adapter
Grounded
OutletBox
Grounded
Outlet
Grounding Pin

6
Moving the Machine
Use the Transport Handle / Rear Step and Transport Wheels to move the machine. The Transport Handle / Rear Step is
located in the middle of the Rail Assembly at the rear of the machine. Tilt the machine forward by lifting upward with the
Transport Handle / Rear Step until the weight is on the Transport Wheels.
Roll the machine on the transport wheels to a new location. Lower your machine slowly into its new location without injury
toyourheadorngers.
Do not use the handlebars, Console Mast, or the Console to lift or move the machine. Injury to you or
damage to the machine can occur.
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 t and able to move the machine safely.
Place the machine on a clean, hard, level surface, free from unwanted material or other objects that may
hamper your ability to move freely. A rubber mat should be used below the machine to prevent the release
of static electricity and protect your ooring.
To prevent unsupervised operation of the machine always turn the power switch to O󰀨 and disconnect the
power cord from the wall outlet and machine power input. Place the power cord in a secure location.
Leveling the Machine
The machine needs to be leveled if your workout area is uneven or if
theRailAssemblyisslightlyo󰀨theoor.Toadjust:
1. Place the machine in your workout area.
2.SafelystandontheRearStepforapproximately20seconds.
3.Stepo󰀨themachine.
4. Loosen the locking nuts and adjust the levelers until they all contact
theoor.
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 nuts.
Makesurethemachineislevelandstablebeforeyouexercise.
Transport Handle / Rear Step

7
CONNECTIVITY
Using the “JRNY™” App with Your machine
ThistnessmachineisequippedwithBluetooth®connectivity and can be wirelessly connected for workouts using the
“JRNY™” app. The app can be accessed with your JRNY™ membership.
Note: Do not connect this machine through your Bluetooth®settings on your device. Simply download the app, start
a workout, and follow the instructions on the app.
1. Download the app named JRNY™. The app is available on the App Store and Google Play™.
Note: For a complete list of supported devices, review the app on the App Store or Google Play™.
2. Install the app.
3. Open the “JRNY™” app, and follow the instructions.
4. When done, tap on the red Bluetooth®icon in the upper right corner of the display.
Note: If Bluetooth®is not active on your device, follow the instructions to activate it.
5. A list of available machines will be displayed. Select your machine from the list of available machines.
6. The JRNY™ app is now ready for use.
Note: Once a Bluetooth®Heart Rate device is connected, that device is engaged to that machine. To use the Heart
Rate device elsewhere, it must be disconnected. Follow the instructions provided in the app to disconnect.
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.
Bluetooth®Audio (Input)
Your machine is able to play audio across a Bluetooth®connection from your smart device through the console speakers.
Note: Bluetooth®audio can only be streamed into the console.
Bluetooth®Low Energy (BLE) Heart Rate Monitor (not supplied)
YourtnessmachineisequippedtobeabletoreceiveasignalfromaBluetooth®Low Energy (BLE) Heart Rate (HR)
Monitor. When connected, the Console will display the Bluetooth®Heart Rate Monitor Connected icon. Follow the
instructions provided with your Bluetooth®Low Energy (BLE) Heart Rate Monitor.
If you have a pacemaker or other implanted electronic device, consult your doctor before using a Bluetooth®
Heart Rate Monitor.
Note: Be sure to remove the protective cover (if provided) from the Heart Rate Sensor before use.
1. Put on your Bluetooth®Low Energy (BLE) Heart Rate monitor and activate it.
2. TheConsolewillactivelysearchforanymonitorsinthearea,andwillrapidlyashtheBluetooth®Heart Rate Monitor
*AJRNY™membershipisrequiredfortheJRNY™experience–seewww.schwinntness.com/jrnyfordetails.For
United States and Canada customers, you can obtain a JRNY™ membership by calling 888-986-5528 or visiting
www.schwinntness.com/jrny.Whereavailable(includingtheUnitedStates),youcanalsoobtainaJRNY™membership
by downloading the JRNY™ app onto your phone or tablet and signing up within the downloaded app. JRNY™
memberships may not be available in all countries.

8
Connected icon.
Note: Any previously connected Heart Rate devices will be disconnected. However, if they are within range, the
ConsolemayndthemagainifunabletolocateyourMonitor.
3. When connected, the Bluetooth®HeartRateMonitorConnectediconwillashwithyourpulseandyourcurrentheart
rate value will be displayed on the Console. You are now ready to workout.
Note: Once a Bluetooth®Low Energy (BLE) Heart Rate device is connected, that device is engaged to that machine.
To use the Heart Rate device elsewhere, it must be disconnected. Follow the instructions provided in the app
to disconnect.

9
MAINTENANCE
Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is required 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 or damaged components must be repaired or replaced immediately.
Only manufacturer supplied components can be used to maintain and repair the equipment.
If at any time the Warning labels become loose, unreadable or dislodged, replace the labels. If purchased
in US/Canada, contact Customer Service for replacement labels. If purchased outside US/Canada, contact
your local distributor for them.
To reduce the risk of electrical shock or unsupervised usage of the equipment, always
unplug the power cord from the wall outlet and/or the machine and wait 5 minutes
before cleaning, maintaining or repairing the machine. Place the power cord in a
secure location.
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 if necessary.
NOTICE: If necessary, only use a mild dish soap with a soft cloth to clean the Console. Do not clean with a
petroleum based solvent, automotive cleaner, or any product that contains ammonia. Do not clean the
Console in direct sunlight or at high temperatures Be sure to keep the Console free of moisture.
The Schwinn™ 490 machine is for home use only.
When the Schwinn™ 590e machine is used in a Studio/Institutional environment, we recommend that the
Pedals be replaced every year to maintain maximum user safety and performance. Only use replacement
Pedals available from Nautilus. Other brands of Pedals may not be designed for this product, and can cause
danger to users and bystanders, and will void the warranty.

10
Console Assembly
Upper Handlebar, Right
Leg, Right
Leg, Left
Rail Assembly
Pedal, Right
Pedal, Left
Upper Handlebar, Left
Console Pivot Cover
Console Mast
Main Assembly
Handlebar Cover,
Exterior
Handlebar
Cover,Exterior
Handlebar
Cover, Interior
Handlebar
Cover, Interior
Power Cord
Maintenance Parts

11
Lower Handle-
bar, Right
Front Upper
Shroud
Crank
Cap
Shroud
Front Lower
Shroud
Lower Handle-
bar, Left
Crank
Cap
Shroud
Crank
Arm
Crank
Arm
Left Main Shroud
Right Main Shroud
Pivot Cover
Outer Cap Inner Pivot
Shroud
Inner Pivot
Shroud
Pivot Cover
Outer Cap
Rear Shroud
Servo Motor
Transport Wheel
Power Switch and Inlet
Flywheel
Speed Sensor Assembly
Incline (Lift) Motor
Drive Pulley
Drive Belt
Idler Pulley
Sensor Board
O󰀪inePowerSupply
Main Assembly Frame
Pivot Rod
Maintenance Parts - Main Assembly

12
TROUBLESHOOTING
Condition/Problem Things to Check Solution
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 cord
or power inlet if either are damaged.
Check data cable integrity All wires in cable should be intact. If any are visibly pinched or
cut, replace cable.
Check data cable
connections/orientation
Be sure cables at base of mast and at back of console are con-
nected securely and oriented properly. Small latch on connec-
tor 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.
Console display shows "0
Base Hub Comm Error"
error code
Check data cable integrity All wires in cable should be intact. If any are visibly pinched or
cut, replace cable.
Check data cable
connections/orientation
Be sure cables at base of mast and at back of console are con-
nected securely and oriented properly. Small latch on connec-
tor 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.
If the above steps do not resolve the problem, contact Cus-
tomer Service (if inside US/Canada) or your local distributor (if
outside US/Canada).
Console display shows "3
Stuck Button Error" error
code
Check console keypad Check for stuck buttons on the Console keypad. Replace Con-
sole if damaged.
Be sure there is no object resting on one of the buttons de-
pressing it. if issue persists, replace console.
Console display shows "5
NVRAM Error" error code
Console IndicatesproblemwithashmemoryonConsole.Contact Cus-
tomer Service (if inside US/Canada) or your local distributor (if
outside US/Canada).
Unit operates but
Bluetooth®Heart Rate
(HR) not displayed
HR monitor (not provided) Follow the troubleshooting instructions provided with the
device.
HR monitor batteries If monitor has replaceable batteries, install new batteries.
Interference Try moving unit away from sources of interference (TV, Micro-
wave, etc).
On/O󰀨LEDbutton Duringaworkout,onlypushtheOn/O󰀨LEDbuttononceto
activate the armband.
Replace HR device If interference is eliminated and HR does not function, replace
HR device.
If the above steps do not resolve the problem, contact Cus-
tomer Service (if inside US/Canada) or your local distributor (if
outside US/Canada).

13
Condition/Problem Things to Check Solution
No speed/RPM reading Check data cable integrity All wires in cable should be intact. If any are cut or pinched,
replace cable.
Check data cable
connections/orientation
Be sure each cable is connected securely and oriented proper-
ly. 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 data cable integrity All wires in cable should be intact. If any are visibly pinched 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 Servo Motor
(requires shroud removal)
Replace Servo Motor if not functioning properly.
Check Console display for
damage
Check for visual sign that console display is cracked or other-
wise damaged. Replace Console if damaged.
Resistance handlebar
connection
Be sure cable from right Upper Handlebar and cables to Con-
sole are secure and undamaged.
If the above steps do not resolve the problem, contact Cus-
tomer Service (if inside US/Canada) or your local distributor (if
outside US/Canada).
Incline does not adjust
(machine turns on and
operates)
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.
Incline handlebar
connection
Be sure cable from left Upper Handlebar and cables to Console
are secure and undamaged.
Incline Adjuster Assembly
(requires shroud removal)
Be sure Incline Adjuster Assembly is attached to Incline Motor
drive screw.
Console display shows
“Incline Cooling” error
code
Additional incline adjustments are disabled for a few minutes to
protect the motor from over heating. Allow the lift motor to cool,
and then resume your workout.
If the above steps do not resolve the problem, contact Cus-
tomer Service (if inside US/Canada) or your local distributor (if
outside US/Canada).

14
Condition/Problem Things to Check Solution
Consoleshutso󰀨(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 cord
or power inlet if either are damaged.
Check data cable integrity All wires in the cable should be intact. If any are cut or pinched,
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.
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.
Pedalsloose/unitdi󰀩cult
to operate
Hardware Tightly secure all hardware on the Pedals, Legs 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 Pedal, Leg and
Handlebar assemblies
Manually move Pedal, Leg, and Handlebar assemblies to iso-
late sound. Replace part making sound.
Check for loose hardware Tightly secure all hardware on the Rail Assembly and the base
of the Console Mast.
Knocking sound during
machine operation
Check hardware at
junction between Lower
Handlebar Arm and Pedal
Make sure that the alignment tab on the Pivot Sleeve goes into
theslotinthehole.BesurethePivotSleeveextendsthrough
the opposite hole in the joint cover.
Squeaking noise
that appears a few
minutes into a workout
and normally will get
progressively worse as
the workout continues
Bolts that connect the
Lower Handlebars to the
axlerunningthroughthe
Main Assembly
Loosen pivot rod bolts slightly until noise goes away. White
lithiumgreasecanalsobeappliedforatemporaryx.Contact
Customer Service (if inside US/Canada) or your local distribu-
tor (if outside US/Canada).
Roller squeaking on rail Apply silicone lubricant to a dry cloth and wipe the rails to
eliminate roller noise.
Console continuously
cycles through program
screens
Console is in demonstra-
tion mode
Press and hold the Schwinn™logo button for 3 seconds. The
settingwilltakee󰀨ectafterthenexttimethemachinegoesinto
Sleep Mode.

15
CONSOLE SETUP MODE
The Console Setup Mode allows you to set units of measurement to either Imperial or metric, adjust screen brightness,
viewmaintenancestatistics(suchasRunTimehoursandsoftwareversion–forservicetechnicianuseonly),orresetthe
Console.
1. Push the Programs button and hold for 3 seconds while in the Power-Up Mode to go into the Console Setup Mode
(System Menu).
Note: Push the Pause/Stop buttontoexittheSystem Menu and return to the Power-Up Mode screen.
2. The Console display shows the System Units prompt with the current setting. The default setting is Imperial English
units. Push the Resistance Increase/Decrease buttons to change between Imperial (MI/LB) and metric (KM/KG).
Note: If the units change when there is data in User Statistics, the statistics convert to the new units.
3. PushtheProgramsbuttontosettheselectionandcontinuetothenextmenuoption.
Note: TosavetheselectionandexittheSystemMenu,pushtheStartbutton.Toexitwithoutsaving,pushthePause/
Stop button.
4. The Console display shows the Screen Brightness prompt with the current setting. The 5 levels of brightness are: 5
(100%), 4 (default, 95%), 3 (90%), 2 (85%), 1 (80%). The display shows the brightness of the selected level. Push the
Resistance Increase/Decrease buttons to move to the desired level.
5. PushtheProgramsbuttontosettheselectionandcontinuetothenextmenuoption.
6. The Console display shows the Disconnect Bluetooth prompt. The default option is NO. The YES option will discon-
nect all Bluetooth®devices. Push the Resistance Increase/Decrease buttons to change between options (YES/NO).
7. PushtheProgramsbuttontosettheselectionandcontinuetothenextmenuoption.
8. The Console display shows the Auto Connect HR (Heart Rate) prompt. The default option is YES. Push the Resis-
tance Increase/Decrease buttons to change between options (YES/NO).
9. PushtheProgramsbuttontosettheselectionandcontinuetothenextmenuoption.
10. The Console display shows the Hardware Variant & Console Firmware Version.
11. PushtheProgramsbuttontocontinuetothenextmenuoption.
12. The Console display shows the Base Serial Number.
13. PushtheProgramsbuttontocontinuetothenextmenuoption.
14. The Console display shows the Hardware Variant (machine type).
15. PushtheProgramsbuttontosettheselectionandcontinuetothenextmenuoption.
16. The Console display shows the Run Time hours (total number of hours of workout time).
17. PushtheProgramsbuttontocontinuetothenextmenuoption.
18. The Console display shows the BLE Version.
19. PushtheProgramsbuttontocontinuetothenextmenuoption.
20. The Console display shows the BTC Version.
21. PushtheProgramsbuttontocontinuetothenextmenuoption.
22. The Console display shows the SENSOR Version.
23. PushtheProgramsbuttontocontinuetothenextmenuoption.
24. The Console display shows the Error Log prompt (for service technician use only). Push the Resistance Decrease
button to move through the logged errors. At the end of the logged errors, the Console display shows the Clear Errors
prompt (for service technician use only). To clear the errors, push the Start button.
25. PushtheProgramsbuttontocontinuetothenextmenuoption.

16
26. TheConsoledisplayshowstheResetConsoleprompt.ThedefaultoptionisNO.PushthePause/Stopbuttontoexit
without starting Reset.
Note: The YES option will reset the System Units, Screen Brightness and Demo Mode to default settings. It does not
reset the Run Time Hours.
Push the Resistance Increase/Decrease buttons to change between options (YES/NO).
PushtheStartbuttontosettheselectionandexittheSystemMenu.
27. The Console will display the Power-Up Mode screen.

17
SENSOR HUB
SERVO
Resistance Sensor
Speed Sensor
SUB ASSY, ENGINE
WIRE ASSY, SPLIT CBL
RESISTANCE SENS, SPEED
SENSOR, & SERVO
HANDLE BAR BUTTONS
CABLE ASSEMBLY, HUB
to MAST HARNESS
CONSOLE MAST
HANDLEBAR RIGHT
ASSY, CABLE/PCBA,
REMOTE BUTTON
- RESISTANCE
HANDLEBAR, LEFT
CONSOLE
ASSY, CABLE/PCBA,
REMOTE BUTTON
- INCLINE
WIRE ASSY - INCLINE
WIRE ASSY - RESISTANCE
WIRE, CABLE ASSY,
CONSOLE MAST
WIRE ASSY, CONSOLE TO MAST
CABLE, SPEED SENSOR
UP
DOWN
LEFT
RIGHT
LIFT CONTROL / POSITION
DC POWER
GND
CABLE, CONNECTOR WIRE POWER
RED
BLACK
WHITE
BLUE
BROWN
GND
LIFT MOTOR
SENSOR HUB
LIFT MOTOR CONTROL
OFFLINE POWER SUPPLY
BLUE
BROWN
SWITCH
INLET
HANDLE BAR BUTTONS
ELECTRICAL WIRING

18
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
!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.

19
Calibrating the Resistance
on the Schwinn™490 / 590e Ellipticals
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.
!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.
• Disconnect all power to the machine before you service it.
•Makesurethattherepairisdoneinanappropriateworkspaceawayfromfoottra󰀩c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.
• Use only replacement parts and hardware that are supplied or approved by Nautilus. Failure to use Nautilus-approved
replacementpartscanadverselya󰀨ectthesafetyandfunctionalityoftheequipmentcreatingarisktousersandwill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 at any time the Warning labels become loose, unreadable or dislodged,
replace the labels. If purchased in US/Canada, contact Customer Service for replacement labels. If purchased outside US/
Canada, contact your local distributor for them.
• 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.
•SAVE THESE INSTRUCTIONS
™
NOTICE: This document provides instructions for the calibration of the Resistance on the Schwinn™490 / 590e Ellipticals.
Note: If the calibration process fails because of a time out, run the procedure again.
If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside
US/Canada). To nd your local distributor, go to: www.nautilusinternational.com
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.
Nautilus, Inc., www.nautilus.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America [phone], [email protected] | outside U.S.
www.nautilusinternational.com | Printed in China | © 2023 Nautilus, Inc. | Schwinn and the Schwinn logo are trademarks owned or licensed by Nautilus, Inc., registered or otherwise
protected by common law in the United States and other nations. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
Skill Level: I
Estimated Procedure Time: 5 minutes
8031263.071523.A
Replacement Procedure

20
1. Plug the power cord into the machine and wall outlet,
andipthepowerswitchtoon.
2. Push the Programs button and hold for 3 seconds while
in the Power-Up Mode to go into the Console Setup Mode
(System Menu).
Note: ToexittheSystem Menu and return to the Power-
Up Mode screen, push the Pause/Stop button.
3. The Console display shows the System Units prompt
with the current setting. Tap the Programs button 4 times to
advance through the System Menu.
4. The Console display shows the Hardware Variant &
Console Firmware Version. The sample screen shows the
format(valuesmaybedi󰀨erent).
Push and hold for 3 seconds the Resistance Level Quick 25
button to go to the Manufacturing Test Menu.
5. The Console display shows the START TEST SUITE
menu option. Push the Resistance Down () button 2 times
to advance to the AUTO CAL_RESISTANCE (Automated
Calibrate Resistance) option.
If the Start button was pushed instead of the Resistance
Down () button twice, turn the Power Switch to OFF and
return to Step 1.
When the display shows “CALIBRATE RESISTANCE” do
NOT push Start. This option is not used. Push the Resistance
Down () button one more time.
If the Resistance Down () button was pushed more than 2
times going past the AUTO CAL_RESISTANCE option, push
the Resistance Increase () button to return to the AUTO
CAL_RESISTANCE (Automated Calibrate Resistance)
option.
Resistance Level Quick 25 button
™
Resistance Down button
!Do not use the Console Resistance Quick Keys to set resistance until the calibration
process is complete and calibration saved.
Note: During the calibration process no one should be pedaling the machine. Standing on the pedals is okay during the
calibration process.