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Schwinn AD7 AirDyne, Service Manual

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Schwinn AD7 AirDyne Service Manual Download Page 2

2

Important Safety Instructions and General Troubleshooting

Information for the Schwinn

®

 AD7 AirDyne

®

 Bike

8014188.083118.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.
•  Disconnect all power to the machine before you service it.
•  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 replacement parts and hardware supplied by Nautilus. 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.

Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, [email protected] | outside U.S. www.nautilusinternational.com |  © 2016 Nautilus, Inc. | 

Schwinn, the Schwinn Quality logo, and AirDyne are trademarks owned by or licensed to Nautilus, Inc., which are registered or otherwise protected by common law in the United 

States and other countries. Polar® is a registered trademarks of its owner.

NOTICE:  

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

®

 AD7 AirDyne

®

 

Bike. 

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.

Summary of Contents for AD7 AirDyne

Page 1: ...Reading the Product Specification Label 3 1 Specifications 3 1 Maintenance 4 1 Locking the Fan Assembly Storage 5 1 Moving the Machine 5 1 Leveling the Machne 6 1 Replacing the Console Batteries 6 1 Troubleshooting 7 1 Console Service Mode 9 1 Console Error Codes 10 1 Maintenance Parts Exploded View 11 1 Torque Specifications 12 1 Replacement Procedure Skill Level 12 Mechanical Procedures 13 2 Bel...

Page 2: ...ine 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...

Page 3: ... Regulatory Approvals Optional AC Power Adapter UL listed Rated 120V 60Hz Input 9VDC 1500mA Output Class 2 53 134 6 cm 53 134 6 cm 26 5 67 3 cm Product specification Serial number WARNING Keep children away Not intended for use by anyone under 14 years of age Prior to use read and understand the Owner s Manual Injury or death is possible if Caution is not used while using this machine Cease exerci...

Page 4: ...ly 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 Weekly Clean the machine to remove any dust dirt or grime from the surfaces Check for smooth seat operation If needed sparin...

Page 5: ...t and Immobilization Strap T around the Crank Arm and the Seat Post and put the end of the strap through the metal ring Tighten the strap to prevent movement of the Pedals and secure the strap 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 safel...

Page 6: ...the machine is level and stable before you exercise Replacing the Console Batteries The Console will display the Battery Indicator icon when the batteries are around 25 of their rated power during power up If you use rechargeable batteries the optional power adapter will not recharge the batteries To open the battery bay loosen the preinstalled screw in the cover When replacing the batteries make ...

Page 7: ... fan cover removal Make sure the Speed Sensor Magnets and the Speed Sensor are in place No speed RPM reading 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 Speed Sensor Magnet pos...

Page 8: ...ficult to pedal Check pedal to crank connection Pedal should be tightened securely to crank arm Be sure con nection is not cross threaded Check crank arm to axle connection Crank arm should be tightened securely to axle Screw torque 60 N m Crank link to pulley connection If the left crank arm still feels loose with correct torque applied and the crank link shaft is moving with the crank arm replac...

Page 9: ... Time Interval field Maximum display is 9999 Total Machine Distance number of miles in 10 mile increments in cumulative metrics field Display cycles MI for 5 seconds then KM for 5 seconds 3 Push STOP RESET to exit Console Service Mode Push the Decrease button to go to the next option 4 The Console display shows CAL calibration To calibrate the machine refer to the Calibration Procedure section Pus...

Page 10: ...ton any button is depressed longer than 90 seconds Console error display format Stuck button SPEED RPM CAL MIN WATTS RATE SELECT ENTER 20 10 INTERVAL 30 90 INTERVAL CUSTOM INTERVAL TIME TARGET ZONES HR START RESUME STOP RESET CAL MI kJ KM SELECT TARGET MI KM CAL kJ TARGET ...

Page 11: ...m Pivot Left H Fan Cage Front X Grommet NN Resistance Fan Assembly I Fan Cage Side Cover Y Seat Post OO RPM Speed Sensor Assembly J Fan Cage Lower Right Z Seat PP Speed Sensor Magnets K Handlebar Right AA Handlebar Left QQ Drive Pulley L Foot Peg Right BB Foot Peg Left RR Drive Belt M Pedal Right CC Strap Transport Immobilization SS Crank Link Assembly N Crank Arm Right DD Data Cable Upper TT AirD...

Page 12: ...out mechanical procedures Disconnect all power to the machine before you service it 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 bike AC Adapter Seat Front Stabilizer Rear Stabilizer Torque Specifications 60 N m 40 N m 40 N m 60 N m 19 N m X2 19 N m X2 19 N m 10 N m ...

Page 13: ...ons 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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy or awkward Enlist the...

Page 14: ...lockwise to decrease NOTICE Make sure to adjust the tension evenly on both sides of the machine 4 Make sure the Fan s center plane is aligned with the center of the bike See Figures 1 and 2 If the Fan is not aligned adjust the Tension Adjustment Nuts B Carefully turn the Crank Arms and check the movement of the Drive Belt The Crank Arms and Fan Assembly should move as one Be sure to keep fingers c...

Page 15: ...d have at least 1 groove visible to the left of the belt and not extend over the right side of the hub 9 Check the side to side position of the Fan The outer face of the Fan hub E should be 28mm from the frame bracket 28mm width of Drive Belt Hand tighten the Fan spindle jam nuts D to secure the side to side position of the Fan hub and lock nuts A as necessary to align the Fan Pulley 10 Loosen the...

Page 16: ...h no popping noises go to Step 17 If the Drive Belt or Fan makes additional noises continue to Step 15 15 Remove the Front Fan Cage see Step 7 Loosen the Tension Adjustment Nuts B until the Spindle Clips G are loose Loosen the right Fan spindle jam nut D Tighten the left Fan spindle jam nut 1 full turn toward the Frame mount bracket Retighten the right Fan spindle jam nut to the mount bracket Repe...

Page 17: ...s 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correc...

Page 18: ...d tighten to prevent cross threading Then tighten fully with pedal wrench Note The Left Pedal is reverse threaded Be sure to attach Pedals on the correct side of the Bike Orientation is based from a seated position on the bike The Left Pedal has an L the Right Pedal an R 3 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use un...

Page 19: ...g 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 Disconnect all power to the machine before you service it Some components of th...

Page 20: ...ws safely aside 2 Remove the Water Bottle Holder from the Mast and set it safely aside 3 Installation is the reverse procedure 4 Discard the old parts 5 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 ...

Page 21: ...ey 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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy or aw...

Page 22: ...bly to the frame Set the hardware safely aside for reassembly NOTICE Hold the Console Mast Assembly so that it does not fall This step may require two people 3 Carefully lift the Console Mast Assembly and disconnect the cables Tie the piece of string to the ends of the cables at the base of the Mast NOTICE Do not let the cables fall down inside the frame This step may require two people ...

Page 23: ...e cables through the Mast tube NOTICE Do not crimp any cables 7 Install the replacement Console to the Mast Untie the string from the cables NOTICE Do not crimp any cables Hold the Console so that it does not fall This step may require two people 8 Connect the cables from the Mast and frame and install the Console Mast assembly to the frame NOTICE Do not crimp any cables This step may require two ...

Page 24: ...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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy ...

Page 25: ...are that attaches Console Mast As sembly to the frame Set the hardware safely aside for reassembly NOTICE Hold the Console Mast Assembly so that it does not fall This step may require two people 3 Carefully lift the Console Mast Assembly and disconnect the cables NOTICE Do not let the cables fall down inside the frame This step may require two people ...

Page 26: ...of the screws from step 1 Use the weight of the screw to route the cables through the replacement Mast tube NOTICE Do not crimp any cables Hold the Console so that it does not fall This step may require two people 9 Install the replacement Console to the Mast Untie the string from the cables and screw Connect the cables from the Mast and frame and install the Console Mast assembly to the frame NOT...

Page 27: ...onents 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating c...

Page 28: ... Transport Wheel D from the bracket E and discard 2 Install the replacement Transport Wheel assembly NOTICE Be sure that the Transport Wheel can turn freely 3 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 Manua...

Page 29: ... 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warra...

Page 30: ...r assembly Hand tighten the hardware Turn the stabilizer feet to adjust until they are evenly balanced and in contact with 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 Make sure the machine is level and stable before you exercise 4 Final Inspection Inspect your machine to ensure that all hardware...

Page 31: ... 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correct...

Page 32: ...ent Seat Post on the frame Release the Seat Post Adjustment Knob C to engage the locking pin Be sure that the pin is fully engaged and fully tighten the adjustment knob 5 Attach the Seat to the Seat Post NOTICE Be sure the Seat is straight Tighten both nuts B on the Seat bracket A to hold the Seat in position 6 Final Inspection Inspect your machine to ensure that all hardware is tight and componen...

Page 33: ...onents 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating c...

Page 34: ...ide 5 Installation is the reverse procedure Completely tighten the Cap Screws A on the Handlebar Arm or torque to 40 N m NOTICE Push the Shoulder Screw com pletely through the Foot Peg and press the Washer tightly onto the end of the Foot Peg Be sure the Washer does not touch the bolt threads Do not let the Washer fall off the Foot Peg during installation Fully tighten hardware Make sure the Handl...

Page 35: ...nt 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the...

Page 36: ...n the new Cap Screws A on the replacement Crank Arms or torque to 60 N m The Left Crank Arm has an L the Right Crank Arm an R Orientation is based from a seated position on the bike Make sure the Crank Arms are secure before you exercise To reinstall the Pedals carefully align the threads and hand tighten to prevent cross threading Then tighten fully with pedal wrench Note The Left Pedal is revers...

Page 37: ...t 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from ...

Page 38: ...remove the 5 screws indicated that secure the Right Shroud Remove the bottom screws first and then the top screws 6 Slowly remove the Right Shroud 7 Turn the Left Crank Arm to point toward the back of the machine Using a 2 Phillips Screwdriver remove the 3 screws that secure the Left Shroud Remove the bottom screws first and then the top screws Slowly remove the Left Shroud 8 Installation is the r...

Page 39: ...f 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly...

Page 40: ...safely aside for reassembly NOTICE Hold each section of the Fan Cage as you loosen the screws so that it does not fall If necessary loosen and remove the screws and clips that attach the sections of the Fan Cage to each other 3 Installation is the reverse procedure NOTICE This step may require two people 4 Final Inspection Inspect your machine to ensure that all hardware is tight and components ar...

Page 41: ... 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all...

Page 42: ...embly Refer to the Replace the Shrouds procedure in the Service Manual Be aware that the Pedals Handlebars and Resistance Fan are connected and when any of these parts move the others do as well 4 Using a 2 Phillips Screwdriver loosen and remove the screws that attach the lower Fan Cage Carefully remove the lower Fan Cage sections Set them safely aside for reassembly 5 Using a 5 mm hex key loosen ...

Page 43: ...ud snap into the Main Assembly Completely tighten the Cap Screws A on the Crank Arms or torque to 60 N m The Left Crank Arm has an L the Right Crank Arm an R Orientation is based from a seated position on the bike Make sure the Crank Arms are secure before you exercise 7 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use unti...

Page 44: ...o 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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy o...

Page 45: ...sen and remove the indicated screws that attach the Front Fan Cage to the frame and carefully remove the sections Remove the bottom screws first and then the top screws Set them safely aside for reassembly NOTICE Hold each section of the Fan Cage as you loosen the screws so that it does not fall 4 Using a 6 mm hex key loosen and remove the hardware that attaches Console Mast Assembly to the frame ...

Page 46: ...his step may require two people 9 Untie the string from the old RPM Data cable and discard the old RPM Sensor 10 Installation is the reverse procedure Tie the string to the cable end B on the replacement RPM Sensor A Carefully pull the cable up through the frame upright To keep the RPM Data Cable clear of the Fan carefully secure RPM Data Cable in the cable clip D with the Power Inlet cable C on t...

Page 47: ... 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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy or awkward Enlist the service of a second person when yo...

Page 48: ... the Arm Pivot assembly Set them safely aside Be aware that the Pedals Handlebars and Resistance Fan are connected and when any of these parts move the others do as well 3 Remove the Right Handlebar Arm and set it safely aside 4 Carefully remove the Top and Right Shrouds Refer to the Replace the Shrouds procedure in this manual 5 Loosen and remove the indicated screws that attach the Fan Adjustmen...

Page 49: ... the Adjustment Nuts C Spindle Clips F and Threaded Tensioners D on both sides of the machine Set them safely aside for reassembly 8 Using a 0 Phillips screwdriver loosen and remove the screws G1 that attach the RPM Sensor G to the Fan Assembly shaft J Carefully remove the RPM Sensor and put it and the RPM Data Cable H safely aside Note If you are only replacing the Drive Belt it is not necessary ...

Page 50: ...de from the bottom of the pulley Be sure to keep fingers clear of all pinch hazards as you turn the Drive Pulley 10 Carefully remove the Fan Assembly from the frame brackets and the Drive Belt M NOTICE This step may require two people L M N M Crank arm not shown Fan shaft removed from frame bracket and Drive Belt ...

Page 51: ...lign the Fan shaft J in the frame brackets Put the Threaded Tensioners D on both ends of the Fan shaft Hand tighten the Fan spindle lock nuts E on each end of the Fan shaft 14 To put the Drive Belt M onto the Drive Pulley L align the grooves of the belt with the grooves at the top of the pulley with the slack of the belt to the outside While holding the belt on the pulley rotate the Drive Pulley b...

Page 52: ...e Fan hub P and the Drive Pulley L The Fan hub should have 1 groove visible to the left of the belt and not extend over the right side of the hub 18 Check the side to side position of the Fan With the Fan spindle lock nuts E loosened adjust the Fan spindle jam nuts K to allow a gap of 28mm between the outer face of the Fan hub P and the frame bracket steel plate 28mm width of old Drive Belt 19 Usi...

Page 53: ...tinue to Step 22 22 Tighten the left Tension Adjustment Nut C on the side of the Fan without the Drive Belt 1 2 turn at a time and test for quiet operation Repeat until the noise is gone If the nut is adjusted more than 2 1 2 turns the Fan Pulley P position may need adjustment This is necessary if the Fan starts to make additional noise If the machine operates with no popping noises go to Step 25 ...

Page 54: ...he Shoulder Bolt A completely through the Foot Peg and press the plastic washer tightly onto the end of the Foot Peg Be sure the washer does not touch the bolt threads Do not let the washer fall off the Foot Peg during installation Fully tighten hardware Make sure the Handlebar Arms are secure before you exercise 29 Final Inspection Inspect your machine to ensure that all hardware is tight and com...

Page 55: ...bey 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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy or a...

Page 56: ...ly remove the Shrouds Refer to the Replace the Shrouds procedure in this manual 4 Using a 2 Phillips Screwdriver loosen and remove the screws that attach the lower Fan Cage Carefully remove the lower Fan Cage sections Set them safely aside for reassembly 5 Using a 19mm open end wrench loosen the Fan spindle lock nuts C on the Threaded Tensioner B on both sides of the machine 6 Using a 10mm open en...

Page 57: ...e sure the Drive Belt is aligned on the Fan pulley H Rear Idler Pulley G and Drive Pulley Be sure to keep fingers clear of all pinch hazards as you turn the Drive Pulley 11 Using a 10mm open end wrench adjust the Tension Adjustment Nuts A to the position recorded in step 2 on both sides of the machine 12 Using the 19 mm open end wrench tighten the Fan spindle lock nuts C on each end of the Fan sha...

Page 58: ...ce 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers...

Page 59: ...hrouds Set them safely aside for reassembly Refer to the Replace the Shrouds procedure in this manual Be aware that the Pedals Handlebars and Resistance Fan are connected and when any of these parts move the others do as well 5 Using a 2 Phillips Screwdriver loosen and remove the screws that attach the lower Fan Cage Carefully remove the lower Fan Cage sections Set them safely aside for reassembly...

Page 60: ...d in position first to align the screws for the Left Shroud Install the top screws first NOTICE Be sure the tabs in the Top Shroud snap into the Main Assembly Completely tighten the Cap Screw A on the Crank Arm B or torque to 60 N m The Left Crank Arm has an L the Right Crank Arm an R Orientation is based from a seated position on the bike Make sure the Crank Arms are secure before you exercise 9 ...

Page 61: ...tions 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 Disconnect all power to the machine before you service it Some components of the equipment can be heavy or awkward Enlist t...

Page 62: ...e and carefully remove the sections Remove the bottom screws first and then the top screws Set them safely aside for reassembly NOTICE Hold the sections of the Fan Cage as you loosen the screws so that they do not fall 4 Loosen and remove the hardware that attaches the Console Mast Assembly to the Frame Set the hardware safely aside for reassembly NOTICE Hold the Console Mast Assembly so that it d...

Page 63: ...he new Power Inlet cable through the hole in the inner side of the Upright tube E and the lower part of the tube and then through the upper part To keep the cables clear of the Fan carefully secure the RPM Data Cable C and a loop of the Power Inlet cable A in the cable clip B on the Frame Upright NOTICE Do not crimp the cables Be sure the routing for the cables is correct to prevent interference f...

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