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.

8014236.083118.B

Schwinn

AD7 AirDyne

Page Number

Bike Service Manual

Service Manual

8014178.083118.B

Table of Contents

Summary of Contents for Schwinn AD7 AirDyne

Page 1: Table Of Contents
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 2: Important Safety Instructions
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 3: Safety Warning Labels And Serial Number
Safety Warning Labels and Serial Numbers WARNING! REVISION REVISIO • Keep children away. 001210 PRODUC • 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.
Page 4: 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.
Page 5: Locking The Fan Assembly / Storage
Locking the Fan Assembly / Storage When the machine is not in use, be sure to lock the Fan Assembly with the Transport and Immobilization Strap. The fan assembly should be locked for storage of the machine. For safe storage of the machine, remove the batteries and install the Transport and Immobilization Strap to secure the Resistance Fan.
Page 6: Leveling The Machne
Leveling the Machine The machine needs to be leveled if your workout area is uneven. Levelers are on each side of the Stabilizers. To adjust: Place the machine in your workout area. Turn the stabilizer feet to adjust until they are evenly balanced and in contact with the floor.
Page 7: Troubleshooting
Troubleshooting Condition/Problem Things to Check Solution Console will not power up/ If bike has AC adapter, Make sure unit is plugged into a functioning wall outlet. turn on/start check electrical (wall) outlet If bike has AC adapter, Connection should be secure and undamaged. Replace check connection at unit adapter or connection at unit if either are damaged.
Page 8 Condition/Problem Things to Check Solution If bike has batteries, Make sure batteries are installed correctly. If batteries are check Battery Indicator correctly installed, replace with a set of new batteries. on console or check batteries. Check Speed Sensor Speed Sensor Magnets should be in place on Fan assembly. Magnet position (requires fan cover removal) Check Speed Sensor...
Page 9: Console Service Mode
Console Service Mode The Console Service Mode lets you see the total time and distance the machine has been used, adjust the altitude value for a more accurate calorie count, or find out which version of Firmware is installed. Hold down the STOP/RESET button and Decrease () button together for 3 seconds while in the Idle Mode to go into the Console Service Mode.
Page 10: Console Error Codes
Console Error Codes Console display error Condition Err 1 Stuck button - any button is depressed longer than 90 seconds. Console error display format CAL/MIN WATTS SPEED Stuck button RATE SELECT 20/10 INTERVAL 30/90 INTERVAL ENTER CUSTOM INTERVAL TIME TARGET CAL/kJ TARGET SELECT...
Page 11 Maintenance Parts Your machine may differ. Use only as a guide. (X3) Console Leveler GG Power Inlet Assembly Console Mast Seat Adjustment Knob Fan Cage, Upper Left Water Bottle Holder Shroud, Left Fan Cage, Lower Left Frame Crank Arm, Left Fan Cage, Lower Filler Stabilizer, Front Pedal, Left...
Page 12: Torque Specifications
Torque Specifications 10 N . m 60 N . m 60 N . m ≤ 19 N . m 40 N . m 40 N . m ≤ 19 N . m (X2) ≤ 19 N . m (X2) REPLACEMENT PROCEDURE SKILL LEVEL Level I : Low - very little mechanical knowledge or exposure.
Page 13 Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 14 NOTICE: It may be necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure Note: Your machine may not match the image. For reference only. To test the Drive Belt tension, sit on the bike and use the pedals and handlebar arms at approximately 20 RPM.
Page 15 Loosen and remove the indicated screws that attach the Fan Adjustment Plate Covers (*) and Front Fan Cage to the frame. Carefully remove the front Fan Cage sections and Fan Adjustment Plate Covers. 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.
Page 16 12. Tighten the left Tension Adjustment Nut (B, on the side of the Fan Left side – Fan tension adjustment (top front view) without the belt) an additional 2 full turns. 13. Reinstall Fan Cage and test ride the machine to as high a speed as possible.
Page 17: Part Replacement
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 18: Pedals
Note: Your machine may not match the image. For reference only. Loosen and remove the old Pedals. Discard the old Pedals. Note: The Left Pedal is reverse-threaded. Orientation is based from a seated position on the bike. The Left Pedal has an “L”, the Right Pedal an “R”.
Page 19: Water Bottle Holder
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 20 Note: Your machine may not match the image. For reference only. Loosen and remove the indicated screws that attach the Water Bottle Holder to the Mast and Console. Set the screws safely aside. Remove the Water Bottle Holder from the Mast and set it safely aside.
Page 21 Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 22 Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Loosen and remove the hardware 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.
Page 23: Console
Loosen and remove the screws that attach the Console to the Mast and Water Bottle Holder. Set the screws safely aside. NOTICE: Hold the Console so that it does not fall. This step may require two people. Remove the Console and pull the cables out of the Mast tube so that the string extends through the tube.
Page 24: Console Mast
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 25 Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Loosen and remove the hardware 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.
Page 26 Loosen and remove the screws that attach the Console to the Mast and Water Bottle Holder. Set the screws safely aside. NOTICE: Hold the Console so that it does not fall. This step may require two people. Carefully remove the Console and pull the cables out of the Mast tube.
Page 27: Transport Wheels
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 28 Note: Your machine may not match the image. For reference only. Using the 13mm wrenches, loosen and remove the hex head bolt (A), acorn nut (B) and lock washer (C) from the old Transport Wheel assembly. Remove the old Transport Wheel (D) from the bracket (E), and discard. Install the replacement Transport Wheel assembly.
Page 29: Levelers
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 30 Note: Your machine may not match the image. For reference only. Place a static object (like a book or box) under the main frame near the Stabilizer. The static object should not be compressible. Using the 13mm wrench, loosen and remove the hex head bolt from the old Leveler.
Page 31 Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 32: Seat Post
Note: Your machine may not match the image. For reference only. Using the 13mm wrench, loosen the Nuts (B) on the Seat bracket (A). Remove the Seat from the Seat Post and set it safely aside for reassembly. Loosen and pull the Seat Post Adjustment Knob (C), and remove the Seat Post.
Page 33: Handlebar Arms And Foot Pegs
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 34 Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Loosen the hardware that attaches Foot Peg to the frame assembly. Remove the hardware and Foot Peg, and set them safely aside.
Page 35: Crank Arm Assembly
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 36 Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Loosen and remove the Pedals. Set them safely aside for reassembly. Note: The Left Pedal is reverse-threaded. Orientation is based from a seated position on the bike.
Page 37: Shrouds And Footpad
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 38 Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Crank arms not shown Slide the Grommet up the Seat Post to expose the screws that attach the Top Shroud to the frame. Note: If necessary, remove the Seat Post and the Seat Adjustment Knob (A).
Page 39: Fan Cage
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 40 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. To remove the lower back Fan Cage sections, it is necessary to remove the Shrouds.
Page 41 Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 42 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. Note: Your machine may not match the image. For reference only. Using an 8mm hex key, remove the Cap Screw (A) from the Crank Arm assembly (B).
Page 43: Linkage Arms
Before installing the new Linkage Arm, check the diameter of the small pivot shaft (P) on the Arm Pivot. Use the appropriate hardware in the Linkage Arm service kit for your machine. 25mm dia. pivot shaft 12mm dia. pivot shaft Installation is the reverse procedure.
Page 44 NNautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 45 Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Using a #2 Phillips Screwdriver, loosen and remove the screws (*) that attach the left Fan Adjustment Plate Cover. Carefully remove the Fan Adjustment Plate Cover.
Page 46: Rpm Sensor (Speed Sensor)
Carefully lift the Console/Mast Assembly. Disconnect the RPM Data Cable (B) and Power Inlet Cable (C). Set the Console/Mast Assembly safely aside for reassembly. NOTICE: Do not let the cables fall down inside the frame. This step may require two people. Observe the cable routing to the RPM Sensor (A).
Page 47: Drive Belt And Fan Assembly
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 48 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It is necessary to adjust the Drive Belt tension at the end of this procedure. Refer to the “Belt Tension Adjustment” procedure. Note: Your machine may not match the image.
Page 49 Using a 19mm open end wrench, loosen and remove the Fan spindle lock nuts (E) on both sides of the machine. Set them safely aside for reassembly. Note: If you are only replacing the Drive Belt, it is only necessary to loosen these parts.
Page 50 Slowly turn the Drive Pulley (L) forward and carefully ease the Drive Belt (M) off the Drive Pulley to the outside from the bottom of the pulley. Be sure to keep fingers clear of all pinch hazards as you turn the Drive Pulley.
Page 51 11. To remove the Drive Belt (M), loosen and remove the hardware (N1) that attaches the right Linkage Arm (N) to the Arm Pivot (O), using the 5 mm hex key. Set the screws safely aside for reassembly. Separate the Linkage Arm from the Arm Pivot.
Page 52 16. Move the Fan spindle backward in the frame brackets to the end of Right side – Fan hub alignment (front top view) the slots. Reinstall the Adjustment Nuts (C) and Spindle Clips (F) on the Threaded Tensioners (D) on both sides of the machine so the the Spindle Clips just touch the frame brackets and the Adjustment Nuts just touch the Spindle Clips.
Page 53 20. Reinstall the RPM Sensor (G) to the Fan shaft (J). Keep the RPM Data cable (H) clear of the Fan. NOTICE: Do not crimp any cables. Make sure the RPM Sensor is oriented correctly on the Fan Spindle. Be sure the routing for the cables is correct to prevent interference from moving parts.
Page 54 26. Reinstall the Fan Adjustment Plate Covers. 27. Reinstall the Shrouds. Refer to the “Replace the Shrouds” procedure in this manual. NOTICE: Be sure the tabs in the Top Shroud snap into the Main Assembly. 28. Reinstall the Right Foot Peg and Right Handlebar Arm. Completely tighten the Cap Screws (B) on the Handlebar Arm or torque to 40 N .
Page 55 Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 56 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It is necessary to adjust the Drive Belt tension at the end of this procedure. Refer to the “Belt Tension Adjustment” procedure Note: Your machine may not match the image.
Page 57: Rear Idler Pulley
Using 13 mm wrench and 6mm hex key, loosen and remove the hardware (F) from the Rear Idler Pulley assembly (G). Remove the Rear Idler Pulley from the bracket and Drive Belt (E). Discard the old Rear Idler Pulley assembly. Install the new Rear Idler Pulley (G).
Page 58: Crank Link Assembly
Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 59 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Using an 8mm hex key, remove the Cap Screw (A) from the Left Crank Arm assembly (B).
Page 60 Using a 6 mm hex key, loosen and remove the Cap Screw (G) that secures the Crank Link Assembly (F) to the Pulley spindle. Remove the old Crank Link Assembly and discard. (40 N . m) Installation is the reverse procedure. Put the replacement Crank Link Assembly (F) in position on the Pulley spindle and completely tighten the Cap Screw (G), or torque to 40 N .
Page 61 Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | 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.
Page 62 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. Note: Your machine may not match the image. For reference only. Unplug the AC Adapter from the wall outlet and machine. Loosen and remove the screws (*) that attach the left Fan Adjustment Plate Cover.
Page 63: Power Inlet
Carefully open the cable clip (B) on the inside Frame Upright (E) to Cable clip and Power Inlet cable (top view) release the Power Inlet cable (A) and the RPM Data cable (C). Hold the Power Inlet cable at the Fan shaft (D) and carefully pull it out of the upper part of the Frame Upright so that the string extends through the tube.

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