LAZBOY 40A, 40B, 40S, 40D, 40E Troubleshooting Manual

Troubleshooting Guide

40A/40B/40D/40E/40S/40W/40X/
410/430/440/460/480/490

SOLUTIONSYMPTOM CAUSE

The legrest
subassembly
partially extends
and hits the
bottom rail.

The legrest
does not hold
in the extended
position.

The base connecting rail
(part of the Mechanism
Side Subassembly) is bent
down causing the legrest
subassembly to hit the
Bottom Rail.

Improper legrest cam
setting for user.

Center Extension Spring
is missing from a chaise
style.

Replace the Mechanism Side Subassembly. Refer
to the work instruction for step‑by‑step details if
needed.

Set the adjustable legrest cams to the high
setting. Stand beside the unit, extend the
legrest, lift the mechanism cover and locate the
two adjustment cams toward the front of the
mechanism (one on each side). Turn the cams
forward, toward the front of the unit for maximum
tension. Set both cams to the same position.

Note: The factory setting is in the center position.

For Chaise Styles: Install a center Extension
Spring. Chaise styles include the center extension
spring as a standard component.

Add a center Extension
Spring to a non-chaise
style.

The legrest is

too difcult to

Improper legrest cam
setting for user.

retract.

For Non‑Chaise Styles: Install a center Extension
Spring if the cams, in the high setting, do
not provide enough tension for the user. The
Extension Spring is not a standard component of
non‑chaise styles produced after 06/2007, but
can be added when the high cam setting does not
resolve the symptom.

Adjust the legrest cams for less tension. Stand
beside the unit, extend the legrest, lift the
mechanism cover and locate the two adjustment
cams toward the front of the mechanism (one on
each side). Turn the cams rearward, toward the
back of the unit for minimum tension. Set both
cams to the same position.

Note: The factory setting is in the center position.

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SOLUTIONSYMPTOM CAUSE

The legrest
is angled, or
leaning when
fully extended.

The back is

difcult to

pre‑recline,
recline, or return
to the upright
position.

Adjustable legrest cams
are in different settings.

Missing legrest cam
on Mechanism Side
Subassembly.

Plastic slide inserts are
loose.

The upholstered units
are positioned too
close together causing
interference and rubbing
on each other.

Set adjustable legrest cams to identical setting.
Stand beside the unit, extend the legrest, lift the
mechanism cover and locate the two adjustment
cams toward the front of the mechanism (one on
each side). Set the cams to the forward position
for maximum tension, to the center position for
average tension, or to the rearward position for
minimum legrest tension.

Replace the Mechanism Side Subassembly.

Verify the plastic slide inserts are installed
properly and push into place if loose

Sofas—Reposition the mechanism to the outside
set of holes on the Bottom Rail(s) to provide more
clearance between the upholstered units. It may
not be necessary to reposition the mechanism on
both (front & rear) Bottom Rails.

Modulars—Extend the length of the ¼‑20 X 1¼"
Truss Head Screw(s) located in the Stud Mount(s)
to provide ample clearance between units for
mechanism operation.

.

Plastic bushing in the
rear seat slide slot, of
the Mechanism Side
Subassembly, is missing.

Friction plate is installed
improperly with locking
tab oriented incorrectly,
inside the slot.

Wing nut tension setting is
too tight for user.

Inspect both the left and right Mechanism Side
Subassembly to verify the bushing is in place.
Replace the Mechanism Side Subassembly if the
plastic bushing is missing

Loosen wing nut until the washer moves freely
and orient friction plate with tab on top of plastic
insert. Tighten wing nut.

Loosen the Wing Nuts. Extend the legrest, reach
under the seat and locate the adjustable tension
wing nuts toward the front of the mechanism
(one on each side). The factory setting for the
tension wing nuts is 7/16" from the wing nut to the
lip of the slide pivot rivet. Adjust both wing nuts
equally.

Never completely tighten or completely loosen the wing
nuts and operate the mechanism.

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Troubleshooting Guide

SOLUTIONSYMPTOM CAUSE

The back reclines
too easily and
will not hold its
position.

The backs appear
crooked on the
mechanism,
do not align
correctly, or
back heights are
uneven.

Incorrect wing nut tension
setting for user.

Missing back bracket
fasteners.

The backs are not properly
seated on the bodies and
locked into position.

Back frame out of square.

Tighten the Wing Nuts. Extend the legrest, reach
under the seat and locate the adjustable tension
wing nuts toward the front of the mechanism
(one on each side). The factory setting for the
tension wing nuts is 7/16" from the wing nut to the
lip of the slide pivot rivet. Adjust both wing nuts
equally.

Never completely tighten or completely loosen the wing
nuts and operate the mechanism.

Check for and install missing screws in the back
bracket attachment; two screws should secure
each back bracket.

Inspect and secure the backs. Push the backs
completely down onto the bodies, making sure the
back and body brackets are completely engaged.
Lock the back brackets using a slotted screwdriver
to push the toggle levers completely down.

Replace back frame spring up assembly or back
upholstered.

Gaps appear
between one
or more of the
following areas:
back(s), seat(s),

Sofas—Mechanism(s)
mounted in the incorrect
hole locations on the
Bottom Rail(s) for the style
and fabric combination.

legrest(s).

Modulars—The ¼‑20 X
1¼" Truss Head Screw(s)
on the Stud Mount(s) are
positioned too far out.

Sofas—Reposition both sides of the mechanism(s) on
the Bottom Rail(s) to the inside set of holes to close
gaps between upholstered areas. Evaluate the gap(s)
and mechanism operation, readjust as necessary. It
may not be necessary to reposition the mechanism
on both (front & rear) Bottom Rails.

Modulars—Shorten the length of the ¼‑20 X 1¼"
Truss Head Screw(s) on the Stud Mount(s) to
close gaps. Evaluate the gaps and mechanism
operation, readjust if necessary.

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SOLUTIONSYMPTOM CAUSE

The arm side of
the sofa is too
high or is raised
in relation to the
center seat.

The arm side
of the sofa
is leaning
downward or
outward.

The unit is not
level —it is angled
downward,
toward the
center.

Incorrect Adjustable Glide

setting, uneven ooring,

or a combination of both
the glide setting and the

ooring.

Incorrect Adjustable Glide

setting, uneven ooring,

or a combination of both
the glide setting and the

ooring.

Adjustable Glide(s) and/
or stationary glides are
missing in the Bottom
Rails.

Level the unit using the Adjustable Glides.
Loosen the upper jam nut, adjust the lower jam
nut (closest to the glide) downwards toward
the glide, rotate the glide clockwise and tighten
the upper jam nut. Readjust until the unit is
level. If necessary, and depending on date of
manufacture, replace the rear stationary glide
with an adjustable glide.

Level the unit using the Adjustable Glides. Loosen
the upper jam nut, rotate the glide counter‑
clockwise, adjust the lower jam nut (closest to
the glide) upwards to the bottom rail and tighten
the upper jam nut. Readjust until the unit is
level. If necessary, and depending on date of
manufacture, replace the rear stationary glide
with an adjustable glide.

Add the correct number of glides (and jam nuts) to
the Bottom Rails. Sofa styles with three seats (such
as 440 and 460) call for a quantity of four Adjust‑
able Glides in the front rail and four stationary glides
in the rear rail. Sofa and loveseat styles with two
seats (such as 430 and 480) call for a quantity of
three Adjustable Glides in the front rail and three
stationary glides in the rear rail. All modular styles

use adjustable glides in both the front and rear rails.

The Legrest will
not remain in the
closed position—
the mechanism

Excessive upholstery
on the back side of the
legrest deck and/or under
the front edge of the seat.

will not lock over
center.

The Cable Return Spring is
installed upside down.

One (or more) of the links
in the legrest subassembly
are bent.

Adjust the upholstery on the Legrest Deck and/or
Seat.

Assemble the Cable Return Spring with the looped
end hooked to the Trip Lever and the spring coils
facing away from
the mechanism.

Cable Return Spring; Looped end of
spring hooks to trip lever and spring
coils face away.

Replace the Mechanism Side Subassembly.

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SOLUTIONSYMPTOM CAUSE

The Release
Subassembly is

difcult to pull

and/or must be
pulled through
the entire stroke
to release the
mechanism.
The mechanism
appears to drag
or operate slowly.

The upholstered legrests
are positioned too
close together causing
interference and rubbing
on each other.

The cable end of the
Release Subassembly
and/or the Cable Return
Spring are installed upside
down.

Trip Lever is too tight in
the side rail and does not
rotate freely.

Sofas—Reposition the mechanism to the outside

set of holes on the Bottom Rail(s) to provide
more clearance between the upholstered legrests.
It may not be necessary to reposition the
mechanism on both (front & rear) Bottom Rails.

Modulars—Extend the length of the ¼‑20 X 1¼"
Truss Head Screw(s) located in the Stud Mount(s)
to provide ample clearance between units for
mechanism operation.

Hook the cable end of the Release Subassembly
with the cable tube facing down, away from the
seat. Assemble the Cable
Return Spring with the looped
end hooked to

Cable Tube;
Faces downward,
away from the seat.

the Trip Lever
and the spring
coils facing
away from the
mechanism.

Cable Return Spring; Looped end of
spring hooks to trip lever and spring
coils face away.

Replace the Trip Lever.

The modular
units will not
join, or “Latch”

Incorrect Adjustable Glide
settings; units are not
vertically aligned.

together.

(continued on page 6)

Modify the Adjustable Glide settings so that they
are at the same height and the units are aligned.

 To Lower—Loosen the jam nut on the top

of the modular bracket component, rotate
the glide clockwise, tighten the bottom jam
nut to the base rail and tighten the top jam
nut down to the modular joining bracket
component. Test the setting, repeat this
procedure as necessary until the units are
level and can be joined or “Latched.”

 To Raise—Loosen the jam nut on the top of

the modular bracket component, rotate the
glide counter‑clockwise, tighten the bottom
jam nut to the base rail and tighten the top
jam nut down to the modular joining bracket
component. Test the setting, repeat this
procedure as necessary until the units are
level and can be joined or “Latched.”

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Troubleshooting Guide

SOLUTIONSYMPTOM CAUSE

The modular
units will not
join, or “Latch”
together.

The modular
units will not
join, or “Latch”
together. For

units shipped
prior to 12-29-12.

The Release
Subassembly
does not trigger
the

mechanism—

legrest

does not

open.

The ¼-20 X 1¼" Truss
Head Screw(s) on the
Stud Mount(s) are
positioned too far in.

Modular units are on a
smooth surface such as a

wood or tile oor.

The "latch arm" does not
swing freely, or is stuck in
the open position. There is
paint build up on the latch
or loose (excess) fabric
around the latch.

The Cable Return
Spring has fallen off the
mechanism.

Missing side Extension
Spring on Mechanism Side
Subassembly.

Adjust the ¼‑20 X 1¼" Truss Head Screw(s)
outward to provide additional length on the
screws to engage the attachment brackets. Test
the setting, repeat this procedure as necessary
until the units can be connected.

Replace the standard Adjustable Glides with non‑
skid Adjustable Glides.

Replace the Latch Subassembly with the Modular
Attachment, or staple the fabric down around the
Latch Subassembly.

Install the Cable Return Spring with the looped
end hooked to the Trip Lever and the spring coils
facing away from the mechanism.

Install an Extension Spring to the side of the
mechanism starting with the front connection.
Make sure to orient the spring so that the open
end of the front hook faces toward the seat.

The mechanism
produces a
squeak.

Both the nylon lock link
and stop drive are of a
similar material, which
may allow for squeaks.

Stop Drive

Hair Pin Clip

Apply lithium grease to the nylon lock link
and stop drive part of the mechanism side
subassembly.

To do this, remove the hair pin clip and slide the
stop drive toward the center of the mechanism

to free it from the lock link. Apply a sufcient

amount of grease to the lock link as shown below,
and reassemble.

Lock Link

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