Nautilus Be Strong Commercial R916, Assembly Manual

Page 1: ...Be Strong 003 3375 060309A Rework Manual Commercial Series Bike R916...

Page 2: ...Affected and Requiring Work 3 Tools Required 3 Parts 4 Parts List 6 Hardware 7 Assembly 8 Software Upgrade 13 Flywheel Intermediate Hub Assembly Belt and Pulley Replacement 16 Final Inspection 23 Fina...

Page 3: ...U0930001 100154ACU09030027 Tools Required FISP s Phillips head screw driver 2 drive s Vice grips s Cloth towel rag s 15 16 socket and socket torque wrench s 13mm socket and wrench s 4 5 6 mm Metric Al...

Page 4: ...ke Kit 1 002 6845 Shroud Spacer 1 2 41375 021 D51 Display Firmware 1 Firmware 3 002 6840 Intermediate Hub Assembly 1 4 000 6432 Belt Alternator U R916 1 5 000 6214 Assembly Overmold Intermediate 8V Pu...

Page 5: ...902 4274 SCW GHCS M8x1 25x25 SS 1 9 9 902 4141 NUT NL M8 1 25 G2 BlkZ 3 9 10 902 4140 NUT NL M6 1 0 G2 Blk Z 2 9 11 002 6858 Rework Sticker Blue 1 9 12 003 3375 060309 R916 Rework Manual 1 9 13 003 3...

Page 6: ...EF DESCRIPTION QTY A Console 1 B Console Mast 1 C Main Frame 1 D Seat Pad 1 E Handlebar 1 F Seat Back Assembly 1 G Right Mast Shroud 1 H Left Mast Shroud 1 I Right Seat Bottom 1 J Left Seat Bottom 1 K...

Page 7: ...Flat Washer M10 Qty 4 Ref 4 Phillips Head Screw 10 32 x 3 4 Qty 10 Ref 5 Phillips Head Screw 1 4 x20 Qty 4 Ref 6 Spring Washer M6 Qty 4 Ref 7 Allen Head Bolt M8x15 Qty 4 Ref 8 Spring Washer M8 Qty 12...

Page 8: ...he Mast B Make sure to reposition the wire tie after the rework 1 2 Align the Mast B with the four holes in the Main Frame N 1 3 Install and hand tighten the hardware The following instructions provid...

Page 9: ...ure 4 3 2 The Right Heart Rate Wire O is labeled with an R Plug the Right Heart Rate Wire into the connector labeled P1 on the back of the console Figure 4 3 3 Plug the Left Heart Rate Wire P into the...

Page 10: ...ad clearance Add four 003 4716 seat spacers between the rail bushings and seat carriage assembly reattach seat assembly to rail bushings NOTE detailed instructions are located at N VW CustomerCare Pro...

Page 11: ...Tools needed two 13mm wrenches and 6mm hex Make sure you do not tighten the Nut so much that it deforms the Seat Carriage bracket If it is too tight the Handle will not be able to pivot Note Make sur...

Page 12: ...s not yet secured to the Seat Carriage It is easier to perform this step if the Carriage is positioned toward the top of the range 6 3 Connect the Heart Rate Cables U from the Handlebars to the corres...

Page 13: ...3 The kit includes e ce of XX when ordering For example OR P N 41376 7XX programmed with the correct C52 program version T9 16 TC9 16 etc The version number should b used in pla if you need revision 3...

Page 14: ...bbon cable and locate the keyed side Remove the plastic access plate on non TMs or the steel plate on the T9 xx or TC9 xx and match the keyed side o cable connector with the corresponding side of the...

Page 15: ...e device and verify that the software has been upgraded Non treadmill machines 5 Wait for the F I S P LED to turn GREEN 6 Once the programming is complete the green LED will turn on Remove the F I S P...

Page 16: ...screws from Flywheel 000 6238 Attach vise grips to the flywheel with a rag between the tool and painted surfaces to prevent damage to the paint this will hold the flywheel in place so the nut can be...

Page 17: ...hex wrench this will allow the belt to removed as well STEP 4 Removing the pulley from interm Remove the 8M 1 25 x 20 alien cap screws 902 4725 from pulley 000 6229 using a 6mm hex wrench After socket...

Page 18: ...intermediate shaft STEP 6 Remove intermediate shaft Using a rubber mallet and punch drive the shaft from the bearing housing in the frame Start shaft into bearing housing Make sure the shaft is insert...

Page 19: ...d in the groove STEP 9 Reattaching intermediate pulley Get 002 0631 Woodruff Key and 000 6229 Intermediate Pulley and place them on the Shaft with a rubber mallet drive the pullet back onto the shaft...

Page 20: ...iate pulley STEP 10 Reinstalling the belt to the c Reverse the process described in Step 4 reinstall the crank drive belt check belt for proper alignment 000 6214 Intermediate Pulley 4 902 5665 Screws...

Page 21: ...lywheel nut using the same method as shown in step 2 Nut should be torque to 30 ft lbs Putting the new belt on the intermediate pulley this is done by feeding the belt back onto the pulley while turni...

Page 22: ...STEP 13 Check machine function belt alignment intermediate hub free wheeling and timing belt alignment adjust as needed Reattach covers 22...

Page 23: ...And Moving Parts And Pull Test Wires Verify PCB Secure To Frame Switch Set to E B Not S And Pull Test Wires Verify Poly V Belt Not Damaged And Aligned On Pulleys Verify Intermediate Shaft Screw Torqu...

Page 24: ...n Back Down To Level 1 Be Alert For Noises Vibration And Differences In Feel And Resistance Verify Information During Scan Mode Verify Upper And Lower CHR Function Check Battery Voltage Is 6 3 Volts M...

Page 25: ...ve the Console from the Mast and move it to the packing bench ast Remove the Mast and move it to the packing bench Quality Check Make sure not to damage the Cables that run up the Mast when removing t...

Page 26: ...area Wrap a 61240 Bag around the Lower Handlebar and place it in the Lower Handlebar Box Run the Wire Tie up the Mast and attach it to one of the Console mounting holes Reattach the wire tie as you pu...

Page 27: ...61240 Bag around the Mast Handlebar and place it in the Mast Handlebar Box Place the Plastics Box in the Mast Handlebar Box Get the Console wrap it in bubble wrap and place it in the Mast Handlebar B...

Page 28: ...t and 001 6988 Assembly Manual and place them in the Mast Handlebar Box Fold the Mast Handlebar Box flaps closed and seal with tape Get 002 0364 Bag and place the Seat Cushion in it Place the bagged S...

Page 29: ...e Seat Cushion against the side of the Box and the Battery Charger against the bottom of the Seat Cushion Fold the Seat Box flaps closed and seal with tape Place the Seat Box in the Lower Handlebar Bo...

Page 30: ...Seat Rail Extrusion Quality Check To center the Bike the Front Stabilizer Feet should be against the paddles Place quicksilver around the Rear Seat Rail Shroud Get 17885 Bag place it over the Bike an...

Page 31: ...ts and place them in the Master Box at the front corners Get 002 0777 Crossmember Support and place it on top of the Upright Supports Get 2 003 3495 2x4 Upright Supports and place them in the Master B...

Page 32: ...e staples run horizontally Move the Pedals to a horizontal position Place the Mast Handlebar Box with the blue decal in the Master Box on the RH side Place the Lower Handlebar Box in the Master Box on...

Page 33: ...Fold the side flaps of the Master Box over and use the bander to secure the Master Box to the Bottom Tray in 3 places 33...

Page 34: ...the former extension setup files but will save to a new 4dx format The person programming the FISPs may need to change the program s file locations if so upon saving this changed program an extension...

Page 35: ...The Multi Build FISP Load screen should look something like this OR 35...

Page 36: ...mber SNo24010622 is displayed 4 Center bottom shows that the FISP is NOT connected to the Target processor Console or VSD 5 At the top the Project Dot is checked and shows that the correct program is...

Page 37: ...e additional restrictions The simplest method of powering them is to connect to an operating Console or VSD If this is done the operator must be more careful since incorrect use could permanently dest...

Page 38: ...ts reserved Nautilus the Nautilus logo My Nautilus Heart Strong Changing the Game in Health and Fitness REACT ROC Remote Operation Control SuperSoft Hyperdrive Be Strong are either registered trademar...