Nautilus Be Strong Commercial R916, Service Manual

Page 1: ...Be Strong PN 001 6884 Rev B 03 27 2007 Service Manual Commercial Series Bike Model U916 R916 Model U916 Model R916 ...

Page 2: ...ommercial Series Bike by other than authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty If you are a consumer and require technical support to resolve a problem with your Nautilus Commercial Series Bike please call Nautilus Customer Service at 800 628 8458 North America or 41 26 460 77 77 outside North America Important Please Read ...

Page 3: ...intenance Logs 18 Machine Configuration 20 ElectricalTroubleshooting 21 U916 R916 Main Wiring Diagram 23 U916 Console Heart Rate Wiring Diagram 24 R916 Console Heart Rate Wiring Diagram 25 General Bike Electronics Troubleshooting 26 MechanicalTroubleshooting 35 Removing Replacing Parts U916 and R916 Common Parts 37 Removing Replacing Parts U916 Parts 48 Removing Replacing Parts R916 Parts 51 Cable...

Page 4: ... Contents ...

Page 5: ...ay C51 blue white LCD with backlight Tactile membrane keypanel Functionality Number of Functions Eleven Heart rate elapsed time calories burned calories burned per hour watts METS resistance level rpm speed distance and workout profile Heart Rate Monitoring Integrated heat rate monitoring system with polar compatible wireless and contact HR Workout Programs Eleven Quick Start Manual Fat Burner Cal...

Page 6: ...ply remove the plug from the AC wall outlet 12 Do not let liquid enter the console If liquid does enter the console the console must be inspected and tested for safety by an approved technician before it can be used again 13 Never drop or insert any object into any opening on the machine 14 Keep the area underneath and around the machine clear 15 Do not operate where aerosol spray products are bei...

Page 7: ... Series Bike Please read all safety precautions and warning information prior to using your product Be sure to replace any warning label if damaged illegible or missing If you need replacement labels please call a Nautilus Representative at 800 628 8458 North America or 41 26 460 77 77 International office Label 2 Label 2 Label 1 Label 1 ...

Page 8: ...ot find or need to replace a warning label please call 1 800 628 8458 North America or 41 26 460 77 77 International office to obtain a new label Label 1 See Figure 1 for general warning label Location The warning label in Figure 1 is located on the side of the console mast Label 2 See Figure 2 for general exercise warning label Location Affixed to the console face below the keypanel Figure 1 Figu...

Page 9: ... Series Bike Service Manual Maintenance 1 Contents Maintenance Records 11 Resetting the Maintenance Hour Timer 11 Routine Maintenance 11 Checking the Battery Charge 11 Recharging the Battery Back up 12 Battery Disposal 12 ...

Page 10: ...10 ...

Page 11: ...lean towel to wipe off the dust which may have accumulated during shipping Your new machine will require minor assembly Refer to the Installation Instructions section for details Cleaning 1 DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANERS ON THE CONSOLE Clean the console daily with a water dampened cloth and wipe dry after cleaning 2 Clean the exterior of the machine daily using soap and ...

Page 12: ...pproximately 24 hours and then recheck it It is okay to use the machine while the battery charger is connected When the bike is not connected to an external power source the console will power on as the user starts to pedal machine and will stay lit for up to 60 seconds in pause mode The console will power off after 60 seconds of stopping exercise If the bike is connected to an external power sour...

Page 13: ...mmerical Series Bike Service Manual Console Codes 2 Contents Overview 15 Defaults 15 Customize 15 Machine Status 16 Diagnostics 17 Maintenance Logs 18 Reset Maintenance Hours 19 Error Log 19 Machine Configuration 20 ...

Page 14: ...14 ...

Page 15: ...ng with 8 Each group of codes is defined below Defaults You can customize several workout parameters on the R916 U916 Bike with default values to conform to your individual requirements including target heartrate 10 90 age 10 99 workout time 5 99 min workout level 1 20 weight 50 400 lbs or 25 180 kg Refer to the following table to scan through and customize the settings Table 2 1 Defaults Step No ...

Page 16: ...tion NOTE All error and history counter data Maint Hours Distance Workouts Run Hours Error Log and QA ID Number will be lost if Set Defaults is selected HR Inputs enables the various heart rate inputs that can be used Heart rate configurations include Locked Inputs both heart rate monitors are read until it detects a valid signal to lock on at which point the other HR inputs are ignored HAND HR PR...

Page 17: ...ower had to be cycled The message also appears when the console assembly has been replaced and no configuration established Configuring the machine will eliminate this message see the table Machine Configuration Distance displays the total distance in miles or kilometers of machine operation This value is auto incremented every 1 100th or 1 10th unit depending on how many miles km have accrued Wor...

Page 18: ...ectively AUX is scaled by 1000 and B is scaled by 300 These values will increase with the speed of the alternator note that both values will reach 0 if the alternator is left at rest The string is displayed at all times since the bikes do not require a magnetic key A Sensor B is used only on the ellipticals The A Sensor B diagnostic screen ensures the optical detector is functional The A value is ...

Page 19: ...ours lets the service technician enter a value representing the maintenance hours Table 2 7 Error Log Step No Press Keys Display What you will see 1 7 ENTER MAINTENANCE LOGS 2 ERROR LOG 3 ENTER NO ERROR or the highest priority error 4 or Scrolls through the error log list 5 CLEAR SELECT WORKOUT Error Log displays fatal errors accrued on the system The log holds up to 8 error entries Errors are han...

Page 20: ...machine type The choices are Stepper StepMill U R916 Elliptical In general only the U R916 machine type is used for the U916 or R916 Refer to the following table to scan through and customize the settings Table 2 8 Machine Configuration Step No Press Keys Display What you will see 1 8 ENTER CHANGE MACHINE 2 ENTER U R916 3 or NTM CONFIG RQD STEPPER CL STEPMILL ELLIPTICAL U R916 4 ENTER Selects your...

Page 21: ...in Power Wiring Diagram 23 U916 Console Heart Rate Wiring Diagram 24 R916 Console Heart Rate Wiring Diagram 25 General Bike Electronics Troubleshooting 26 Contact Heart Rate Testing 28 Battery Charge Testing 29 Alternator Testing 30 Start Up Circuit Testing 31 Load Resistor Testing 32 Shut Down Testing 33 ...

Page 22: ...22 ElectricalTroubleshooting ...

Page 23: ...tilus Commerical Series Bike Service Manual U916 R916 Main Power Wiring Diagram 2 7 2 5 7 4 30 3 3 2 84 0 7 2 7 4 44 29 2 3 34 2 4 2 4 2 5 2 AIN 0OWER 7IRING 46 7 2 7 4 U916 and R916 Main Power Wiring Diagram ...

Page 24: ...NT GRIP BLACK REAR GRIP 41700 CONSOLE 40679 001 5378 001 5378 NAUTILUS FIXED T BAR CONTACT HEART RATE GRIPS 41702 RIGHT LEFT TO BIKE POWER ELECTRONICS AND ALTERNATOR 25473 41187 TELEMETRY SENSOR 40466 RIGHT HANDGRIP 40465 LEFT HANDGRIP 001 6349 PCBA 001 6349 PCBA U916 Console Heart Rate Wiring Diagram U916 Console Heart Rate Wiring Diagram ...

Page 25: ...01 6349 PCBA LEVEL UP DOWN DISPLAY LOCK QUICKSTART RED FRONT GRIP BLACK REAR GRIP RED FRONT GRIP BLACK REAR GRIP 41703 CONSOLE TO BIKE POWER ELECTRONICS AND ALTERNATOR 001 5100 NAUTILUS R916 Console Heart Rate Wiring Diagram 41187 TELEMETRY SENSOR 41702 RIGHT LEFT 001 6349 PCBA 25473 001 5110 R916 Console Heart Rate Wiring Diagram ...

Page 26: ...tery voltage 6V or greater Yes No Perform general bike electrical testing Have a helper pedal bike at 25 RPM or greater Perform Battery Charge Testing On the 27451 PCB measure the voltage on J5 pins 1 and 10 Is voltage here 6V or greater Yes No Perform Start Up Circuit Testing 2 Does a heart symbol appear Yes No In 10S or less does the heart beat Yes No Perform Contact Heart Rate Testing This sect...

Page 27: ...red Approximately 1 minute after pedaling stops the console should shut off Did the console shut off Yes No Bike Is Operating Properly Perform Shut Down Testing 3 Remove 4 screws holding console to mast While noting locations carefully unplug all connections to console coming from mast Using OHM Meter perform continuity check on main interface cable using wire colors as a guide Is continuity OK Ye...

Page 28: ...ng locations carefully unplug the suspect Contact Heart Rate cable Using OHM Meter perform continuity check on cable using wire colors as a guide Is continuity OK Yes No Replace Contact Heart Rate cable Replace console Remove the screws securing the Contact Heart Rate plates Reverse the polarity of the plates wires Red should be on top black on bottom Have you had success previously with Contact H...

Page 29: ... external power supply first confirming AC voltage is present Remove the battery connector from the 27451 PCB at location J1 Is the voltage 6 8V 3 Yes Measure the voltage on the 27451 s J1 pins 2 and 3 Replace the battery No Replace the 27451 PCB Measure the voltage on test points 1 and 3 of the 27451 Is the voltage 9V 10 Yes No General bike electrical testing Unplug the external power supply cabl...

Page 30: ...ired Depending on the desired resistance level the console can control the alternator s output voltage by controlling the logic level of pin 7 of J5 on the 27451 PCB A logic low on pin 7 tells the 27451 to control at 7 8V or a logic high sets 9 8V If the alternator is not powering on first confirm the bike is cranked at 50 RPM and that pin 2 of J5 TP 11 is NOT high If it is and a workout has been ...

Page 31: ...e sensor Using the Battery Charge Testing section as a reference confirm operation of external power supply and external power cable 9V 10 measured on TP1 Yes No 8V measured on J5 1 Yes No Replace 27451 PCB General bike electrical testing Perform continuity check on main interface cable pins 1 and 10 Continuity OK Yes No Replace console Replace or repair main interface cable General bike electrica...

Page 32: ...No Is voltage present Yes Measure the voltage potential on the resistor terminals General bike electrical testing Resolve any loose connections and replace the resistor cable or the resistor is opened Is the resistance high Yes No Is the resistance low Yes Resolve any shorted connections in the resistor cable or resistor Replace the console No Measure the voltage potential on J5 pin 4 Is voltage l...

Page 33: ...uld turn off Does the console shut off No Is external power supplied Yes No General bike electrical testing It is normal for the 27451 PCB to keep the console powered if externally powered Measure the voltage potential of J5 pin 9 and 10 Yes Is this close to 0V Yes No Replace the 27451 PCB Replace the console General bike electrical testing ...

Page 34: ...34 ElectricalTroubleshooting ...

Page 35: ... Removing the Right and Left Pedals 39 Removing the Load Resistor 40 Removing the Battery 41 Removing the Power Board 41 Removing the Power Inlet Connector 42 Removing the Speed Sensor 43 Removing the Alternator 44 Removing the HTD Belt 46 Removing the Poly V Wheel 47 Removing Replacing Parts U916 Parts 48 Removing the Upper Handle Bar 48 Replacing the Upper Right or Left CHR Plates 48 ...

Page 36: ... Bar Right or Left CHR Plates 49 Removing the Seat Assembly 50 Removing the Side Covers 50 Removing Replacing Parts R916 Parts 51 Removing the Side Covers 51 Removing the Left and Right Rear Covers 52 Cable Connections U916 53 Cable Connections R916 56 ...

Page 37: ... top of the Mast so that you can connect the cables to the PC board Figure 2 For specific connector locations refer to the CABLE CONNECTIONS segment later in this section This section of the Service Manual provides instructions for removing and replacing parts of the U916 and R916 bikes The first segment contains procedures that apply to both bike models The second segment contains instructions sp...

Page 38: ...r the U916 only Remove the Upright Handlebar according to REMOVING THE UPPER HANDLE BAR procedure Step 3 Remove the right and left Mast covers with a phil lips screw driver See Figure 3a and 3b Step 4 For the U916 only Remove the Cupholder from the Mast with a phillips screwdriver see Figure 4 Step 5 Using a 8mm Allen wrench remove the four bolts securing the Mast to the bottom half frame See Figu...

Page 39: ...lace your left hand on the left pedal to stabilize it Step 2 Using a 15mm Wrench turn the pedal nut clockwise to loosen and remove the left pedal Figure 7 Step 3 Position yourself on the right side of the bike and place your right hand on the right pedal to stabilize Step 4 Using a 15mm Wrench turn the pedal nut counter clockwise to loosen and remove the pedal Figure 8 Figure 5b Unbolt mast from f...

Page 40: ... a 5 16 Nutdriver and Phillips screwdriver remove the hardware attaching the black and white wires of the Load Resistor cable from the tabs of the resistor See Figure 9a and 9b Step 3 Using a Phillips screwdriver remove the two mounting screws attaching the Load Resistor to the frame Figure 10a and remove the resistor Figure 10b Figure 9a Detach resistor wires U916 Figure 9b Resistor wires R916 Fi...

Page 41: ...p 3 Disconnect the black and white Battery cable from the Battery See Figure 12 Step 4 Lift and remove the Battery Figure 13 REMOVING THE POWER BOARD Tools needed Phillips screwdriver or Cordless drill with Phillips tip Step 1 Remove the right and left side covers according to the appropriate REMOVING THE SIDE COVERS procedure U916 and R916 Step 2 Disconnect the attaching cables from Power board S...

Page 42: ...and left side covers according to the appropriate REMOVING THE SIDE COVERS procedure U916 or R916 Step 2 Disconnect the cable end of the Inlet connector from J3 on the Power board See Figure 16 Step 3 Cut the cable tie from the wire bundle to remove the cable See Figure 17 Figure 14b Power board cables disconnected R916 shown Figure 15 Power board mounting screws Figure 16 Disconnect inlet connect...

Page 43: ...nnector See Figure 19a and 19b REMOVING THE SPEED SENSOR Tools needed Phillips screwdriver or Cordless drill with Phillips tip Wire cutters Step 1 Remove the right and left side covers according to the appropriate REMOVING THE SIDE COVERS proce dure U916 or R916 Step 2 Cut the cable tie from the wire bundle See Figure 20 Figure 18 Remove ground wire screw Figure 19a Remove mounting screws Figure 1...

Page 44: ...20 040 REMOVING THE ALTERNATOR Tools needed Phillips screwdriver or Cordless drill with Phillips tip Wire cutters Impact cordless wrench 15 16 socket and ratchet 6mm Allen wrench 8mm Allen wrench 9 16 socket Step 1 Remove the right and left side covers according to the appropriate REMOVING THE SIDE COVERS procedure U916 or R916 Step 2 Remove all the attached cables from the Alternator then detach ...

Page 45: ...4 Remove the Alternator Poly V belt by slowly walking off the belt in a clockwise motion Figure 25 Step 5 Remove the Flywheel and Fan disk Figure 26 Step 6 Using a 6mm Allen wrench 8mm Allen wrench and 9 16 socket with ratchet remove the two bolts that attach the Alternator to the frame See Figure 27a and 27b Figure 25 Figure 26 Figure 27a Remove alternator mounting bolts Figure 27b ...

Page 46: ...ed Phillips screwdriver or Cordless drill with Phillips tip 17mm Wrench 19mm Wrench Step 1 Remove the Side covers according to the appropriate REMOVING THE SIDE COVER procedure U916 or R916 Step 2 Using a 17mm wrench and 19mm wrench loosen the belt tensioner and slide upward along the slotted cut out Note Do not completely remove the screw See Figure 29a and 29b Step 3 Remove the belt and place a ...

Page 47: ...ench Snap ring pliers Step 1 Remove the Side covers according to REMOVING THE SIDE COVER procedure for the U916 or R916 Step 2 Remove the Alternator Poly V belt by slowly walking the belt off the Poly V wheel in a clockwise motion See Figure 31 Step 3 Using a 3 16 Allen wrench loosen and remove the four mounting screws See Figure 32 Step 4 Remove the Snap ring Figure 33 and pull off the Poly V whe...

Page 48: ...en screws attaching the Handlebar to the frame with a 6mm Allen wrench See Figure 34 Step 3 Carefully pull the cables out from the Mast Figure 35 Step 4 Reverse the steps to install a new Handlebar assembly on the machine REPLACING THE UPPER RIGHT OR LEFT CHR PLATES Tools needed 0 Phillips screwdriver Step 1 Carefully remove the two screws from the rear CHR plate and separate the plates See Figure...

Page 49: ...not to pinch the cable wires when reattaching the Front and Rear housings REPLACING THE LOWER T BAR RIGHT OR LEFT CHR PLATES Tools needed 0 Phillips screwdriver Step 1 Carefully remove the two screws from the rear CHR plate and separate the plates See Figure 40 Step 2 Disconnect the black CHR wire from the rear plate and place to the side Step 3 Disconnect the red CHR wire from the top plate and p...

Page 50: ...er or Cordless drill with Phillips tip Step 1 Position yourself on the left side of the bike and remove the 13 phillips screws from the left side cover See Figure 42 Step 2 Position the left pedal so the cover may be carefully lifted and removed See Figure 43 Step 3 Position yourself on the right side of the bike and remove the two phillips screws from the bottom of the right side cover Step 4 Pos...

Page 51: ...lace the covers to the side Step 2 Position yourself on the left side of the bike and remove the eight phillips screws from the left side cover See Figure 45 Step 3 Move the Seat Assembly back to the top position on the seat rail Position the left pedal so the cover may be carefully lifted and removed See Figure 46 Step 4 Position yourself on the right side of the bike and remove the one phillips ...

Page 52: ...ove the left and right Front covers according to the REMOVING THE LEFT AND RIGHT FRONT COVERS procedure Step 2 Position yourself on the left side and remove the 13 Phillips screws from the side cover then carefully lift and remove See Figure 49a and 49b Step 3 Position yourself on the right side and remove the three Phillips screws from the side cover then care fully lift and remove See Figure 50 ...

Page 53: ...w Wiring diagrams for the U916 console handles and main power are provided in Section 2 Main and TV Cables Frame to Front Mast Connect the attached long Wire Tie to the main and TV cables and use it to pull the cables up through the Mast Discard the Wire Tie after use NOTE TAKE CARE NOT TO PINCH CABLES WHEN ASSEMBLING WIRE TIE MAST MAIN FRAME Cables enter Mast Cables exit from Mast ...

Page 54: ...nter Mast through handlebar support arm Cables exit from Mast Connect the attached long Wire Tie to the handlebar cables and use it to pull the cables out through the Mast Discard the Wire Tie after use The main and TV cables are not shown for clarity NOTE TAKE CARE NOT TO PINCH CABLES WHEN ASSEMBLING ...

Page 55: ...ight Heart Rate Wire into the connector labeled P1 on the back of the console Plug the Left Heart Rate Wire into the P2 connector Plug the Center Heart Rate Wire into the P3 connector Gently push the excess wires back down into the mast NOTE If installing the optional LCD Monitor refer to the NV915 installation manual at this time If not installing the LCD Monitor wrap the end of the TV Cables wit...

Page 56: ...power are provided in Section 2 Main and TV Cables Frame to Front Mast Connect the attached long Wire Tie to the main and TV cables and use it to pull the cables up through the Mast Discard the Wire Tie after use NOTE TAKE CARE NOT TO PINCH CABLES WHEN ASSEMBLING CABLES WIRE TIE MAST MAIN FRAME Cables enter Mast Cables exit from Mast Cables exit from Mast Mast attached to Main Frame ...

Page 57: ...e is labeled with an R Plug the Right Heart Rate Wire into the connector labeled P1 on the back of the console Plug the Left Heart Rate Wire into the P2 connector NOTE If installing the optional LCD Monitor refer to the NV915 installation manual at this time If not installing the LCD Monitor wrap the end of the TV Cables with electrical tape and tuck them into the Mast Main Console Wire TV Cables ...

Page 58: ...s from the Handlebars to the cor responding connectors exiting the Seat Carriage NOTE Use caution as the Seat Assembly is not secured to the Seat Carriage It is easier to connect the cables if the Carriage is positioned toward the bottom of the the range To avoid damage to the Heart Rate Cables do not apply excessive force SEAT CARRIAGE HEART RATE CABLES CABLE CONNECTORS ...

Page 59: ...59 Nautilus Commerical Series Bike Service Manual Appendixes Contents Appendix A Required Tools 60 Appendix B Using a Multimeter 61 Appendix C International Power Plug Configurations 64 ...

Page 60: ...ral Wire cutters General 15mm Pedal Wrench Removing Pedals 8mm Allen Wrench Removing Installing crank bolts ISIS Crank puller Removing Crank Arms 17mm and 19mm open end wrench Adjusting timing belt tension Impact cordless drill Flywheel 3 16 Allen Poly V wheel 5 16 Nut driver Resistor cable 9 16 socket Alternator Snap Ring Pliers Intermediate Hub 5mm Allen Wrench Intermediate Pulley 6mm Allen Wren...

Page 61: ...eters are available in digital and analog models Digital meters give an output in numbers usually on a LCD Analog meters move a needle along a scale We recommend using a digital meter While analog meters can be very cheap they are difficult for beginner to read accurately especially on resistance scales Also the components are delicate and easily damaged Settings For the beginner the multimeter ca...

Page 62: ...asuring DC voltage output Set here to check AC voltage Black negative lead always goes here These are for checking amps and are not needed for our purposes Set here to check resistance ohms Or here to listen for an audible response useful when testing a sensor Set here to check AC or DC voltage Set here to check resistance ohms Set here for an audible response Black negative lead always goes here ...

Page 63: ... cause problems resulting in blown fuses or fried components 1 Set the multimeter to the lowest OHMs resistance range 2 Attach one test lead of the multimeter to one wire and check all adjacent wires This can all be done at one end of the cable However the other end of the cable must be disconnected from the circuit board All wires should be insulated from each other and therefore test open 3 Obse...

Page 64: ...64 International Power Plug Configurations Table B 1 International Power Plugs Power Cords System Country G UK C E F Europe J Swiss K Australia L Appendix ...

Page 65: ... consequential losses damages or expenses in connection with its exercise products Nautilus liability hereunder is expressly limited to the replacement of goods not complying with this warranty or at Nautilus election to the replacement amount of the purchase price of the exercise product in question Some states do not permit the exclusion or limitation of implied warranties or incidental or conse...

Page 66: ...66 ...

Page 67: ...ORATE HEADQUARTERS Nautilus Inc World Headquarters 16400 S E Nautilus Drive Vancouver Washington USA 98683 Phone 800 NAUTILUS CAN ADA OFFICE Nautilus Fitness Canada Inc 925 Keewatin Street Winnipeg MB Canada R2X 2X4 Phone 866 381 5996 Fax 800 532 6934 e mail nfcpartsandservice nautilus com INTERNATIONAL CUSTOMER SERVICE INTERNATIONAL OFFICE Nautilus International S A Rue Jean Prouvé 6 1762 Givisie...

Page 68: ... rights reserved Nautilus the Nautilus Logo ROC Remote Operation Control Be Strong StairMaster and StepMill are either registered trademarks or trademarks of Nautilus Inc All others are trademarks of their respective company Nautilus Inc World Headquarters 16400 SE Nautilus Drive Vancouver Washington USA 98683 1 800 628 8458 www Nautilus com Model U916 Model R916 ...