Nautilus E614, Service Manual

Page 1: ...le 18 5 Static Handlebar and Water Bottle Holder 20 6 Upper and Lower Handlebar Arms 22 7 Pedals and Legs 25 8 Front Stabilizer 27 9 Lift Assembly and Rail Assembly 29 10 Transport Wheels Front Endcaps and Footpads 34 11 Shrouds 36 12 Console Mast 41 13 Data Cable in the Mast 44 14 Brake Assembly 48 15 Servo Motor 51 16 Drive Belt and Flywheel Assembly 54 17 Tensioner Assembly Idler Assembly 57 18...

Page 2: ...equest 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 This product contains magnets Magnet...

Page 3: ...les avertissements avant d utiliser cette machine Soyez prudent lorsque vous utilisez cet équipement pour ne pas vous infliger de gravesblessures Cette machine supporte un poids maximal de 300lbs 136kg Remplacez toute étiquette d avertissement endommagée illisible ou manquante La fréquence cardiaque qui s affiche sur la console est une approximation et doit être utilisée seulement à titre indicati...

Page 4: ...roleum based products Monthly or after 20 hours Make sure all bolts and screws are tight Tighten as necessary NOTICE Do not clean with a petroleum based solvent or an automotive cleaner Be sure to keep the Console free of moisture FCC Compliance Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user s authority to operate the equipm...

Page 5: ...lliptical Abrupt motions can affect the computer operation Leveling the Machine The machine needs to be leveled if your workout area is uneven or if the Rail Assembly is slightly off the floor To adjust 1 Place the machine in your workout area 2 Safely stand on the back of the Rail Assembly for approximately 20 seconds 3 Step off the machine 4 Loosen the locking nuts and adjust the levelers until ...

Page 6: ...ave difficulty with dried out or calloused hands A conductive electrode cream heart rate cream can help make better conduct These are available on the web or at medical or some larger fitness stores Static Handlebar If tests reveal no other issues Static Handlebar should be replaced No speed RPM reading Console displays Please Stride error code Check data cable integrity All wires in cable should ...

Page 7: ...all hardware on the Stabilizers and the base of the Console Mast Foot pedals loose unit difficult to operate Hardware Tightly secure all hardware on the Pedal Arms and Handlebar Arms Drive train click tick noise once per full crank revolution Check crank pulley assembly Disconnect left and right foot assemblies and rotate crank If sound persists replace crank pulley assembly If sound does not come...

Page 8: ...etting Push the Increase Decrease buttons to change between ON and OFF 11 Push OK to set 12 The Console display shows the TOTAL RUN HOURS for the machine To go to the next Console Setup Mode prompt push the OK button To enter the Manufacturing Menu MFG Menu hold down the PAUSE END button and Down button together for 3 seconds The Console display shows the Firmware Version string Push the Up Down b...

Page 9: ...et individual segments one at a time until all segments are illuminated Press any key to exit i RESET CONSOLE Resets the data from user inputs The Console setup user records and workout records will be reset to defaults This option does not reset MFG NVM non volatile memory 13 The Console display shows the Software Version prompt 14 For the next prompt push the OK button 15 The Console will displa...

Page 10: ...onsole Cable Upper Q Shroud Left DD Drive Pulley E Arm Pivot Rod R Console Cable Lower EE Speed Sensor Magnet F Console Mast S Incline Assembly FF Speed Sensor G Water Bottle Holder T Frame Assembly GG Flywheel H Handlebar Arm Lower Right U Front Stabilizer HH Servo Motor I Handlebar Arm Upper Right V Rail Assembly II Brake Assembly J Pedal Arm Right W Crank Assembly Left JJ Power Inlet K Crank As...

Page 11: ...UIRED C AU T I O N To reduce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wall outlet and wait 5 minutes before cleaning maintaining or repairing this machine Place the power cord in a secure location When disposing of old parts obey the applicable local and provincial requirements For instructions to replace the following parts please r...

Page 12: ...rs 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 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 pa...

Page 13: ...e Figure 2 It should turn only 90 degrees 1 4 turn to vertical If the tension is correct go to Step 6 If the tension is too loose or too tight adjust the nuts and bolt on the Tensioner Assembly Idler Assembly Continue to Step 3 To reduce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wall outlet and wait 5 minutes before cleaning maintaini...

Page 14: ... the crank arm and check the movement of the drive belt The Crank Arms and Flywheel should move as one Be sure to keep fingers clear of all pinch hazards when you turn the Drive Pulley Adjust the belt tension again if necessary 6 Reassembly is the reverse procedure NOTICE Be sure not to crimp any cables 7 Final Inspection Inspect your machine to ensure that all hardware is tight and components are...

Page 15: ...he 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 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 ...

Page 16: ... 5 x 10 cardboard between the Brake Magnet A and the Flywheel B and tape the cardboard to the Brake Magnet Note Be sure the cardboard covers all of the Brake Magnet 4 Turn the power on again Machine is on Current is active There is risk of electrical shock 5 Use the console to set the resistance to the highest level This moves the Brake Magnet Arm A1 forward After the Brake Mag net Arm stops at th...

Page 17: ...y attaching the Shrouds remove the cardboard from between the Brake Magnet A and the Flywheel B Power up the machine to verify that the Magnet Arm can move freely and that the Brake Magnet and Flywheel do not touch 8 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 fo...

Page 18: ...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 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 awkwa...

Page 19: ...rrect performance in accordance with the Owner s Manual Initial Setup During the first power up the Console should be set up with the date time and your preferred measurement units 1 Date Push the Increase Decrease buttons to adjust the currently active value flashing Push the Left Right buttons to change which segment is the currently active value month day year 2 Push OK to set 3 Time Push the I...

Page 20: ...e 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 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 heav...

Page 21: ...onsole Mast Use a rubber band or wire tie This step may require two people 3 Using a Phillips screwdriver remove the 3 indicated screws and remove the Water Bottle Holder 4 Using a 6 mm hex key remove the 3 indicated bolts and remove the Static Handlebar NOTICE Do not crimp the cables when removing the Static Handlebar Do not allow the cables to fall down into the Console Mast Use a rubber band or...

Page 22: ...nician 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 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 s...

Page 23: ...ot match the image For reference only 1 E616 only loosen and remove the 4 screws from the Handlebar Shrouds Remove the Handlebar Shrouds and set them safely aside 2 Using a 6 mm hex wrench remove the 8 indicated bolts from the Upper Handlebar Arms 3 Remove the Upper Handlebar Arms and set them safely aside 4 Using a 6 mm hex wrench and a 13 mm wrench remove the 2 indicated bolts from the Lower Han...

Page 24: ...e Handlebar Arms and set them safely aside 7 Installation is the reverse procedure Make sure the Upper Handlebar Arms are secure before you exercise 8 Discard the old parts 9 Inspect your machine to ensure that all hardware is tight and compo nents 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 25: ...chnician 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 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...

Page 26: ...Using a 6 mm hex wrench remove the indicated bolts from the Pedal and Lower Handlebar Arm Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed 3 Remove the Pedal 4 Using a 6mm hex key loosen and remove the indicated hardware and remove the Leg 5 Repeat steps on opposite side 6 Installation is the reverse procedure 7 Discard the old parts 8 Inspect your machine ...

Page 27: ... 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 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 t...

Page 28: ...ont Stabilizer 3 Installation is the reverse procedure 4 Dispose of the old part 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 6mm X2 To reduce the risk of electrical shock or unsupervised usage of the equipment always...

Page 29: ...ders 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 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...

Page 30: ...o the desired height In order to avoid possible serious injury when lowering the Rails be careful to avoid fingers or hands being caught or pinched c Release the Incline Release Button Push down on the Pedals to be sure the Rails are secured by the Incline Assembly If you are only replacing the Lift Assembly carefully lift the Leg and Pedal together to move the Roller off the Rail and set it on th...

Page 31: ...m the Lower Handlebar Arms 4 Using a 13 mm wrench remove the hardware from the Lower Handlebar Arms and the Arm Pivot Rod Remove the hardware Upper and Lower Handlebar Arms and Arm Pivot Rod Set them safely aside for reassembly 5 Using a 6mm hex key loosen and remove the indicated hardware from the Legs and set it safely aside for reassembly On each side of the machine remove the Leg and Pedal tog...

Page 32: ...e the four bolts that attach the Rail Assembly to the Frame Assembly Be aware that the Frame Assembly may be unstable and slightly top heavy 9 Remove the Rail Assembly 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 safely NOTICE This step may require two people 10...

Page 33: ...en placing or removing the Arm Pivot Rod 12 Using a 6 mm hex key and a 13 mm wrench reinstall the Legs and Pedals Arm Pivot Rod and Upper and Lower Handlebar Arms NOTICE This step may require two people Make sure the Upper Handlebar Arms are secure before you exercise 13 Dispose of the old parts 14 Inspect your machine to ensure that all hardware is tight and components are properly assembled Do n...

Page 34: ... 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 warning st...

Page 35: ...abi lizer D Set the Endcap and screw safely aside 4 Using the 6mm hex key and 13mm wrench loosen and remove the hardware C1 from the old Transport Wheel assembly C Remove the old Transport Wheel from the front stabilizer bracket D1 Set the Transport Wheel and hardware safely aside 5 Installation is the reverse procedure NOTICE Before fully attaching the Endcap be sure that the Transport Wheel can ...

Page 36: ...ildren 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 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 n...

Page 37: ... and a 13 mm wrench remove the 2 indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 2 Using a small flathead screwdriver pry the Caps from the Lower Handlebar Arms 3 Using a 13 mm wrench remove the hardware from the Lower Hand...

Page 38: ...ud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Top Shroud up the Mast If you are not replacing the Top Shroud go to Step 7 If you are replacing the Top Shroud continue to Step 6 6 Remove the hardware indicated from the Mast Gently pull the Mast out and disconnect the cables Set the hardware Mast and Top Shroud safely aside NOTICE Do not crimp the cables This st...

Page 39: ...olt CP1 of the Crank Puller is flush with the Nut CP2 as shown before use 10 Using a wrench turn the inner portion CP3 of the Crank Puller clockwise The Crank Arm with Plastics will slide off as it is tightened 11 Using a 2 Phillips screwdriver loosen the 7 indicated screws from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Left Shroud NOT...

Page 40: ... cables Note Self tapping screws attach the Shrouds to the Frame No screws hold the Lift Cover Shroud in position Reach through the left or right side opening to stabilize it while installing the screws Be sure the tabs in the Top Shroud snap into the Main Assembly Installation does not require the use of the crank puller Be sure the Crank Arms are connected at 180 from each other 15 Dispose of th...

Page 41: ... 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 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 y...

Page 42: ...e image For reference only 1 Remove screws that attach Console to the Mast Carefully lift the Console off the Mast 2 Disconnect the cables from the back of the Console Set the Console and screws safely aside for reassembly 3 Using a 6 mm hex key remove the 3 indicated bolts and remove the Static Handlebar Set the hardware and Static Handlebar safely aside for reassembly NOTICE Do not crimp the Hea...

Page 43: ... from the Mast Gently pull the Mast out and disconnect the cables Set the hardware and Top Shroud safely aside for reassembly Discard the Mast NOTICE Do not crimp the cables Do not allow the Data Cable to fall down into the Main Unit This step may require two people 8 Installation is the reverse procedure NOTICE Do not crimp the cables Do not allow the Data Cable to fall down into the Console Mast...

Page 44: ...ian 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 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 step...

Page 45: ...e image For reference only 1 Remove screws that attach Console to the Mast Carefully lift the Console off the Mast 2 Disconnect the cables from the back of the Console Set the Console and screws safely aside for reassembly 3 Using a 6 mm hex key remove the 3 indicated bolts and remove the Static Handlebar Set the hardware and Static Handlebar safely aside for reassembly NOTICE Do not crimp the Hea...

Page 46: ...aside for reassembly 6 Bend the edges of the Top Shroud to disengage the inside tabs from the Main Assembly and slide the Mast Boot and Top Shroud up the Mast 7 Remove the hardware indicated from the Mast Gently pull the Mast out and disconnect the cables Set the hardware and Top Shroud safely aside for reassembly NOTICE Do not crimp the cables Do not allow the Data Cable to fall down into the Mai...

Page 47: ...the Mast NOTICE Do not crimp the cables 10 Connect the new Data Cable to the Data Cable from the Main Frame NOTICE Do not crimp the cables This step may require two people 11 Reassembly is the reverse procedure NOTICE Do not crimp the cables Untie the string from the Data Cable Do not allow the cables to fall down into the Console Mast Be sure the tabs in the Top Shroud snap into the Main Assembly...

Page 48: ...ildren 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 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 n...

Page 49: ...w Brake Magnet Be sure the cardboard will completely cover the new Brake Magnet before installation NOTICE Do not crimp the cables 7 Before fully attaching the Shrouds remove the cardboard from between the Brake Magnet A and the Flywheel B Power up the machine to verify that the Magnet Arm D can move freely and that the Brake Magnet and Flywheel do not touch at the maximum resistance level Machine...

Page 50: ...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 After replacing the Brake Assembly the resistance levels of the machine may be different The user should adjust their workout levels accordingly ...

Page 51: ...ll times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders 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 Nautilus replacement p...

Page 52: ...our machine Disconnect the Speed Sensor Cable D and Power Inlet Cable E from the wiring harness 6 Tie the length of string to the end of the lower Console Cable G at the top of the Mast mount Remove the zipties that attach the lower Console Cable to the Frame Pull the cable and string down through the hole H on the side of the Frame so that the string extends through the Frame 7 Untie the string f...

Page 53: ...s on Current is active There is risk of electrical shock 14 Use the console to set the resistance to the highest level Unplug the machine Disconnect all power and allow to sit for 5 minutes 15 Put the Brake Arm K back in position and connect the Tension Spring J with the needlenose pliers Note Before fully attaching the Shrouds remove the cardboard from between the Brake Magnet B and the Flywheel ...

Page 54: ...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 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...

Page 55: ...place the Shrouds procedure 2 Insert 2 5 x 10 cardboard between the Flywheel A and the Brake Magnet B and tape the cardboard to the Brake Magnet Note Be sure the cardboard covers all of the Brake Magnet 3 Observe the position of the Tensioner Assembly C on the Frame upright F and mark the position on the Tensioner Assembly Measure or mark a piece of scrap paper the adjustment length of the Tension...

Page 56: ...the Flywheel axle A2 in the Main Frame brackets F Hand tighten the hardware from step 4 on each end of the Flywheel axle 12 Put the Drive Belt H onto the Drive Pulley G Make sure the Drive Belt is aligned on the Flywheel pulley A1 Belt Tensioner C3 and Drive Pulley 13 Before you fully tighten the Flywheel hardware I adjust the Tensioner Assembly C to the position marked in step 3 and tighten the h...

Page 57: ...p 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 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 repl...

Page 58: ...taches the Tensioner Assembly B to the frame upright Note Use the hex key to hold the bolt A in place on the outside and turn the nut from the inside 5 Remove the Tensioner Assembly B from the Frame Assembly and the Drive Belt 6 Installation is the reverse procedure Note Be sure to adjust the replacement Tensioner Bolt D and nuts C to the previous length 7 Dispose of the old parts 8 Inspect your m...

Page 59: ... 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 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 o...

Page 60: ...a 2 Phillips screwdriver remove the indicated bolt B from the RPM Sensor Assembly C Note The Speed Sensor Magnet D is on the Drive Pulley Assembly 4 Remove the RPM Sensor Assembly C and replace with the new assembly 5 Installation is the reverse procedure NOTICE Do not crimp any cables Be sure the routing for the new RPM Sensor cable A and other wiring is correct to prevent interference from movin...

Page 61: ...standers 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 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 replacem...

Page 62: ...sconnect the Power Inlet cable A from the wiring har ness B on the Servo Motor 3 Using a 17mm wrench loosen and remove the thin Nut from the Power Inlet C on the outside of the front of the Frame NOTICE Do not crimp the cable 4 Pull the Power Inlet plug C out of the hole toward the inside of the main unit Discard the old Power Inlet assembly 5 Installation is the reverse procedure NOTICE Do not cr...