Nautilus Be Strong Commercial R916 User manual

Be Strong.®
003-3375-060309A
Rework Manual
Commercial Series Bike R916

Table of Contents
Products 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
Final Packaging……………………………………………………………………………………..25
Appendix............................……………………………………………………………………..34

Products Affected and Requiring Rework
R916 Recumbent Bike
Product SKU Made In Serial Numbers
Domestic 380002 Taiwan All
Domestic 380002 USA 38002071108001-38002081027017
International 380003 Taiwan All
International 380003 USA 38003080103001-38003081208036
Global 100154 Taiwan 1000154ACU0930001-100154ACU09030027
Tools Required
FISPs
Phillips head screw driver (#2 drive)s
Vice-gripss
Cloth towel/rags
15/16” socket and socket torque wrenchs
13mm socket and wrenchs
4, 5, 6 mm Metric Allen wrenchess
Snap ring pliers (for 25mm shaft)s
Rubber mallets
Bearing puller (for pulley removal)s
Adjustable Crescent wrench (for all nuts)s
6mm hex drive bit and torque wrench (may be same torque wrench as used with 15/16” socket)s
Cyanoacrylate adhesive (a.k.a.: CA, SuperGlue™, CrazyGlue™).s
3

Item PN Description Qty R
Bike
Kit
U
Bike
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 Pulley
1
6 SM40329 Flywheel, Cast, 5300 1
4

7
003-4716
Spacer, Seat, R916
4
9
8
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
003-3376-
060
U916 Rework Manual
1
9
5

PARTS LIST / BOX CONTENTS
PARTS LIST / BOX CONTENTS
REF # 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 Hardware Pack (not shown) 1
H
I
J
A
B
C
D
E
F
G
6

HARDWARE AND TOOL LIST
HARDWARE BAG - NOTE: ILLUSTRATIONS ARE NOT TO SCALE.
The Hardware Bag contains the following individual parts and tools.
Ref #1 Allen Head Bolt M10x25 Qty. 4
Ref #2 Spring Washer M10 Qty. 4
Ref #3 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
Ref #9 Flat Washer M8 Qty. 12
Ref #10 Allen Head Bolt M8 x 40 Qty. 4
Ref #11 Allen Head Bolt M8x20 Qty. 4
Ref #12 Phillips Head Screw M4x12 Qty. 1
Ref #13 6mm Allen Wrench / Phillips Screwdriver
Ref #14 8mm Allen Wrench
7

Step 1:
Locate the following for this step:
Parts:
sConsole Mast (B)
Hardware:
sRef #1 Allen Head Bolt M10x25 Qty. 4
sRef #2 Spring Washer M10 Qty. 4
sRef #3 Flat Washer M10 Qty. 4
Tools:
s8mm Allen Wrench
1-1 Connect the attached long Wire Tie (L) to the
main and TV cables (M) and use it to pull the
cables up through the 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 provide direction in assembling the base unit for the Nautilus® Commercial Series Bike model
R916. All instructions in the manual are given with the orientation of sitting on the bike facing the console. The console is
the front, while the seat is the back.
ASSEMBLY WITH SEAT CARRIAGE AND BRAKE
Figure 1:
B
L
M
N
1
2
3
8

ASSEMBLY GUIDE
Step 2:
Locate the following for this step:
Parts:
sDisplay Console (A)
Hardware:
sRef #5 Phillips Head Screw 1/4”x20 Qty. 4
sRef #6 Spring Washer M6 Qty. 4
Tools:
sPhillips Head Screwdriver
3-1 Plug the Main Console Wire (Q) into the large
Connector (J5 ) on the back of the Console.
(Figure 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 P2
connector. (Figure 4)
NOTE: If installing the optional LCD Monitor refer
to the NV915 installation manual at this
time. If not installing the LCD Monitor, tuck
the TV Cables (S) into the Mast.
3-4 Align the Console with the Mast, install two screws
only.
Figure 3:
A
O
S
P
5
Q
6
Figure 4: P1 P2
J5
9

Seat Carriage Assembly Spacers and Brake
Assembly
STEP 3A: Adding seat spacers to seat carriage for
brake pad 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\ProductSu
pport\Commercial\1-
Nautilus\Bikes\R916\BULLETIN
S\ServiceBulletins, # NLS R916
003.3209.SB.051509.B
10

STEP 3B: Checking and replacing linkage nuts.
Replace center Hex head
bolt with button head
screw 902-4274. Note B.
If the nuts
connecting the
linkage together
Check and replace if needed
with 003-3810 nylock nuts,
tools needed 10mm wrench
and a 4mm hex wrench
or not nylon lock
nuts they must
be replaced with
902-4141 nylock
nut three places.
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 sure one or both of the Brake Pads moves away from
the Brake Rail when the Handle is lifted. If they do not move,
loosen the three Nylock Nuts one-half turn until they do move.
STEP 3D: Reassemble. Replace all parts in reverse
order steps 15-14.
11
Note B: Add some grease to the top of the button head to reduce
friction with adjoining metal plate.

Step 4:
Locate the following for this step:
Parts:
sSeat Pad
Hardware:
sRef #
11 Hex Head Bolt M 8 x 20 Qty. 4
sRef # 9 S.S. Flat Washer M 8.5 Qty. 4
Tools:
s
6 mm Hex Wrench
6-1 Carefully Align the Seat Pad with the
Seat Carriage (T).
6-2 Install and completely tighten the hardware.
Note: Use caution during this step as the Seat
Assembly is 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 corresponding connectors
exiting the Seat Carriage (Figure 6).
6-4 Carefully place excess cable from Contact Heart
Rate cables in between the Seat and and the Seat
Carriage (Figure 6).
Note: To avoid damage to the Heart Rate Cables,
Do Not apply excessive force to the cables
while assembling connectors.
Figure 6:
U
T
ASSEMBLY GUIDE
11
9
12

perform
ftware upgrades on all C51/52 consoles / controllers using a FISP Dongle.
ed:
SOFTWARE UPGRADE PROGRAMMING INSTRUCTIONS
TREAD and NON-TREAD C51 and C52 CONSOLE/CONTROLLERS –
USING THE FIELD IN-SYSTEM PROGRAMMER (FISP) DONGLE
Occasionally it will be necessary to reprogram the console if there has been a software revision. Use these instructions to
so
Parts need
e
ce of XX when ordering. For example
Kit, FISP
•P/N 41375-7XX) programmed with the correct C51 program version (T9.14, EV9.16 etc). The version number should b
used in pla , if you need revision 3, then you would order p/n 41375-703. 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, then you would order p/n 41376-703. The kit
includes:
•
are available separate from the kit - use p/n 27834.
•1 x Programming Instructions (this document)
arts needed:
•1 x F.I.S.P.
1 x F.I.S.P. programming cable
Note: Replacement F.I.S.P. programming cables
P
it, F.I.S.P.
. Program the console
t goes into the idle stage and powers down. If the unit is a treadmill,
turn the circuit breaker switch to OFF.
K
F.I.S.P.
Programming
ribbon cable
F.I.S.P
A
1. Power OFF the console/controller. If the unit has a power supply, disconnect the power supply. If the unit is
battery operated, make sure that the uni
13

with the corresponding side of the F.I.S.P. dongle.
f the ribbon
ack of the C5X
console/controller. Plug the F.I.S.P. into the back of the console/controller.
NOTE: IF F ONG WAY.
MAKE SURE IT IS ORIENTED CORRECTLY.
tly. If the F.I.S.P. LED still does not turn on, replace the F.I.S.P. programming ribbon cable (p/n
27834).
2. Connect one side of the F.I.S.P. programming ribbon cable (doesn’t matter which side) to the F.I.S.P.
dongle. Match the keyed side of the cable connector
Keyed slot
3. Look at the end of the F.I.S.P. programming ribbon 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 10-pin connector on the b
ORCED, THE CONNECTOR CAN FIT THE WR
4. There is one Light Emitting Diode (LED) that can turn three different colors, depending on the
programming status. Power ON the console/controller. Verify that the LED on the F.I.S.P. turns YELLOW
for a few seconds and then starts to blink. If the LED does not turn on, verify that the connector is plugged
in correc
F.I.S.P. LED
Note: shown is a C40 non-
treadmill console. The
connection for a C51/C52
controller will look similar.
10-Pin connector
located here
14

If the LED turns RED, it indicates a failed program sequence. If
this happens, try the above process again.
ing cable
from the console/controller. Power does not need to be turned off prior to removing the cable.
. The C5X console/controller should display the machine configuration, status, and then the startup screen.
B. he console/controller for the correct exercise 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. programm
7
Configure t
TER], on the C5X console. The console will display “CHANGE MACHINE.” Press
[ENTER] again.
2. Press [^] until “BIKE,” Rev B shows on the display. Press [ENTER] to select that machine type.
4] [ENTER] then [INC or DEC] on
the C5X console. The console will display “CONS 4137X-0XX.”
1. Press [^], [8], [EN
3. Verify that the correct software version is in the console. Press [^] [
15

the left and right side of bike.
STEP 2: Removing flywheel from alternator
C. Flywheel Intermediate Hub Assembly, Belt and
Pullet Replacement
STEP 1: Remove the Phillips head 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
broken loose.
Using a 15/16 socket and ratchet turn
the flywheel nut counter clockwise to
remove, tap the back side of the
flywheel or pull to remove it from
the shaft.
16

Remove the belt and black intermediate pulley.
ediate shaft.
STEP 3:
Remove the four
902-5665 screws
from the
intermediate shaft
using a 5mm 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 head cap has
been broken loose, remove
the belt from the crank
pulley by turning the crank
clockwise and working the
b
elt off the ed
g
e.
17

Caution: Beware of sharp edges on intermediate shaft.
STEP 5: Removing pulley 000-6214 and snap ring
STEP 7: Installing new intermediate shaft.
from the intermediate shaft.
Remove external snap ring from
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 inserted
straight or it will bind, using a
rubber mallet tap the shaft
through the bearings until snap
ring grove is exposed on the
opposite side. Important: mallet
must only contact the end of the
shaft.
18

STEP 8: Reattach the snap ring to the intermediate shaft.
.
Make sure the Snap Ring is
closed and seated 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. Get 902-
4725 Screw, 902-6024 Flat Washer, 902-
6027 Flat Washer and secure the Pulley
to the Shaft.
19

rank pulley and intermediate shaft.
Torque intermediate pulley screw to 20 ft. lbs.
STEP 11: Install new intermediate 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, and (4) 27579 Lock
Washers.
Hand start the Screws and Washers into the
Pulley.
Tighten using a 5mm hex wrench.
20