Nautilus ONE User manual

Nautilus®Bowflex®Schwinn®Fitness Pearl Izumi®StairMaster®Universal®Nautilus Institute®
Service Manual
001-7147-120507A
Nautilus ONE™

Table of Contents
Safety Warnings ...........................................................................................................................1
Exploded Views ...........................................................................................................................2
Service Procedures......................................................................................................................5
Tower Shroud Removal ..............................................................................................5
Tower Shroud Installation ..........................................................................................7
Weight Drive Installation/Removal ............................................................................9
Screw Belt Adjustment ............................................................................................. 11
Bottom Loading Gas Spring Replacement..............................................................12
Knob Removal ........................................................................................................... 18
Contact Information .................................................................................................................. 19
Required Tools
1) 9/16" Socket Wrench
2) 3/4" Socket Wrench
3) Torque Wrench
4) 9/16" Wrench
5) Adjustable Wrench
6) 5/32" Hex Wrench
7) 5/16" Hex Wrench
8) 7/32" Hex Wrench
9) 1/4" Hex Wrench

Safety Warnings
This icon means a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Obey the following warnings:
Read and understand all Warnings on this machine. Specific Caution, Warning and/or Danger decals may be
applied to call attention to specific hazards.
• Carefully read and understand the Service Manual before you work on the machine. Failure to follow
instructions and safety warnings could result in injury to service technician or bystanders.
• Damaged machines or machines under repair must be marked as “Out of Service”, set aside and
prohibited from being used by customers or others.
• Keep bystanders and children away from the product being serviced at all times.
• Make sure that repair is done in an appropriate work space away from foot traffic and exposure to
unauthorized personnel.
• Adjustments and repairs to Nautilus equipment must only be performed by a professional service
technician trained to service Nautilus equipment.
• Some components of the equipment may be heavy or awkward. Use a second person or other
resources when performing maintenance steps involving these parts. Do not perform steps that require
heavy lifting or awkward movement on your own.
• Use only genuine Nautilus replacement parts and hardware. Failure to use genuine replacement parts
may cause a risk to users, keep the machine from operating properly, or void the warranty.
• Make sure that all warning stickers and instructional placards on the machine stay attached and are in
good condition. Request replacement warning stickers or placards if necessary from Nautilus customer
service.
• Do not attempt to modify the design or functionality if the machine. This could compromise user safety
and may void the warranty.
• Do not place the machine back in service until the machine, shrouds, instructions, warning labels and
have been verified and tested for proper performance.
• If you any questions regarding the Service Manual or the servicing of our equipment, please contact
qualified Nautilus personnel immediately.
Service Manual
1

Service Manual
2
WT-SYS-250-5 Weight Tower View #1
Top Cap
Placard Lens
Rear Shroud
Center Cap
Inside Shroud
Outside Shroud
Weight Select Knob Assembly
NLS ONE™ 3” Dome Decal (000-6491)
Belt and Cam Assembly
Frame and Engine Mounts
Graphic Bezel
Nautilus ONE™ Back Dome
Engine WT-250-5
Exploded Views
Assembly Manual
2

Service Manual
3
WT-SYS-250-5 Weight Tower View #2
Exploded Views
Service Manual
3
Rear Shroud
Front Tower Foot Pad
Graphic Bezel
Outside Shroud
Center Cap
Inside Shroud
Rear Tower Foot Pad
Placard Lens
Top Cap
Button Head Socket Cap Screw 1/4" - 20 x 3/4"
Button Head Socket Cap Screw 1/4" - 20 x 3/8"

Exploded Views
Weight Selection Knob Assembly
Weight Selection Front Bezel
Number Wheel
Number Wheel Base
Add-on Weight Lever
Weight Selection Backing Plate
BH Bolt 1/4"-20 UNC X
Wheel Adjustment Screw #8 x 1/2"
#8 Steel Washer Plastic Washer 1.0 ID
x 1.5 OD x 0.0625 L
IGUS Bushing 1" ID x 1/2"
IGUS Bushing 1" ID x 1/2"
Steel Washer 1.0" ID
WT-SYS-250-5 Weight Selection Assembly
Service Manual
4

Nautilus ONE™ Tower Shroud Removal
Tools Required: 9/16” Socket Wrench
9/16" Wrench
5/32" Hex Wrench
Remove the Top Cover
1-1 Remove the two mounting screws on the rear of the
top cover with a 5/32" Hex wrench (Figure 1).
1-2 Remove the cover by lifting the rear edge up and
forward to clear the front slot (Figure 2).
Remove the Handlebar
2-1 Remove the (4) 3/8" hex head bolts, (4) lock washers
and (4) lock nuts with a 9/16" socket wrench.
2-2 Carefully lift the handlebar and place aside
(Figure 3).
Remove the Rear Shroud
3-1 Remove one screw at the top of the shroud with a
5/32" Hex wrench. Lift up and out of the bottom slot
(Figure 4).
(Shroud Removal continued on next page)
Figure 1
Service Procedures
Figure 2
Figure 3
Figure 4
Service Manual
5

Nautilus ONE™ Tower Shroud Removal (cont.)
Remove the Outside Shroud
Note: The large round bezel does not need to be removed from
the outside shroud.
4-1 Lift the shroud up until the tabs stop at the top of the
P-slot (Figure 5).
NOTICE: Do not attempt to remove shroud by prying with any
kind of tool.
4-2 Pull shroud outward to remove from the P-slots (Figure 6).
Remove the Inside Shroud
5-1 Remove the center cap behind the dial. Adjust the dial to
the lowest setting and lift the dial up and out of the way.
Unsnap the center cap out of the shroud opening tabs
(Figure 7).
5-2 Lift the shroud up until the tabs stop at the top of the
P-slot.
5-3 Pull the shroud outward to remove it from the P-slots
(Figure 8).
P-Slot
Figure 5
Service Procedures
Figure 6
Figure 7
Figure 8
Service Manual
6

P-Slot
Nautilus ONE™ Tower Shroud Installation
Attach the Rear Shroud
1-1 Put Rear Shroud into the Bottom slot and secure with one
screw at the top.
Attach the Inside Shroud
2-1 Put Inside Shroud into P-slots in the Steel Frame and fit
the adjustment knob assembly through the center hole of
the shroud.
2-2 Insert front and back tabs into the P-slot openings (See
Fig. 1).
2-3 Push down on both front and back to seat tabs at the
bottom of the P-slots.
NOTICE: Do not attempt to force the shroud downward or
tabs may be broken off. When the tabs are aligned
to the P-slots, the cover should drop down into the
slots with minimal resistance.
2-4 I nstall the center cap behind the dial. Adjust the dial to
the lowest setting and lift the dial up and out of the way
(Figure 2). Snap the center cap into the shroud opening
tabs. Make sure to align the cap to the open ring.
Attach the Outside Shroud
3-1 Put Outside Shroud into the P-slots in the Steel Frame.
3-2 Push down on both front and back to seat tabs at the
bottom of the P-slots. When the tabs are aligned to the
P-slots, the cover should drop down into the slots with
minimal resistance.
3-3 Align and attach the tab/slot where the front of both side
shrouds meet at the top of the front post.
NOTICE: Do not attempt to force the shroud downward or
tabs may be broken off.
Attach the Handlebar Assembly
4-1 Position the handle bars over the plastic shrounds (Figure 3).
4-2 Attach the handlebar with (4) hex head bolts, (4) lock
washers and (4) lock nuts.
Attach the Rear Shroud
5-1 Position the handle bars over the plastic shrounds (Figure 4).
Service Procedures
Figure 1
Figure 2
Figure 3
Figure 4
Service Manual
7

Nautilus ONE™Tower Shroud Installation
(cont.)
Attach the Top Cover
6-1 Lower the top cover onto side shrouds making sure that
the tops edges of both side shrouds fit securely into
the slots on each side of the top cover (Figure 5and 6).
Note: Push inward on the top edge of the length of both side
shrouds to assure the top cover is securely attached.
If you can push the shroud inward, it is not in the slot
and needs to be installed again.
6-2 Install the two mounting screws on the rear of the top
(Figure 7).
Note: Overtightening the shield screws may cause the top
shield to crack.
Figure 6
Figure 7
Figure 5
Service Manual
8

3
1
2
Return plates to:
Nautilus Inc.
709 Powerhouse Rd.
Independence, VA
24348
Seat Frame
Weight Drive
Seat Frame
Plate
Weight Drive Installation/Removal
Tools Required: 3/4” Socket Wrench,
AdjustableWrench
Installation Tip: Inspect the seat frame movement
arm(s) before assembly to the weight tower. If the
movement arm(s) are not resting firmly against the rubber
stop(s), reduce belt tension as necessary. The movement
arm must rest against the rubber stops to ensure proper
initial weight drive to seat frame assembly and jackshaft
timing. Belt tensioning procedures are located on Page 11
of this service manual.
1-1 Remove (3) 1/2-13 x 3” bolts from the Tower with
3/4” socket wrench (Figure 1).
1-2 Remove the Weight Drive Support from the Seat
Frame by removing (4) 1/2-13 x 1 1/4” bolts and
(4) 1/2-13 Lock Nuts with 3/4” socket wrench and
adjustable wrench. Discard (1) bolt and (1) nut
(Figure 2).
NO. PART NO. DESCRIPTION QTY.
156-0161 WEIGHT DRIVE SUPPORT 1
201-1331 BOLT HH 1/2-13 X 3” 3
301-1271 BOLT HH 1/2-13 X 1 1/4” 4
403-1055 LOCK NUT 1/2-13 4
1
2
4
3
3
Seat Frame
Weight Drive
Weight Drive
Support
Tower
Weight Drive
Service Procedures
Figure 1
Figure 2
Service Manual
9

Service Procedures
Weight Drive Installation/Removal
(cont.)
1-3 Align the Seat Frame Weight Drive holes to Tower
Weight Drive holes and pins. Insert (3) 1/2 x 1 1/4”
bolts into weight drive and (3) 1/2 x 3” bolts into
seat frame plate. Carefully align Seat Frame to the
Tower and tighten all bolts (Figure 3).
Note: Confirm that the movement arm is at rest
against the rubber stop(s). If the movement
arms are not resting on the rubber stops, then
reduce seat frame belt tension (see page
11). Ensure that the Weight Drive belt cam
is resting against the cam stop. If it is not at
rest, then refer to "Troubleshooting Steps" on
this page to reduce Weight Engine Drive belt
tension. Make sure that the dial selects and
engages the weight plates.
1-4 Reverse steps 1-1 through 1-3 for Weight
Drive removal.
Troubleshooting Steps
Tools Required: 3/8" wrench
2-1 If the dial does not select and engage the
weight plates, the Weight engine Drive Belt
may be too tight.
2-1.1 Ensure clearance is 1/8" between the weight
hooks and the weight plate hooks (Figure 2,
page 11).
2-1.2 Refer to the "Remove the Top Cover"
instructions (steps 1-1 through 1-2) on page
5 of this Service Manual.
2-1.3 With the top cover removed, loosen (do not
remove) the two Belt Clamp Retaining Bolts
with a 3/8" wrench (Figure 2, page 11).
2-1.4 Turn the weight selection dial to the minimum
resistance setting and lift the weight drive engine
assembly up several inches by the dial assembly.
2-1.5 Release the knob to allow the work box to
drop. This should allow the belt to "slip" in
the clamp, reducing tension on the Weight
Engine Drive Belt.
Figure 3
Weight Drive belt cam stop
Service Manual
10
2-1.6 Turn the weight selection dial to several different
resistance settings to confim the dial now engages
the weight plates.
2-1.7 Tighten the two Belt Clamp Retaining bolts with a 3/8"
wrench. Confirm that the weight selection dial will
select and engage the weight plates.
2-1.8 Replace the top cover.
2-2 If the movement arms do not rest fully against the
rubber stop(s) in the starting position, the Weight
Engine Drive (steps 2-1-1 through 2-2-8) will be the
steps to correct.

Service Procedures
Articulating
Clamp Mount
5/16" Hex Wrench
Sliding Belt
Adjustment Clamp Button Head Belt
Adjustment Bolt
Seat Frame
Belt Cam
Seat Frame Belt Cam Adjustment
Tools Required: 5/16" Hex Wrench
1-1 Use a 5/16" Hex Wrench to tighten or
loosen the Button Head Belt Adjustment
Bolt.
Note: Turning the screw clockwise increases
tension. Turning the screw counter
clockwise reduces tension (Figure 1).
Note: Increasing tension on the belt tensioning
screw tightens not only the seat frame belt
and proportionately increases tension on
the weight engine drive belt. Excessive belt
tension will cause weight hook to weight
plate hook malfunctions. (Figure 2).
Figure 1
Figure 2
Weight Engine
Drive Belt
Weight Hooks
Weight Plate
Hooks
Maintain proper
clearance of 1/8"
between the
Weight Hooks and
weight Plate Hooks
3/8" Belt Clamp
Retaining Bolts
Service Manual
11

Service Procedures
Bottom Loading Gas Spring Replacement
These procedures apply to the following units:
• Nautilus ONE™ Mid Row (S6MR)
• Nautilus ONE™ Lat Pull (S6LATP)
• Nautilus ONE™ Chest Press (S6CP)
• Nautilus ONE™ Shoulder Press (S6SP)
• Nautilus ONE™ Bicep Curl (S6BC)
• Nautilus ONE™ Tricep Extension (S6TE)
Tools Required:
•9/16" Socket and Ratchet
• 7/32" Hex Wrench
• 1/4" Hex Wrench
1-1 Remove (2) 3/8" upholstery bolts with a 9/16" Socket and
Ratchet.
1-2 Remove the seat pad by pulling it upwards (Figure 1).
1-3 Remove the release handle shoulder bolt with a 1/4" Hex
wrench and a 9/16" Socket and ratchet (Figure 2).
1-4 Remove the handle.
Figure 1
Figure 2 Remove using a 1/4"
Hex head wrench and
9/16" socket and ratchet
Service Manual
12

Service Procedures
Figure 3
Figure 4
1-5 Remove the top 7/32" Hex head screw with a 7/32" Hex
Wrench (Figure 3).
1-6 Remove the bottom 7/32" Hex head screw while supporting
the seat bracket with your free hand (Figure 4).
Service Manual
13

Service Procedures
Note: It is neccessary to disassemble the seat frame from the
weight stack. This will allow the service personnel to
access the gas spring assembly. Please refer to pages
9 and 10 of this service manual for the seat frame/tower
disassembly and belt timing.
1-7 Once the seat frame has been disconnected from the weight
tower and with the seat bracket removed (Figure 5), tip the
seat frame on its back ( Figures 6 & 7).
The seat frame is heavy. Use two people for this step to
prevent injury.
Figure 5
Figure 6
Figure 7
Service Manual
14

Service Procedures
Figure 8
Figure 9
Figure 10
Note: Figure 8 shows a seat disconnected from the weight tower
to gain access to the gas spring seat adjustment assembly.
1-8 Remove the (2) plate retaining screws with a 7/32" Hex
wrench (Figure 9).
1-9 Pull the gas spring seat adjustment assembly out of the seat
frame tube (Figure 10).
Plate Retaining
Screws
Service Manual
15

Service Procedures
1-10 Finish removing the gas spring seat adjustment assembly
(Figure 11).
1-11 Replace the gas spring if neccessary (not pictured).
1-12 Insert the gas spring seat frame assembly into the seat
frame tube (Figure 12).
1-13 Confirm the horse shoe shaped bracket is aligned
(Figure 13).
Note: If the plate is installed backwards, the gas spring seat frame
assembly will not operate properly.
1-14 Tighten (2) 7/32" Hex screws with a 7/32" Hex wrench
(Figure 14).
1-15 Refer back to pages 9-10 for seat frame/tower installation
instructions.
Figure 11
Figure 12
Figure 13
Plate Retaining
Screws
Figure 14
Horseshoe
Shaped Bracket
Service Manual
16

Service Procedures
Weight Selection Knob Removal
Tools Required: Torque Wrench
Remove the Center Cap
1-1 Adjust the dial to the lowest setting.
1-2 Lift the dial assembly up and move it aside (Figure 1).
1-3 Remove the center cap by carefully prying between the inside
shroud and center cap.
Remove the Nautilus ONE™ 3" Decal
2-1 Carefully pry the 3" decal from the knob.
2-2 Remove the plastic decal by slowly working the prying tool
between the back of the decal and the front surface of the knob
(Figure 2).
Remove the Weight Selection
Knob Assembly Retaining Bolt
3-1 Hold the knob assembly and use the 5/32" Hex wrench to turn the
button head screw counter clockwise (Figure 3).
Note: The 1/4" x 20 x 1" long screw was installed with removable strength
thread-lock. Apply more removable strength thread-lock when
replacing the Assembly Retaining Bolt and tighten to 10 lb. ft. with a
torque wrench.
3-2 Pull the weight selection knob assembly away from the weight
tower (Figure 3).
Remove the Bezel
4-1 Unsnap the bezel from the add on weight lever housing and set it
aside (Figure 5).
Figure 1
Figure 2
Figure 3
Figure 5
Figure 4
Service Manual
17

Knob Removal (cont.)
Remove Number Wheel
5-1 Pull the number wheel assembly away from the weight
tower (Figure 6).
Remove the Add On Weight Lever
6-1 The handle adjustment knob has two index pins
that insert into the add on weight cam. Use a small
flat head screwdriver to help separate the add on
weight lever from the black plastic cam. Pull the
add on weight lever assembly away from he tower
approximately 1.5".
Note: The lever assembly should rotate freely but the weight
selection backing plate will stay affixed.
6-2 Use a 1/2" socket with 6" socket wrench extension to
remove the top weight selection backing plate bolt
(Figure 7).
6-3 Rotate the add on weight lever clockwise and remove
the bottom bolt with a 1/2" socket (Figure 8).
6-4 Remove the add on weight lever and weight selection
backing plate by pulling away from the weight tower
(Figure 9).
6-5 Reverse these steps to assemble the knob.
Figure 6
Service Procedures
Figure 7
Figure 8
Figure 9
Service Manual
18