Nautilus Commercial Series TreadClimber TC916 User manual

Be Strong.™
P/N: 001-7013 Rev B (11/09/2006)
Assembly Manual
TreadClimber® Model TC916
Commercial Series

2
FOR DETAILED INSTRUCTIONS AND INFORMATION ON
HOW TO USE AND CARE FOR YOUR TREADCLIMBER®
COMMERCIAL SERIES EXERCISE MACHINE, MODEL TC916,
REFER TO THE OWNER’S MANUAL.
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Nautilus® TreadClimber® Model TC916 Assembly Manual
TABLE OF CONTENTS
TREADCLIMBER®FEATURES ............................................................................................................................ 4
PRODUCT SPECIFICATIONS .............................................................................................................................. 5
IMPORTANT SAFETY PRECAUTIONS .............................................................................................................. 6
WARRANTY INFORMATION:
TIME PERIOD ......................................................................................................................................... 8
WHAT THIS WARRANTY DOES NOT COVER .................................................................................... 8
LIMITATIONS .......................................................................................................................................... 8
PROCEDURES ......................................................................................................................................... 8
GETTING STARTED:
SELECT YOUR WORKOUT AREA ......................................................................................................... 9
POWER PLUG RECEPTACLE ................................................................................................................ 9
TURNING ON THE POWER .................................................................................................................. 9
UNDERSTANDING THE DISPLAY AND CONTROLS ......................................................................... 9
LIMITED ACCESS CONTROL/MAGNETIC SAFETY STOP ................................................................ 10
MAGNETIC KEY SAFETY STOP ACTIVATION ................................................................................... 10
QUICK START GUIDE ............................................................................................................................. 11
MOVING INSTRUCTIONS:
MOVING INSTRUCTIONS FOR FULLY ASSEMBLED UNIT:
MOVING YOUR TREADCLIMBER® TC916 ................................................................................... 12
REMOVING MACHINE FROM PALLET ......................................................................................... 13
MOVING UNIT INTO POSITION IN FACILITY .............................................................................. 14
DISASSEMBLY OF UPRIGHT UNIT:
IMPORTANT INFORMATION TO READ BEFORE DISASSEMBLING UPRIGHT UNIT .. 16
REMOVING REAR STEP ........................................................................................................ 17
REMOVING UPRIGHTS ......................................................................................................... 18
REMOVING BASE PLASTIC ................................................................................................. 19
MOVING TOOL INFORMATION ........................................................................................................... 20
ASSEMBLY INSTRUCTIONS FOR CRATED UNIT:
BEFORE YOU ASSEMBLE
BASIC ASSEMBLY PRINCIPLES ............................................................................................ 22
HARDWARE AND TOOL LIST ............................................................................................................... 23
PARTS LIST REFERENCE GUIDE .......................................................................................................... 24
UNPACKING GUIDE .............................................................................................................................. 26
ASSEMBLY GUIDE ................................................................................................................................. 29
BELT TENSION AND ALIGNMENT ................................................................................................................... 40
IMPORTANT CONTACT NUMBERS: ................................................................................................................. 41

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TREADCLIMBER®FEATURES
Console
Ergo Bar
Power On/Off Switch
Adjustable Feet
Model:TC916

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Nautilus® TreadClimber® Model TC916 Assembly Manual
PRODUCT SPECIFICATIONS
User Weight Capacity: 400 lbs (182 kg)
Speed Range: 0.5 to 6 mph (default set to 4.0 mph)
0.8 to 9.7 km/h (default set to 6.4 km/h)
Treadle Displacement Levels: MIN (half the total displacement) and
MAX (full treadle displacement)
Walk Surface (W x L): 21” x 48” defined by two separate left and right
treadmill belt assemblies (treadles), each treadle 10”
x 48” in length, with a 1” or less separation between
the belts.
(Metric Walk Surface: 53 x 122 cm.)
Floor Space (W x L): 36” x 70” / 91.5 x 178 cm
TreadClimber®Weight: 684 lbs / 310 kg
Shipping Weight: 806 lbs / 366 kg
Power Requirements: USA: 110 Volt, 20 amp dedicated circuit.
International: 230V, 10 amp dedicated circuit
Warranty: 3 years - parts, 1 year - labor, 1 year -wear items, and
15 years - frame and AC-motor.
(May vary outside the USA.)
Model:TC916
Regulatory Approvals:
Meets:
Safety - EN 60335-1
EMC Directive 89/336/EEC
Machinery Directive - 98/37/EC
Low Voltage Directive - 89/336/EEC
CSA Certified, UL Listed
Meets:
FCC - Part 15
Canadian ICES-003 Regulations for Class A apparatus
Patent Information:
U.S. and International Patents Pending
Recycling
Do not dispose of this product as refuse. This product is to be recycled. For information
on the proper method of disposal contact a Nautilus Customer Service Representative.
Contact information is available in the Important Contact Numbers section in this manual.

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IMPORTANT SAFETY PRECAUTIONS
SAVE THESE INSTRUCTIONS:
The following definition applies to the word “Warning” found throughout this manual:
Used to call attention to POTENTIAL hazards that could result in personal injury or loss
of life.
WHEN USING ELECTRICAL EQUIPMENT ALWAYS FOLLOWTHESE BASIC PRECAUTIONS:
READ ALL INSTRUCTIONS BEFORE USINGTHE MACHINE.
Read this manual in full before operating the TreadClimber®machine. Failure to follow these guidelines can produce a
serious or possible fatal electrical shock hazard or other serious injury. Consult a qualified electrician as required.
1. The controller Stop Key does not turn off the electrical current to the TreadClimber®exercise machine. The
TreadClimber®machine continues to draw power, even when the controller is off. To avoid electric shock, do not
remove TreadClimber®hood or place hands beneath the TreadClimber® exercise machine while the machine is plugged
into a power source.
2. Do not start the TreadClimber®machine when someone else is standing on the walk belts.
3. Keep walk speed and treadle displacement at the lowest settings when getting on and off the TreadClimber® machine.
4. Keep the area underneath and around the TreadClimber®exercise machine clear.
5. Never position the TreadClimber®exercise machine with the back end (direction of belt travel) facing a wall or any other
objects such as furniture or other pieces of fitness equipment. Failure to keep the rear space of the machine clear can
prevent safe exit of the TreadClimber®machine in an emergency situation such as falling. Allow a minimum of four feet
behind the TreadClimber®exercise machine.
To reduce the risk of electrical shock, always unplug the external
power supply from the electrical outlet before cleaning, maintaining, or
repairing.
To reduce the risk of burns, electric shock or injury to persons read
and follow all safety warnings and instructions in this manual.
Secure long hair and loose clothing before use.
DO NOT USE NEAR WATER!
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Nautilus® TreadClimber® Model TC916 Assembly Manual
6. Before each use of this equipment, check the power receptacle for signs of damage. Do not operate the equipment if the
integrity of the power receptacle is in question.
7. To avoid potential safety and electrical problems, replace with manufacturer’s specified parts only.
8. This equipment is classified Class I, Type B, ordinary equipment. Not protected against fluid ingress. Rated for continuous
operation. Do not operate this equipment in the presence of flammable anesthetic mixtures.
9. Do not let liquid enter the controller. If it does, the controller must be inspected and tested for safety by an approved
technician before it can be used again.
10. Increased risk due to leakage current can result if this equipment is not grounded properly.
11. The TreadClimber®machine must be on an appropriate, dedicated electrical circuit. Nothing else should be connected to
the circuit.
12. Do not stand on the TreadClimber®TC916’s hood or front trim cover.
13. Close supervision is necessary whenever the machine is used by or near children, invalids, or disabled persons.
Failure to follow the conditions set forth below shall limit, to the extent allowed by law, Nautilus Inc.’s responsibility for the
safety, reliability, and performance of this equipment.
• The operator manual must be read in full by each owner and trainer before the product is first used. Each user must
be instructed in the proper use of the TreadClimber®machine and its accessories.
• Do not remove the TreadClimber®hood: dangerous voltages are present. Components are serviceable only by
qualified service personnel.
• The electrical wiring within the TreadClimber®equipment setting and the electrical installation of the TreadClimber®
machine must comply with the applicable local or provincial requirements.
• The equipment must be used in accordance with the instructions for use.
• For further information or instruction on use, maintenance or specifications, please contact your Authorized Nautilus
Fitness Dealer or Service Technician.
IMPORTANT SAFETY PRECAUTIONS

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COMMERCIAL MARKET WARRANTY INFORMATION
**For warranty information outside of the United States or Canada,
contact the International office listed in the Important Contact Numbers section of this manual. **
WARRANTY INFORMATION
All Nautilus®exercise products are warranted to the commercial market purchaser to be free from defects in materials
and workmanship. Warranty coverage valid to the original purchaser only and proof of the purchase will be required. Any
product sold or placed in an application not recommended by Nautilus, Inc. will void any warranty coverage set forth by
Nautilus, Inc. warranty policies and procedures.
Time Period (May vary outside U.S.A.)
• 15 - Years - Frame and AC-motor
• 3 - Years - Mechanical and electrical parts
• 1 - Year - Labor
• 1 - Year - Wear items
What this Warranty Does Not Cover
1. Any damage, failure or loss caused by accident, misuse, neglect, abuse, improper assembly, improper maintenance or
failure to follow instructions or warnings in Owner’s Manual.
2. Use of product in a manner or environment for which it was not designed.
Limitations
The foregoing warranties are in lieu of and exclude all other warranties not expressly set forth herein, whether expressed
or implied by operation of law or otherwise, including, but not limited to, warranties of merchantability or fitness for a
particular purpose. Nautilus, Inc. shall in no event be liable for incidental or 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
consequential damages, so the preceding limitations and exclusions may not apply to you.
Procedures
Warranty service will in most cases be performed by an authorized Nautilus Fitness Dealer or Service Technician. The
original purchaser must provide proof of purchase, Service calls and/or transportation to and from the Nautilus Dealer is
the responsibility of the purchaser.
1. Nautilus, Inc. will have the option to repair or replace any exercise product, which requires service.
2. Nautilus, Inc. will replace any equipment frame that is structurally defective with a new frame or replace the unit with
a unit of equal value.
3. Nautilus, Inc. is not responsible for dealer labor charges for the component changeovers completed after the labor
related warranty period stated herein.
4. If you elect to repair an exercise product or part yourself, using the services of someone other than an authorized
Nautilus Fitness Dealer or Service Technician, or use a replacement part not supplied by Nautilus, Inc., Nautilus shall
not be liable for any cost, damage, failure or loss caused by the use of such unauthorized service or parts.

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Nautilus® TreadClimber® Model TC916 Assembly Manual
GETTING STARTED
GETTING STARTED
Select Your Workout Area
Select the location where you are going to put your
Nautilus®TreadClimber®exercise machine carefully. The
best place for your TreadClimber®machine is on a hard, level
surface. You will need at least two feet (61 cm) on each side
and in front of your TreadClimber®machine, and at least four
feet (122 cm) behind it for dismount.
Make sure that the location you choose has a grounded,
3-prong power outlet within reach of the TreadClimber®
machine power cord, preferably to the front of the machine
where you will be less likely to step on the cord during
dismount.
NOTE: The TreadClimber®machine is designed to plug into grounded, non-GFI outlets only. To determine if your
outlet or circuit breaker is GFI, look for a test and reset button on them. If they have the test and reset
button it is a GFI outlet or circuit breaker, and therefore not suitable for plugging the TreadClimber®
machine into.
Power Plug Receptacle
The Commercial Series TreadClimber®TC916 has one power plug receptacle located on the front side of the motor pan (see
Figure 1).
Turning on the Power
The TreadClimber®exercise machine can be turned on by moving the power switch located at the front of the machine, to
the ON position (see Figure 1).
Understanding the Display and Controls
The TreadClimber®console display is a computerized panel used to operate the TreadClimber®exercise machine and see
all workout data and operational status. You should familiarize yourself with the operation of the TreadClimber®machine
and location of all keys before beginning use. Detailed descriptions and usage information is available in the TreadClimber®
Commercial Series, Model TC916, Owner’s Manual.
Figure 1: On/Off Switch & Power Plug

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GETTING STARTED
Limited Access Control/Magnetic
Safety Stop
Limited-access control lets you restrict TreadClimber®
machine use to authorized personnel. It also lets you
stop the TreadClimber®machine in an emergency. The
magnetically-activated control is located on the bottom of
the display as shown (see Figure 2). The limited-access
control is deactivated on machines shipped from the
factory.
Magnetic Key Safety Stop Activation
To activate the limited-access control and restrict access,
place the magnetic safety stop key supplied with the
TreadClimber®machine in the designated area located
below the display (see Figure 3).
The magnetic key will activate the control. If you remove
the key, the TreadClimber®treadle belts will stop and the
console controller will not respond to any key presses.
Accumulated values will remain on the display until you
turn off the power, or press [CLEAR].
The console will display a message, “REPLACE MAGNET”
when you remove the magnetic key from its designated
area. You must replace the key or deactivate the control
to start the walk belt.
Figure 2
Figure 3

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Nautilus® TreadClimber® Model TC916 Assembly Manual
GETTING STARTED
To Start:
Insert the Magnetic Safety Stop Key and press the [QUICK START] key , or select a program key .
To Stop:
Press [STOP] to pause the workout. Press [STOP] again to end the workout.
During the workout:
• After selecting a program, follow the Display prompts and use the numeric keypad to enter information.
• Walk speed may be changed at any time during the workout by pressing the [Speed: UP] key to increase the walk speed, or
the [Speed: DOWN] key to decrease the walk speed.
• Treadle displacement may be changed at any time during the workout by pressing the [Treadle: MAX] key to increase the
height, or the [Treadle: MIN] key to decrease the height.
WARNING: For detailed information on use and safety, refer to your Owner’s Manual file located on CD ROM.
Quick Start Guide
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MOVING INSTRUCTIONS
DELIVERY LOGISTICS
The TreadClimber®TC916 may be delivered fully-assembled, shipped on a pallet crate, and blanket wrapped;
• Pallet crate shipping weight: 806 pounds
• Unit weight: 684 pounds
- OR -
Delivered in a one box configuration, requiring assembly.
• Boxed Unit shipping weight: 850 pounds
• Unit weight: 684 pounds
MOVING INSTRUCTIONS FOR FULLY ASSEMBLED UNIT INCLUDE:
1. Taking unit off pallet crate.
2. Moving unit into position in facility, if door ways are greater than 40 inches (101 cm) wide.
3. Disassembly of Upright Unit Instructions, if door ways are less than 40 inches (101 cm) wide.
4. Moving Tool Information to assist with moving fully assembled TreadClimber®unit.
ASSEMBLY INSTRUCTIONS FOR ONE BOX CONFIGURATION UNIT INCLUDE:
1. Unpacking Instructions.
2. Assembly Instructions.
TO REDUCE THE RISK OF INJURY TO PERSONS READ AND
FOLLOW ALL SAFETY WARNINGS AND INSTRUCTIONS IN THIS
MANUAL.
TWO PEOPLE ARE REQUIRED TO UNLOAD AND MOVE THE
TREADCLIMBER®TC916 EXERCISE MACHINE INTO POSITION IN
THE FACILITY.
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Moving your Fully Assembled TreadClimber®TC916

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Nautilus® TreadClimber® Model TC916 Assembly Manual
Removing Machine from Pallet
Tools Needed:
7/16 Socket
Ratchet
Step 1: Remove TC916 from pallet by removing restraining
stabilizer brackets with socket and ratchet from
stabilizer feet (see Figure 1).
Step 2: Manually slide TC916 to one side of the pallet -
over hanging approximately 12 to 15 inches off the
side of the pallet (see Figure 2).
Step 3: Tilt unit to side and slide edge of frame to ground
(see Figure 3).
Step 4: Tilt to 40 degrees and move pallet out of the way,
lowering TC916 to ground (see Figure 4).
NOTE: If removing the TreadClimber®TC916 from
pallet you should be placing the unit in its
final position in the facility when removing
it from the pallet.
Figure 1
Figure 2
Figure 3
Figure 4
MOVING INSTRUCTIONS

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Tools Needed:
7/16 Socket
Ratchet
Moving Dolly
Lift Bar
Step 1: Remove TC916 from pallet by performing steps
in section “Removing Machine from Pallet” in
this manual.
Step 2: Tilt to 40 degrees (see Figure 1). While tilted
place 4-wheel moving dolly under center of
TreadClimber®frame (see Figure 2).
Step 3: Carefully, lower the TreadClimber®Model TC916
onto 4-wheel moving dolly (see Figure 3).
Step 4:
Once in position in the facility, prepare to
remove unit from 4-wheel dolly by locking
castors.
MOVING INSTRUCTIONS
Moving Unit into Position in Facility
Figure 1
Figure 2
Figure 3
Figure 4
WHEN LOWERING THE TREADCLIMBER®
UNIT ONTO DOLLY BE SURE THAT THE
CASTORS ARE LOCKED SO THAT IT DOES
NOT MOVE OUT FROM UNDER THE
TREADCLIMBER®UNIT.
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NOTE: Perform the following moving procedure to position
your TreadClimber®Model TC916 in your facility if
your door ways are greater than 40 inches wide.

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Nautilus® TreadClimber® Model TC916 Assembly Manual
MOVING INSTRUCTIONS
Step 5: Carefully tilt TreadClimber®machine onto one-side
of frame towards ground (see Figure 4).
Step 6: Tilt unit to 40 degrees and remove moving dolly.
Step 7: Place Moving Tool under the machine according to
the “Moving Tool Instructions” section located in
this manual and wheel the unit into position.

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IMPORTANT INFORMATION TO READ
BEFORE DISASSEMBLING UPRIGHT UNIT.
During delivery of this unit it may become necessary to disassemble the upright portion of the unit to reduce the size and
weight. The upright portion of the unit has wheels integrated into it, making it possible to wheel it away from the base
and handle it as a separate unit.
Only use this option if delivery of the unit is not possible using one of the two preferred moving options:
Moving unit into position in facility, if door ways are greater than 40 inches (101 cm) wide, or
One boxed configuration, requiring assembly before use.
TO AVOID ELECTRICAL SHOCK OR DAMAGE TO THE UNIT YOU
MUST POWER OFF THE UNIT AND MAKE SURE ALL POWER HAS
BEEN DRAINED FROM THE UNIT AND CAPACITORS BY ENSURING
THERE ARE NO LIGHTED LEDS ON THE CONSOLE.
DETACHING AND MOVING THE UPRIGHT PORTION OF THIS
PRODUCT REQUIRES TWO PEOPLE! YOU MUST HAVE A MINIMUM
OF TWO PEOPLE TO PROPERLY SUPPORT THE HEAVY UPRIGHT
STRUCTURE SO THE CONSOLE DOES NOT FALL AND CAUSE
DAMAGE TO THE UNIT.
Disassembly of Upright Unit
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MOVING INSTRUCTIONS

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Nautilus® TreadClimber® Model TC916 Assembly Manual
MOVING INSTRUCTIONS
1.0 REMOVING REAR STEP
Tools Needed:
• Phillips head screw driver
• Magnetic 3/8” Nut Driver with long shaft
• Magnetic 3/8” socket
• Ratchet
Step 1: Unplug the unit from the power source and ensure
that all power has been drained from the unit.
Step 2: Remove two (2) middle screws (see Figure 1-1).
Step 3: Slide step cover plate back to remove
(see Figure 1-2).
Step 4: Depending upon the Step Weldment style of the
unit:
4A: Remove the four corner screws and slide the
weldment outward (see Figure 1-3).
- OR -
4B: Remove the two side screws. One screw on
left and right, then slide the weldment outward
(see Figure 1-4).
Removing the step cover plate provides access to the I/O
cables needed for the next step.
Figure 1-1
Figure 1-2
TO AVOID ELECTRICAL SHOCK OR DAMAGE
TO THE UNIT YOU MUST POWER OFF THE
UNIT AND MAKE SURE ALL POWER HAS BEEN
DRAINED FROM THE UNIT AND CAPACITORS BY
ENSURING THERE ARE NO LIGHTED LEDS ON
THE CONSOLE.
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Figure 1-3
Figure 1-4
Four Screws
Two Screws

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2.0 REMOVING UPRIGHTS
Tools Needed:
• Phillips head screw driver
• 5/32 Allen wrench
• 3/4 inch wrench or socket
• 1/2 inch drive Ratchet
• 1/2 inch drive Torque wrench
Step 1: Remove for the four Button head screws at-
taching the console to the Upright weldment,
disconnect the cables and remove the console
from the machine.
Step 2: Remove the Rear Step as directed in Section 1:
Removing Rear Step.
Step 3: Disconnect the Base Cable (P/N - 17826) from
the Handrail Cable (P/N - 17824) located in the
lower left hand corner (see Figures 2-1 and 2-2).
Step 4:
Remove rear plastic cover by loosening six (6)
screws (see Figure 2-3 and Figure 2-4).
Step 5:
Remove right and left lower plastic parts by
removing seven (7) screws located on the right
and left upright inside panels (see Figure 2-5 and
Figure 2-6).
Step 6: Remove the four (4) upright bolts (see Figure 2-7)
Step 7: Wheel upright structure away to safe location
(wheels are integrated into upright portion of
unit).
NOTE: To replace the upright unit, reverse the
directions. The four handrail screws are
to be torqued to a setting of 75 ft. lbs.
Figure 2-1 Figure 2-2
Figure 2-3 Figure 2-4:
Rear plastic cover off.
Figure 2-5:
Lower plastic parts.
Figure 2-6
Figure 2-7
DETACHING AND MOVING THE UPRIGHT PORTION OF
THIS PRODUCT REQUIRES TWO PEOPLE! YOU MUST
HAVE A MINIMUM OF TWO PEOPLE TO PROPERLY
SUPPORT THE HEAVY UPRIGHT STRUCTURE SO THE
CONSOLE DOES NOT FALLAND CAUSE DAMAGE TO
THE UNIT.
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MOVING INSTRUCTIONS

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Nautilus® TreadClimber® Model TC916 Assembly Manual
MOVING INSTRUCTIONS
NOTE: You should only use this step if you need to
rotate the lower base unit up onto its side to
transport it.
3.0 REMOVING BASE PLASTIC
Tools Needed: 1/8 Allen bit
Step 1: Remove three (3) front plastic screws
(see Figure 3-1).
Step 2: Remove right and left side plastic covers - four (4)
screws each side (see Figure 3-2).
Step 3: Remove right and left side pan covers - two (2)
screws each side (see Figure 3-3 and Figure 3-4).
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4:
Pan without
covers.

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MOVING INSTRUCTIONS
Moving Tool Information
Figure 1
Figure 2
FRAME WHEEL CLEVIS CLIP
MOVING TOOL PARTS:
The following parts are shown in the figure to the
right, in order listed:
• Wheel Bar – one frame, two wheels, two clevis clips
• Caster Cart – one base, two wheels
• Lifting Tool – one piece
• Two 4x4x6 inch (ca. 10x10x15.5 cm) Blocks of Wood
- not pictured
BEFORE MOVING THE TC916 UNIT:
1 - Make sure the power cord is not running under
the machine.
USAGE DIRECTIONS:
Step 1: Lift the right side of the TC916 and brace with a
4x4x6 inch (ca. 10x10x15.5 cm) block of wood near
the middle of the machine.
Step 2:
Lift the left side of the TC916 and brace with a
4x4x6 inch (ca. 10x10x15.5 cm) block of wood near
the middle of the machine.
Step 3: Slide the Wheel Bar under the machine near the
front of the TC916. Tilt the TC916 towards the rear,
raising the front of the machine to provide room to
slide the Wheel Bar underneath.
Step 4: Tilt the machine forward, towards the Console and
slide the Caster Cart under the rear of the machine
(see Figure 1). Position the Caster Cart under the
machine flush with the bottom of the frame so that
it hooks between the frame and the leveling pads.
Wheel Bar
Caster Cart