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Nautilus Be Strong Commercial U916 Manual
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Nautilus Be Strong Commercial U916 Manual

Commercial series
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Be Strong.
®
Rework Manual
Commercial Series Bike U916
003-3376-060309A

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Summary of Contents for Nautilus Be Strong Commercial U916

  • Page 1 Be Strong. ® Rework Manual Commercial Series Bike U916 003-3376-060309A...

  • Page 2: Table Of Contents

    Table of Contents Products Affected and Requiring Work………………………………………………………3 Tools Required………………………………………………………………………………………..3 Parts………………………………………………………………………………………………………4 Parts List………………………………………………………………………………....6 Hardware………………………………………………………………………………………………..7 Assembly………………………………………………………………………………………………..8 Software Upgrade………………………………………………………………………………….11 Shield Spacer Installation..................14 Flywheel Intermediate Hub Assembly, Belt and Pulley Replacement…………….15 Final Inspection……………………………………………………………………………………..20 Final Packaging……………………………………………………………………………………..22 Appendix……………………….……………………………………………………………………..32...

  • Page 3: Products Affected And Requiring Work

    Products Affected and Requiring Rework U916 Upright Bike Product Made In Serial Numbers Domestic 380000 Taiwan Domestic 380000 38000070913007-38000081201012 International 380001 Taiwan International 380001 38001071030004-38001081215048 Global 100155 Taiwan 100155ACU09030001-100155ACU09030030 Tools Required FISP Phillips head screw driver (#2 drive) Vice-grips Cloth towel/rag 15/16”...
  • Page 4 Item PN Description Bike Bike 002-6845 Shroud Spacer 41375-021 D51 Display Firmware Firmware 002-6840 Intermediate Hub Assembly 000-6432 Belt, Alternator, U/R916 000-6214 Assembly, Overmold, Intermediate 8V Pulley SM40329 Flywheel, Cast, 5300...
  • Page 5 902-4274 SCW-GHCS M8x1.25x25 SS 902-4141 NUT NL M8-1.25 G2 BlkZ 902-4140 NUT NL M6-1.0 G2 Blk 002-6858 U916 Rework Sticker - Blue 003-3375- R916 Rework Manual 060309 003-3376- U916 Rework Manual 060309 Note: PN's for individual parts are for reference only.
  • Page 6 PARTS LIST / BOX CONTENTS PARTS LIST / BOX CONTENTS REF # DESCRIPTION Console Console Mast Main Frame Seat assembly Handlebar Right Mast Shroud Left Mast Shroud Water Bottle Holder Hardware Pack (not shown)
  • Page 7 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 #9 6mm Allen Wrench / Phillips Screwdriver Ref #4 Phillips Head Screw 1/4”x20 Qty.

  • Page 8: Parts

    The following instructions provide direction in assembling the base unit for the Nautilus® Commercial Series Bike model U916. 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.

  • Page 9: Assembly Guide

    ASSEMBLY GUIDE Step 2: Locate the following for this step: Parts: Figure 2: Handlebar (E) Hardware: Ref #6 Allen Head Bolt M8x20 Qty. 4 Ref #7 Spring Washer M8 Qty. 4 Tools: 6mm Allen Wrench 2-1 Connect the attached long Wire Tie (L) to the handlebar cables (M) and use it to pull the cables out through the Mast (B) as shown in fig 3.
  • Page 10 ASSEMBLY GUIDE Figure 3: Step 3: Locate the following for this step: Parts: Display Console (A) Hardware: Ref #4 Phillips Head Screw 1/4”x20 Qty. 4 Ref #5 Spring Washer M6 Qty. 4 Figure 4: Tools: Figure 5: Phillips Head Screwdriver 3-1 Plug the Main Console Wire (Q) into the large connector labeled J5 (large connector) on the back of the Console.

  • Page 11: Software Upgrade

    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 perform ftware upgrades on all C51/52 consoles / controllers using a FISP Dongle.
  • Page 12 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 with the corresponding side of the F.I.S.P. dongle. 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 f the ribbon cable connector with the corresponding side of the 10-pin connector on the b...
  • Page 13 5. Wait for the F.I.S.P. LED to turn GREEN. If the LED turns RED, it indicates a failed program sequence. If this happens, try the above process again. 6. Once the programming is complete, the green LED will turn on. Remove the F.I.S.P. programm ing cable from the console/controller.
  • Page 14 SHEILD SPACER INSTALLATION Step 1: Remove the left cover. Using a Phillips head screwdriver remove the left cover. Step 2: Adding spacer to standoff. Add a drop of CA adhesive to part 002-6845 before attaching to the standoff. Push the right side cover away from the frame, Add part 002-6845 to the standoff as shown in the...
  • Page 15 INTERMEDIATE HUB ASSEMBLY, BELT AND PULLEY REPLACEMENT Step 1: Remove the belt and black intermediate pulley. Remove the four 902-5665 screws from the interm ediate shaft using a 5mm hex wrench, this will allow the belt to removed as well. Step 2: Removing pulley from the inter mediate shaft.
  • Page 16 Step 3: Removing pulley and external snap ring. Remove pulley 000-6214 from intermediate shaft with puller or pry bar. Remove external snap ring from intermediate shaft located behind 000- 6214 pulley. Step 4: Removing intermediate shaft. Beware of sharp edges on intermediate shaft. Using a rubber mallet and punch drive the shaft from the bearing housing in the frame.
  • Page 17 Step 5: Installing new intermediate shaft. 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.
  • Page 18 Reverse the process described in Step 4 reinstall the crank drive belt. Step 9: Attach new intermediate pulley and torque to 20 ft lbs. 000-6214 Intermediate Pulley, (4) 902- 5665 Screws, and (4) 27579 Lock Washers. Hand start the Screws and Washers into the Pulley.
  • Page 19 When the Belt is installed correctly there is a groove visible on each side of the Pulley. Step 12: Step 11: Reattach cover.
  • Page 20 Document #: SM-QTY-F-133 Rev. Level: C Release Date: 7/23/08 Page 1 of 2 SUBJECT: U/R916 FINAL GOODS INSPECTION CHECK SHEET Step 1 Serial # Made in Check Powder Coat On All Parts For Bare Metal, Light Coverage, Etc. (Per SM-QTY-G-030) Check Pedals And Cranks For Scratches, Damage, Etc.
  • Page 21 Verify Shroud Mounting Hardware Secure Verify Pedals Secure After Shrouds Installed Run Test After Shrouds Installed To Ensure Proper Fit Verify Water Bottle Holder Secure (U916 Only) Verify CHR Plates Stretch-Wrapped Check All Decals And Console Overlay For Scratches, Air Pockets, Alignment, Etc.

  • Page 22: Final Packaging

    DESC: FINAL PACKAGING Quality Note: Remove handle bar from mast being careful in pulling the wires out of the neck. Screws are used over and new mounting screws are placed in hard ware kit. Wrap quick silver around mounting and where wires handle bar is mounted.
  • Page 23 Place handle bar in xxx bag. Place wrapped handle bar in carton Wrap console in bubble wrap and place in box. Close up box. Close and tape shut the carton. The carton will be put in with the bike at later time. Break screws loose.
  • Page 24 Use dewalt to remove screws holding mast. Use care when pulling wires thru mast off. Pull wire tie back through and reattach The customer pulls the cables up the mast. Get 000-4897 bag and place over mast.
  • Page 25 Place mast in carton. Remove seat from bike. Get 000-4897 bag and place over seat assembly.
  • Page 26 Place seat post in carton and block with foam from the console. Wrap up cables and stuff into the mast mounting opening using care not to cut insulation on cables. Wrap quick silver on legs and pedals.
  • Page 27 Get bag 17885 and place over bike. Get 002-0587 tube and place over bike. Place hardware bag in carton with mast and fold top down and tape.
  • Page 28 Place Battery Charger in carton. Intl 21756 Dom 002-0677 Close carton and tape. Place handle bar and console box inside tube.
  • Page 29 Place mast and hardware bag on top of mast and console box. Get (4) 2x4 upright supports and place in box on both ends. Get (2) cross boards and place on supports. Place seat carton inside tube.
  • Page 30 Staple 2x4 upright supports to side of box using BOSTICH gun 1 ½ staples gun. Close carton and staple top flap Staple (4) xxx corner protectors to carton.
  • Page 31 Band box shut on both ends. Place bands where the upright supports are in box.

  • Page 32: Appendix

    Appendix Console Firmware Upgrade to V21 Using FISP Setting up the FISP for One or Two Device Programming There are various versions of the FISP windows application in use, the earliest versions do not have as many features as the later and the first step toward successful programming the FISPs will be to access the vendor’s web site and download the most current version: http://www.4d-electronics.co.nz/Business/productsbusiness/productdownloadbusiness.htm The vendor has upgraded the FISP loading application to include a web based programming...
  • Page 33 The Multi-Build FISP Load screen should look something like this: -OR-...
  • Page 34 For single device loads (not recommended), it’s more versatile to do a mult-device Load: At this point some important information is seen on the screen and the setup procedure follows: Connect the supplied USB cable to power up the device (do not connect the FISP to the Target or device to be programmed yet).
  • Page 35 9- Clear the Data Transfer window and VERIFY the Programs were loaded correctly. “Click” on FISP at the TOP off the window (not bottom) and select Verify FISP. The below screen should be seen (NOTE the “OK” on the Verifying lines): 10- Clear the Data Transfer window and disconnect the FISP, from the USB cable.
  • Page 36 For more information about our Commercial Series exercise equipment or other Nautilus equipment for your home, visit www.Nautilus.com. © 2008 Nautilus, Inc. All rights reserved. Nautilus, the Nautilus logo, Remote Operation Control, Be Strong are either registered trademarks or trademarks of Nautilus, Inc.