Nautilus Be Strong Commercial R916 Assembly Manual
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Nautilus Be Strong Commercial R916 Assembly Manual

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

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Summary of Contents for Nautilus Be Strong Commercial R916

  • Page 1 Be Strong. ® Rework Manual Commercial Series Bike R916 003-3375-060309A...

  • 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………………………………………………………………………………….13 Flywheel Intermediate Hub Assembly, Belt and Pulley Replacement…………….16 Final Inspection……………………………………………………………………………………..23 Final Packaging……………………………………………………………………………………..25 Appendix......……………………………………………………………………..34...

  • Page 3: Products Affected And Requiring Work

    Products Affected and Requiring Rework R916 Recumbent Bike Product Made In Serial Numbers Domestic 380002 Taiwan Domestic 380002 38002071108001-38002081027017 International 380003 Taiwan International 380003 38003080103001-38003081208036 Global 100154 Taiwan 1000154ACU0930001-100154ACU09030027 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 5 003-4716 Spacer, Seat, R916 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 Rework Sticker - Blue 003-3375- R916 Rework Manual 060309 003-3376- U916 Rework Manual 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 Pad Handlebar Seat Back Assembly Right Mast Shroud Left Mast Shroud Right Seat Bottom Left Seat Bottom 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 #9 Flat Washer M8 Qty. 12 Ref #2 Spring Washer M10 Qty. 4 Ref #10 Allen Head Bolt M8 x 40 Qty.

  • Page 8: Parts

    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.

  • Page 9: Assembly Guide

    ASSEMBLY GUIDE Step 2: Figure 3: Locate the following for this step: Parts: Display Console (A) Hardware: Ref #5 Phillips Head Screw 1/4”x20 Qty. 4 Ref #6 Spring Washer M6 Qty. 4 Tools: Phillips Head Screwdriver 3-1 Plug the Main Console Wire (Q) into the large Connector (J5 ) on the back of the Console.

  • Page 10: 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...
  • Page 11 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 or not nylon lock nuts they must be replaced with 902-4141 nylock nut three places. Tools needed Make sure you do not tighten the two 13mm...
  • Page 12 ASSEMBLY GUIDE Step 4: Locate the following for this step: Parts: Seat Pad Hardware: Ref # 11 Hex Head Bolt M 8 x 20 Qty. 4 Ref # 9 S.S. Flat Washer M 8.5 Qty. 4 Tools: Figure 6: 6 mm Hex Wrench 6-1 Carefully Align the Seat Pad with the Seat Carriage (T).

  • Page 13: 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 14 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 15 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 16: Flywheel Intermediate Hub Assembly, Belt And Pulley Replacement

    C. Flywheel Intermediate Hub Assembly, Belt and Pullet Replacement STEP 1: Remove the Phillips head screws from the left and right side of bike. STEP 2: Removing flywheel from alternator 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...
  • Page 17 STEP 3: Remove the belt and black intermediate pulley. 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 ediate shaft. Remove the 8M-1.25 x 20 alien cap screws (902-4725) from pulley (000-6229)
  • Page 18 Caution: Beware of sharp edges on intermediate shaft. STEP 5: Removing pulley 000-6214 and snap ring 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.
  • Page 19 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 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.
  • Page 20 STEP 10: Reinstalling the belt to the c rank pulley and intermediate shaft. Reverse the process described in Step 4 reinstall the crank drive belt, check belt for proper alignment Torque intermediate pulley screw to 20 ft. lbs. STEP 11: Install new intermediate pulley.
  • Page 21 STEP 12: Installing flywheel (SM40329) Place belt behind the intermediate pulley as shown before placing belt on flywheel pulley. Install flywheel with the belt around the grooved pulley on the flywheel. NOTE: make sure the keyway slot is lined up with the alternator key before pushing the flywheel onto the alternator Flywheel SM40329 shaft.
  • Page 22 STEP 13: Check machine function, belt alignment, intermediate hub free wheeling, and timing belt alignment, adjust as needed. Reattach covers.

  • Page 23: Final Inspection

    Final Inspection and Rework Sticker Application Document #: SM-QTY-F-133 Rev. Level: C Release Date: 7/23/08 Page 1 of 1 U/R916 FINAL GOODS INSPECTION Step 1: SKU____________ Serial Number, _____________ Made in: _______________ Check Pedals And Cranks For Scratches, Damage, Etc.
  • Page 24 Document #: SM-QTY-F-133 Rev. Level: C Release Date: 7/23/08 Page 2 of 2 Console Should Turn On With One Crank Of Pedals Verify Quick Start And Level Keypads Work Properly Configure Console For Appropriate Bike If Needed ( ^ 8 ) Configure Console For Proper Language If Needed ( ^ 3 ) Check And Record Unit (Standard or Metric) Configuration ( ^ 3 ) Check And Record Software Version ( ^ 4 ) V21...

  • Page 25: Final Packaging

    Description: Final Packaging Remove the Seat Pad from the Seat Carriage and move it to the packing bench. Remove the Console from the Mast and move it to the packing bench. Remove the Mast and move it to the packing bench. Quality Check: Make sure not to damage the Cables that run up the Mast when removing the M...
  • Page 26 Wrap the Cables in the Mast area. Wrap a 61240 Bag around the Lower Handlebar and place it in the Lower Handlebar Box. Run the Wire Tie up the Mast and attach it to one of the Console mounting holes. Reattach the wire tie as you pull out the console cables.
  • Page 27 Wrap a 61240 Bag around the Mast Handlebar and place it in the Mast Handlebar Box. Place the Plastics Box in the Mast Handlebar Box. Get the Console, wrap it in bubble wrap, and place it in the Mast Handlebar Box.
  • Page 28 Get an R916 Bagged Hardware Kit and 001-6988 Assembly Manual and place them in the Mast Handlebar Box. Fold the Mast Handlebar Box flaps closed and seal with tape. Get 002-0364 Bag and place the Seat Cushion in it. Place the bagged Seat Cushion in the Seat...
  • Page 29 Get a Battery Charger (see below) and place it in the Seat Box. DOMESTIC Bikes get a 002-0677 Charger. INTERNATIONAL Bikes get a 001- 0501 Charger Quality Check: Place the Seat Cushion against the side of the Box and the Battery Charger against the bottom of the Seat Cushion.
  • Page 30 Slide the Seat Carriage towards the front as far as it will go. Place the Seat Back Assembly on the Seat Rail Extrusion. Quality Check: To center the Bike, the Front Stabilizer Feet should be against the paddles. Place quicksilver around the Rear Seat Rail Shroud.
  • Page 31 Get 002-0595 Master Box and fold it. Place the Master Box over the Bike and Bottom Tray. Get (2) 003-3495 2x4 Upright Supports and place them in the Master Box at the front corners. Get 002-0777 Crossmember Support and place it on top of the Upright Supports. Get (2) 003-3495 2x4 Upright Supports and place them in the Master Box in front of the Rear Stabilizer Feet.
  • Page 32 Make sure the Master Box is seated on all sides of the Bottom Tray. Staple the Master Box to the Upright Supports with (6) staples in each. Quality Check: Make sure the staples run horizontally. Move the Pedals to a horizontal position. Place the Mast Handlebar Box (with the blue decal) in the Master Box on the RH side.
  • Page 33 Fold the side flaps of the Master Box over and use the bander to secure the Master Box to the Bottom Tray in (3) places.

  • Page 34: 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 35 The Multi-Build FISP Load screen should look something like this: -OR-...
  • Page 36 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 37 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 38 © 2008 Nautilus, Inc. All rights reserved. Nautilus, the Nautilus logo, My Nautilus, Heart Strong, Changing the Game in Health and Fitness, REACT, ROC, Remote Operation Control, SuperSoft, Hyperdrive, Be Strong are either registered trademarks or trademarks of Nautilus, Inc.

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