Service Manual Commercial Series Elliptical · authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty. If you are a consumer and require

Be Strong.™

Service Manual

PN 40478A Rev B (8/2006)

Model: E916 & EV916

Commercial Series Elliptical

2

This manual is intended for authorized Nautilus or Nautilus certified service personnel and not for the consumer. There are no user serviceable parts. Servicing of the Nautilus® Commercial Series Elliptical by other than authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty.

If you are a consumer and require technical support to resolve a problem with your Nautilus® Commercial Series Elliptical, please call Nautilus Customer Service at 800-864-1270 (USA) or +41 460 77 88 (outside USA).

Important—Please Read

�Nautilus® Commerical Series Elliptical Service Manual

Important Safety Information..................................................................................................................5

Product SpecificationsEV916 Elliptical Trainer...............................................................................................................................................6

E916 Elliptical Trainer.................................................................................................................................................7

Console CodesOverview...................................................................................................................................................................11

Defaults ....................................................................................................................................................................11

Customize .................................................................................................................................................................11

Machine Status ........................................................................................................................................................12

Diagnostics ...............................................................................................................................................................13

Maintenance Logs ....................................................................................................................................................14

Machine Configuration .............................................................................................................................................16

Wiring SchematicsEV916 Top Level Wiring Diagram ............................................................................................................................18

EV916 Power and Alternator Wiring Diagram .........................................................................................................19

E916 Console Heart Rate Wiring Diagram ..............................................................................................................20

E916 Main Power Wiring Diagram ..........................................................................................................................21

TroubleshootingEV916 Top Level Wiring Diagram ............................................................................................................................18

AppendixesRequired Tools ..........................................................................................................................................................68

International Power Plug Configurations .................................................................................................................68

Warranty Information ......................................................................................................................................................69Contact Numbers ............................................................................................................................................................70

Table of Contents

4

Contents


ImPoRTAnT SAfeTy InfoRmATIon: SAVE THESE INSTRUCTIONS

The following definition applies to the word “Warning” found throughout this guide:

WARnInG - Used to call attention to POTENTIAL hazards that could result in personal injury or loss of life.

Read All Instructions

This symbol appearing ThroughouT This manual means pay aTTenTion! be alerT! your safeTy is involved!

1. Read, understand and carefully follow all warnings, instructions and procedures in this manual. Failure to do so can produce a serious electrical shock hazard or other serious injury.

2. The external power supply should always be unplugged from the AC wall outlet before removing or installing parts. Never make adjustments or repairs while an exercise program is in progress.

3. Close supervision is necessary whenever the machine is being used or serviced whenever children, invalids, or disabled persons are in the vicinity.

4. Keep hands away from all moving parts. Keep feet on the pedals while exercising or testing the machine.

5. Do not operate the machine with the side covers removed, or outdoors.

6. Use this machine only for its intended use as described in this Manual. Do not use parts, attachments, or accessories other than those provided by Nautilus, Inc.

7. Do not use the external power supply if it has a damaged cord or plug, it is not working properly, if it has been dropped or damaged, or dropped in water. Contact our Technical Service Department to arrange for the return of damaged parts.

8. To avoid potential safety and electrical problems, replace with manufacturer’s specified parts only.

9. Connect the external power supply to a properly grounded AC wall outlet.

10. Keep all cords away from heated surfaces.

11. To disconnect the external power supply, remove the plug from the AC wall outlet.

12. Do not let liquid enter the console. If liquid does enter the console, the console must be inspected and tested for safety by an approved technician before it can be used again.

13. Never drop or insert any object into any opening on the machine.

14. Keep the area underneath and around the machine clear.

15. Do not operate where aerosol (spray) products are being used.

16. Always wear insulated gloves when handling batteries.

17. Do not crush, incinerate, or dismantle the battery.

18. The safety level provided by the design of this equipment can only be maintained when the equipment is regularly examined for damage and wear. Inoperable components should be replaced immediately or the equipment be put out of use until it is repaired.

19. Failure to follow the guidelines may compromise the effectiveness of the exercise experience, expose you (and possibly others) to injury, and reduce the longevity of the machine. Follow all training instructions listed in the manual and/or on the machine.

Failure to follow the conditions set forth below shall limit, to the extent allowed by law, Nautilus, Inc. 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 elliptical and its accessories.

• The equipment must be used in accordance with the instructions for use.

• Only Nautilus-trained or Nautilus-authorized personnel should carry out assembly operations, extensions, readjustments, modifications, or repairs.

• For further information or instruction on use, maintenance or specifications, please contact your Authorized Nautilus Fitness Dealer or Service Technician.

ThE ElECTROlyTE CONTAINS SUlFURIC ACID, whICh CAN CAUSE SERIOUS DAMAgE TO EyES AND SKIN. ShOUlD

ThIS OCCUR, FlUSh pROFUSEly wITh wATER AND SEEK MEDICAl ATTENTION.

Safety Requirements

6

Safety Warning Labels

The following safety warnings are located on the Nautilus® Commercial Series Elliptical. Please read all safety precautions and warning information prior to using your product. Be sure to replace any warning label if damaged, illegible, or missing. If you need replacement labels, please call a Nautilus Representative at (800) 628-8458 (North America) or +41-26-460-77-77 (International office).

Label 1

Label 1

7Nautilus® Commerical Series Elliptical Service Manual

Safety Warning Labels

The following safety warnings are located on the unit. Please review and understand the safety warning labels and their locations on the unit prior to use.

If you do not have, or cannot find, or need to replace a warning label please call 1-800-628-8458 (North America) or +41-26-460-77-77 (International office) to obtain a new label.

Label 1: See Figure 1 for connector warning label for the battery charger plug.

Location: The warning label in Figure 1 is located on the back of the machine above the battery charger plug.

figure 1

8

Ele

ctric

al

powerCordless, or 108-132VAC, 50/60 hz, 20 watts maximum (operation with charger connected)

Battery Type 6VDC sealed lead-acid

Battery Charge Time 8 hours to full charge, starting with discharged battery

Display C51 blue/white lCD with backlightTactile membrane keypanel

Phy

sica

l

length 94 in. (239 cm)

width 28 in. (71 cm)

height 62 in. (157.5 cm)

weight 350 lb. (147 kg)

Max User weight Supported 400 lb. (181 kg)

Belt(s) Two: 10-groove drive belt and 6-groove alternator belt

Func

tiona

lity

Ellipse Stride length Dynamically variable up to 30” (76 cm)

Number of Functions

Ten: heart rate, elapsed time, calories burned, calories burned per hour, watts, METS, resistance level, rpm, distance, and workout profile

heart Rate Monitoring Integrated heat rate monitoring system with polar-compatible wireless and contact hR

workout programs

Twelve: Quick Start, Manual, Fat Burner, Calorie Burner, Intervals, hR Zone Trainer, multi-stage Fit Test’. Custom Intervals, hR Intervals, Random play

Resistance Range Twenty: 20 watts (level 1, 20 rpm) to 300 watts (level 20, 100 rpm)

language Options English, german, French, Spanish, Italian, Dutch, portuguese

C-Safe Compatible level 2 compatible. Owner/manager will be able to customize console.

Env

ironm

enta

l Operating Temperature 50–90 oF (10–32 oC)

Storage Temperature -25–50 oC

Operating humidity (non-condensing) 3–95% relative humidity

Storage humidty (non-condensing) 3–95% relative humidity

Specifications - EV916 Elliptical Trainer with MyStride® Technology


Specifications - E916 Elliptical Trainer with SyncLink® Stride Technology

Ele

ctric

al

powerCordless, or 108-132VAC, 50/60 hz, 20 watts maximum (operation with charger connected)

Battery Type 6VDC sealed lead-acid

Battery Charge Time 8 hours to full charge, starting with discharged battery

Display C51 blue/white lCD with backlightTactile membrane keypanel

Phy

sica

l

length 82 in. (208 cm)

width 28 in. (71 cm)

height 62 in. (157.5 cm)

weight 325 lb. (147 kg)

Max User weight Supported 400 lb. (181 kg)

Belt(s) Two: 10-groove drive belt and 6-groove alternator belt

Func

tiona

lity

Ellipse Stride length 18” (46 cm)

Number of Functions

Ten: heart rate, elapsed time, calories burned, calories burned per hour, watts, METS, resistance level, rpm, distance, and workout profile

heart Rate Monitoring Integrated heat rate monitoring system with polar-compatible wireless and contact hR

workout programs

Twelve: Quick Start, Manual, Fat Burner, Calorie Burner, Intervals, hR Zone Trainer, multi-stage Fit Test’. Custom Intervals, hR Intervals, Random play

Resistance Range Twenty: 20 watts (level 1, 20 rpm) to 300 watts (level 20, 100 rpm)

language Options English, german, French, Spanish, Italian, Dutch, portuguese

C-Safe Compatible level 2 compatible. Owner/manager will be able to customize console.

Env

ironm

enta

l Operating Temperature 50–90 oF (10–32 oC)

Storage Temperature -25–50 oC

Operating humidity (non-condensing) 3–95% relative humidity

Storage humidty (non-condensing) 3–95% relative humidity

10


Console Codes1

Contents

Overview ..................................................................................................... 11

Defaults ....................................................................................................... 11

Customize .................................................................................................... 11

Machine Status ........................................................................................... 12

Diagnostics.................................................................................................. 13

Maintenance Logs....................................................................................... 13

Reset Maintenance Hours ...................................................................... 14

Error Log.................................................................................................. 14

Machine Configuration................................................................................ 15

12

1�Nautilus® Commerical Series Elliptical Service Manual

OverviewTo enter a Service Mode, the unit must be in IDLE DISPLAY state or an ERROR. The service screens cannot be entered during a workout, paused or in a WARNING state. (If the unit is in a Warning state, you must press [CLEAR] before entering the Service Modes.) To access the console codes, press the Level Up button (▲), the group number code, and [ENTER]. Then use the arrow buttons to scroll through the menu options for each group. The procedures are outlined in the tables below.

There are six groups of Service Mode console codes: Defaults (codes starting with 2), Customize (codes starting with 3), Machine Status (codes starting with 4), Diagnostics (codes starting with 6), Maintenance Logs (codes starting with 7), and Change Machine (codes starting with 8). Each group of codes is defined below.

DefaultsYou can customize several workout parameters on the E916/EV916 Elliptical with default values to conform to your individual requirements, including:• % target heartrate (10-90%) • age (10-99) • workout time (5-99 min) • workout level (1-20)• weight (50-400 lbs. or 25-180 kg)

Refer to the following table to scan through and customize the settings: Table 2–1. Defaults

Step no. Press Keys Display (What you will see)

1 ▲, 2, enTeR DEFAULTS

2 ▼ or ▲ CHR PERCENT, AGE, TIME, LEVEL, WEIGHT

3 enTeR Selected choice

4 ▼ or ▲ (or numeric keypad) Default value changes

5 enTeR DEFAULTS

6 CLeAR SELECT WORKOUT

CustomizeYou can customize several console settings on the E916/EV916 Elliptical with default values to conform to your individual requirements, including:• resetting all configurable settings to factory defaults (see below)

• adjusting lower screen contrast (0-15)

• adjusting upper screen contrast (0-15)

• console language

• choosing type of heartrate inputs (description below)

Customization

14

• change units (USA units or metric units)

• cooldown time (1-10 min)

• maximum time limit (10-99 min or OFF)

Refer to the following table to scan through and customize the settings: Table 2–2. Customize

StepNo. PressKeys Display(Whatyouwillsee)

1 ▲,3,ENTER CUSTOMIZE

2 ▼ or▲ SET DEFAULTS, CONTRAST ADJ LOWER, CONTRAST ADJ UPPER, LANGUAGE, SELECT STATS*, HR INPUTS, CHANGE UNITS, COOL DOWN, MAX TIME LIMIT

3 ENTER Selected choice

4 ▼ or▲(or numeeric keypad) Default value changes

5 ENTER CUSTOMIZE

6 clEaR SELECT WORKOUT

*The SELECT STATS menu display option is not active for the E916 and EV916. Set Defaults – resets the machine to the factory defaults for all configurable values. Please note that selecting this option will require the machine to be reconfigured (see Change Machine section).

noTe: All error and history counter data (Maint Hours, Distance, Workouts, Run Hours, Error Log, and QA ID Number) will be lost if Set Defaults is selected.

HR Inputs – enables the various heart rate inputs that can be used. Heart rate configurations include: Locked Inputs (both heart rate monitors are read until it detects a valid signal to lock on, at which point the other HR inputs are ignored), HR PRGM OFF, Both HR OFF, Hand Only, Telemetry Only, and Either Input (if one input is lost, then the other input may become active).

Change Units - changes all displayed data (service information and user data) to the selected units. Units are: Miles or Kilometers, MilesPerHour or KilometersPerHour, Pounds (LB) or Kilograms (KG), MinutesPerMile or MinutesPerKM.

Machine StatusUse the machine status codes to view maintenance information such as:• maintenance hours

• machine type (Elliptical)

• console software version

• distance traveled

• number of workouts

• machine run-time hours

machine Status


Refer to the following table to scan through and customize the settings:

Table 2–3. Machine Status


1 ▲,4,ENTER MACHINE STATUS

2 ▼ or▲ MAINT HOURS, ELLIPTICAL [or other], CONS, DISTANCE, WORKOUTS, RUN HOURS


Maint Hours – displays the number of hours (incremented every hour) the machine has been running. The start value is set under the Maintenance Logs service screen. (The start value can be set to any value—e.g. if the service tech had entered 100 in the Maintenance Logs service screen and there was 1 hour of running time on the machine, the value under this Maint Hours screen would read 101).

Machine Type – should display Elliptical. “NTM Config REQD” appears on the console if the software has been updated on the machine or the machine froze up and the power had to be cycled. The message also appears when the console assembly has been replaced and no configuration established. Configuring the machine will eliminate this message (see the table “Machine Configuration”).

Distance – displays the total distance in miles (or kilometers) of machine operation. This value is auto-incremented every 1/100th or 1/10th unit, depending on how many miles/km have accrued.

Workouts – displays the total number of workouts performed on the machine. This value is auto-incremented only if the user enters a workout and either completes the workout or presses the [STOP] key twice.

Run Hours – displays the total number of hours on the machine.

noTe: The R&D options (codes starting with 5) are not used for servicing machines. Do not change these settings. If an R&D setting is inadvertently changed, it will reset when the machine is powered off and then back on.

DiagnosticsUse diagnostic codes to test various components of the machine such as the:• tachometer

• alternator

• I/O

• sensor (for EV9.16 only)

• serial ports

• keypad

• display

Diagnostics

16

Refer to the following table to scan through the diagnostic tests and view diagnostic information:Table 2–4. Diagnostics


1 ▲,6,ENTER DIAGNOSTICS

2 ▼ or▲ TACH TEST, ALT TEST, I/O TEST, A SENSOR B, SERIAL PORTS, KEY TEST, DISPLAY TEST


4 clEaR DIAGNOSTICS


Tach Test – performs a tachometer test. On the left hand side of the display the target rate of 2000 rpm is displayed. On the right hand side of the display the actual rpm is displayed. If the actual rpm is above the target rate, then the alternator field turns on (the level increases). If the actual rpm is below the target rate, then the alternator field shuts off (the level decreases).

Alt Test – performs an alternator test. By pressing the level up key, the alternator field will turn on and the steps will become harder to rotate. By pressing the level down key, the alternator field will turn off and the steps will become easier to rotate.

I/O Test – The AUX and B+ values represent the current and voltage delivered from the alternator respectively. AUX is scaled by 1000 and B+ is scaled by 300. These values will increase with the speed of the alternator (note that both values will reach 0 if the alternator is left at rest). The “---” string is displayed at all times since the ellipticals do not require a magnetic key.

A Sensor B – is used only on the EV9.16. The A Sensor B diagnostic screen ensures the optical detector is functional. The A value is displayed on the left hand side of the upper display (B is not used on the EV9.16). Under normal conditions, the A value should toggle between the “0” and “1”.

Serial Ports - tests the serial ports (UARTS) for proper functionality. The tech can choose from either the CSAFE-1 Loopback or TM Loopback tests. Both of these tests result in PASS or FAIL. Please note that a null modem must be used to perform these tests.

Key Test - tests all of the user interface keys. Once a key is pressed, its value will show up on the display screen. After all keys have been pressed and are functional, a PASS message appears on the display.

Display Test - will test all segments on both the top and bottom displays.

Maintenance LogsThe MAINTENANCE LOGS settings allow you to view the quality assurance data, the machine’s error log, and reset the time between service and maintenance calls.

maintenance Logs


Refer to the following table to scan through the Maintenance Logs tests and view diagnostic information:

Table 2–5. Maintenance Logs


1 ▲,7,ENTER MAINTENANCE LOGS

2 ▼ or▲ QA ID NUMBER*, MAINT HOURS, ERROR LOG


4 clEaRafterviewing(orreset) MAINTENANCE LOGS


* The QA ID NUMBER option is not used for servicing machines in the field.

The following tables provide the steps for resetting the time between service or maintenance calls, and for viewing the error log:

Table 2–6. Reset Maintenance Hours



2 ▼,▼ MAINT HOURS

3 ENTER MAINT HOURS ####

4 clEaRtoexitafterviewing,or0,ENTERtoreset

MAINTENANCE LOGS


Maint Hours – lets the service technician enter a value representing the maintenance hours.

Table 2–7. Error Log



2 ▼,▼,▼ ERROR LOG

3 ENTER NO ERROR or the highest priority error

4 ▼ or▲ Scrolls through the error log list


Error Log – displays fatal errors accrued on the system. The log holds up to 8 error entries. Errors are handled in two ways:

n First, as a non-fatal Warning, which will display the error response text but continue system operation until you press the [CLEAR] key. Warnings are not logged in the Error Log.

n The second way is a fatal Error, which will stop the exercise and return the system to an idle intensity state. The console will display the error response and a number showing how many errors were logged during the specific event. (Some errors trigger multiple responses). To view the non-displayed errors, access the Error Log. The unit will not let you restart the program unless power has been turned off and then back on.

maintenance Logs

18

Once you access the Error Log, you can cycle the display through 8 entries by using the up/down keys. Each entry displays the error label, its position in the log (1-8), and the time (hours) the error occurred. Note that the most recent error might not be in log position 1—as the number of errors exceeds 8, the newest error will overwrite the oldest. In addition, if a new error is identical to the log’s previous entry, the system checks the time. If the time is the same (within minutes), the error is not logged, to help prevent redundant errors.

The only way to reset the Error Log is to reconfigure the machine.

Machine ConfigurationUse Machine Configuration to change the machine type. The choices are:• Stepper • StepMill • Bike• Elliptical

In general, only the Elliptical machine type is used for the EV916 or E916.

Refer to the following table to scan through and customize the settings:Table 2–8. Machine Configuration


1 ▲, 8, enTeR CHANGE MACHINE

2 enTeR ELLIPTICAL

3 ▼ or▲ NTM CONFIG RQD, STEPPER CL, STEPMILL, ELLIPTICAL, BIKE

4 enTeR Selects your choice

5 CLeAR SELECT WORKOUT

NTM Config RQD – resets the machine to a “blank” configuration. The configuration must be set to Elliptical (or other machine type) for the workout functions to operate.

Stepper CL – configures the machine as a cordless Stepper. Please note that there is a sense line to let the software know if the system is a Stepper PT (corded); if the system is indeed a Stepper PT, then Stepper PT will appear in the screen instead of Stepper CL.

machine Status


Electrical Troubleshooting2

Contents

Common Electrical Problems and Potential Causes .............................. 19

Troubleshooting Flowcharts ................................................................... 22

No Display .......................................................................................... 22

Resistance Problem ............................................................................ 24

Wiring Schematics

EV916 Power and Alternator Wiring Diagram ................................... 25

EV916 Top Level Wiring Diagram ....................................................... 26

E916 Main Power Wiring Diagram .................................................... 27

E916 Console Heart Rate Wiring Diagram ......................................... 28

20


Common electrical Problems and Potential Causes

The following tables provide possible causes and solutions to the most common types of electrical and electronic problems. while the information in these tables nay not resolve all problems, they should help you isolate the area affected by the problem.

Table2–1.TachometerProblem Potentialcauses Remedy

Does not maintain 2000 rpm during diagnostic test when pedals are in motion.

Alternator is bad. • Replace the alternator.

Field wire is loose or open. • Tighten screws on field wire.

• Replace field wire.

Inductive switch is open. • Adjust the gap on the inductive switch.

• Replace the inductive switch.

Main cable is open. • Replace the cable.

Table2–2.alternatorProblem Potentialcauses Remedy

There is no resistance to the pedals.

Alternator may be bad. • Replace the alternator.

Alternator drive belt is loose. • Adjust the alternator drive belt tension.

Table2–3.RemotecontrolProblem Potentialcauses Remedy

Remote control buttons on the swing arms do not work.

The cables are not plugged into the back of the console.

• Plug the cables into the back of the console.

The cable is not plugged into the elliptical swingarm PCBA.

• Plug the cable into the elliptical swingarm PCBA.

A screw has pierced through the cable(s).

• Replace the cable(s).

There is a short in the membrane switch.

• Replace the elliptical swingarm PCBA.

The remote control buttons are working backwards (i.e., the Quick Start button works as Speed Down button, and the Speed Down button works as the Quick Start button).

The right and left cables are reversed in back of the console.

• Reverse the cables in the back of the console.

commonElectricalProblemsandPotentialcauses

22

Table2–4.contactHeartRateMonitor(cHR)Problem Potentialcauses Remedy

CHR on a swingarms does not work.

The cables not plugged into the back of the console.

• Plug cables into the back of the console.

The cables are incorrectly plugged into the back of the console.

• Check to make sure cables are plugged in correctly.

The cable is not plugged into the contact plate on the grip.

• Plug the cable into the contact plate.


• Replace the cable(s).

The contact heart rate board is not functioning.

• Replace the CHR board in the console.

CHR on the fixed handle assembly does not work.

The cables not plugged into the back of the console.

• Plug the cables in the console.

The cables are incorrectly plugged into the back of the console.

• Make sure the cables are properly connected to the console.

The cable is not plugged into the contact plate on the grip.

• Plug the cable into the contact plate.


• Replace the cable.

The Contact Heart Rate (CHR) board is not functioning.

• Replace the CHR board.



Table2–5.consoleProblem Potentialcauses Remedy

The console does not power up (dead).

The console is not plugged into the main cable.

• Plug the main cable into the console.

The main cable is not plugged into the power board.

• Plug the main cable into the power board.

A screw has pierced through the CHR/ Remote Button cable.

• Remove the CHR cables from the console. If the console powers up, the screw is the problem. Replace the cable.

A screw has pierced through the main cable, or the main cable is pinched.

• Connect the power board to the console with the main cable on the outside of machine. If the console powers up, a screw or pinched cable is the problem. Replace the cable, and make sure not to crimp the cable when replacing it.

The battery is dead. • Charge the battery using the suppied charger.

• Replace the battery.

The speed sensor is too far from the speed disk.

• Readjust the gap.

The console is bad. • Replace the console.

The console powers up but locks up or flashes on and off.

A screw has pierced the CHR/ Remote Button cable.

• Remove the CHR cables from console. If the console powers up, a screw is the problem. Replace the cable.

A screw has pierced the main cable, or the main cable is pinched.

• Connect the power board to the console with the main cable on the outside of the machine. If the console powers up, a screw or pinched cable is the problem. Replace the cable, and make sure not crimp the cable when replacing it.

The console is bad. • Replace the console.

The battery is below 6.0V. • Refer to the electronic troubleshooting flowchart. Verify that the battery is bad with no secondary problem occurring.


24

No Display

Short TP7 to TP10 on the Power

Board.

Doesthe Console

displaylight?

Unplug J6 and check that the

voltage between the two contacts on the plug is 3 –

3.5VAC while rotating the crank

arms.

Isthe voltage

good?

Check that the gap in the Speed Sensor is no

greater than 1/16 of an inch.

Is the gap good?

Replace the Battery.

End

Readjust the Speed Sensor

gap.

Check that the voltage between TP12 (GND) and pin 1 of J3 on the

Power Board reads 6VDC when the pedals move.

Isthe voltage

good?

Replace the Power Board.

Replace the Speed Sensor.

End

No

Yes

No

Yes

No

Yes

EndNext Page

No

Yes

TroubleshootingFlowcharts


Check that the voltage between

U1 heatsink (GND) and pin 1 reads

6VDC.

Isthe voltage

good?Replace the cable.

EndCheck that the voltage between

U1 heatsink (GND) and pin 3 reads

5.5 to 6VDC.

Isthe voltage

good?

Replace the Processor/

Controller PCBA.

Replace the lens.

End

Previous Page

No

Yes

No

Yes


26


No Resistance

Disconnect the plug from J2 on

the Power Board, and check the

resistance between the plug’s

contacts.

Doesresistance read

.5 ohms?

Replace the Load Resistor.

Verify the voltage between TP5 and

TP9 varies between 4.4VDC and -3VDC as the

workout level changes from 1 – 20 respectively.

Isthe voltage

good?

Check that the level changes on

the Console display.

Workoutlevel changes

on thedisplay?

Replace the Processor/

Controller PCBA.

Replace the keypad.

End

Remove the plug on J1, short pins 1 and 3, and pedal.

Is therefull resistance

when you pedal?

Replace the Power Board.

Replace the Alternator.

End

No

Yes

No

Yes

No

Yes

No

Yes

End


main Power Wiring Diagram

BROW

N

BLAC

K(G

ROUN

D)

WHI

TE(B

+)

1358

4

(2144

5)

(4067

7)

SPEE

DSE

NSOR

POW

ER

BLAC

K

WHI

TE

-+

BATT

ERY

RESI

STOR

(4060

3)

(1357

2)

(4084

4)

(4047

1)

ALTE

RNAT

OR

32120

4

EV91

6 w

iring

mai

n fra

me

EV91

6El

liptic

alP

ower

Ele

ctro

nics

and

alte

rnat

orW

iring

Dia

gram

Not

es:

Plac

e fie

ld d

iode

ass

embl

y (2

1204

) bet

wee

n fie

ld a

nd g

roun

d te

rmin

als

on th

e al

tern

ator

(226

61).

Wiring Schematics overview

Use the schematics on the following pages to assist you in isolating and correcting electrical and electronic problems.

28

Console Heart Rate Wiring Diagram

(4046

6)RI

GHT S

WIN

GARM

(40

465)

LEFT

SWIN

GARM

(4069

2 SW

INGA

RM

PCBA

)(40

692 S

WIN

GARM

PC

BA)

"LEVE

L (UP

) - (DO

WN)"

"DIS

PLAY

LOCK

QU

ICKS

TART

"

GREE

N

BLAC

K

RED

WHI

TE

RED

FRON

TGR

IP

BLAC

KRE

ARGR

IP

RED

FRON

TGR

IP

BLAC

KRE

ARGR

IP

(4080

1 CON

SOLE

)

TO EL

LIPTIC

AL

POW

ER EL

ECTR

ONIC

S AN

D AL

TERN

ATOR

(4067

9)

(4084

4)

(4068

0)

(4068

0)

(4083

4ST

RIDE

SENS

OR)

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�1Nautilus® Commerical Series Elliptical Service Manual

Mechanical Troubleshooting3

Contents

Common Mechanical Problems and Solutions ...................................... 31

EV916 Top Level Wiring Diagram ........................................................... 18

EV916 Power and Alternator Wiring Diagram ....................................... 19

E916 Console Heart Rate Wiring Diagram ............................................. 20

E916 Main Power Wiring Diagram......................................................... 21

�2

mechanical Troubleshooting

��Nautilus® Commerical Series Elliptical Service Manual


Common Mechanical Problems and Solutions

Table3–1.FootPedalsProblem Potentialcauses Solutions

1 The plastic pedal cover screws are coming loose.

• The foot support and pedal cover holes are misaligned.

• Realign the foot pedal and foot support, then tighten the screws.

Table3–2.connectingarmProblem Potentialcauses Solutions

1 The connecting arm is making contact inside the rear pod cover, causing squeaking noise.

• The connecting arm has too much back and forth play during machine operation.

• Place Teflon washer behind the connecting arm end attached to the foot pedal weldment.

2 The seal is coming out of the self-aligning bearing (rear of the connecting arm).

Table3–3.PodcoversProblem Potentialcauses Solutions

1 The pod cover is loose. • The pod cover inserts are pulled out or stripped.

• Replace the pod cover.

2 There is a rubbing noise. • The pod cover is hitting the drivetrain cover.

• Verify that the snap ring securing the eccentric crank arm to the crank arm is flush against the back side of the crank arm.

Table3–4.NoisesProblem Potentialcauses Solutions

1 There is a clanking noise at the foot pedal(s).

• Screws holding the foot pedal in place have come loose.

• Tighten the screws attaching the foot pedal to the foot support.

• There is too much play between the foot support and the pivot shaft.

• Tighten the 5/16" button head screws attaching the foot support to the pivot shaft.

• The foot support is broken. Remove the foot pedal to verify.

• Replace the foot support.

�4


Table3–4.NoisesProblem Potentialcauses Solutions

2 There is a clunking feeling or noise when running on the machine (once per revolution).

• The crank arm is loose. • Tighten the screws securing the crank arm and foot plate. Replace if the screws are broken.

• Set screws in the drive pulley are loose.

• Tighten the set screws.

3 There is a rubbing noise. • The pod cover is hitting the drivetrain cover.

• Verify that the snap ring securing the eccentric crank arm to the crank arm is flush against the back side of the crank arm.

• The crank cover is hitting the drivetrain cover.

• Tighten the srews securing the crank cover to the crank arm.

4 There is a squeak where the the connectig arm and swing arm join.

• There is possible rust on the swing arm shaft.

• Clean the rust off the shaft using #000 steel wool.

5 Noise is coming from the drive belt.

• The drive belt is not tracking correctly on either the drive pulley or the intermediate pulley.

• Center the drive belt, making sure it rides correctly in the grooves on the drive and intermediate pulleys.

• Make sure the set screws securing the main drive pulley shaft are tight.

• The drive belt is worn. • Replace the drive belt.

• The intermediate pulley is cracked, causing the drive belt not to track correctly.

• Replace the intermediate pulley.

Table3–5.ResistanceProblem Potentialcauses Solutions

1 There is no resistance. • The drive pulley is loose.

• The belt has come off the drive or the alternator.

• The alternator is bad.

• See the Electrical Troubleshooting guide.


mechanical Procedures

E916 and EV916 Procedures

BElT TENSION ADjUSTMENT

Tools needed: • Ratchet• Cordless drill• 9/16 Socket • 7/16 Socket • phillips bit• Belt gauge (Kent Moore BT-33-73-F or equivalent)

Step 1: Remove the outer covers of the frame. Model: E916 -

1-1 Remove attaching screws to Drivetrain Cover. See Figure 1-1. Set the screws aside for Step 10.

1-2 place left Footlink pod in upswing position (see Figure 1-2).

1-3 Remove the attaching screws to the left Drivetrain Cover, and carefully move the cover over the pod toward the front of the machine (see Figure 1-3).

1-4 Repeat steps 1-2 and 1-3 on the Right Drivetrain Cover.

Model: EV916 - 1-1 Remove attaching screws to Drivetrain Cover (see

Figure 1-1). 1-2 place left Footlink pod in upswing position (see

Figure 1-2). 1-3 Remove the attaching screws to the left Rear Back

Cover and set aside. 1-4 Repeat steps 1-2 and 1-3 on the Right Rear Back

Cover.

Step 2: Remove attaching screws to Assembly, Resistor and Bracket (see Figure 1-4).

This section of the Service Manual provides instructions for servicing the EV916 and E916 ellipticals. The first segment contains procedures that apply to both elliptical models. The second segment contains instructions specific to the E916 elliptical, and the third contains instructions specific to the EV916 elliptical. For part number information, please refer to the separate documents for warranty parts lists and exploded drawings.

figure 1-1

figure 1-2

To avoid damage to the unit or electrical shock, unplug the e/eV9 machine before disassembling the

console or removing covers.

figure 1-3

�6


Step 3: loosen Bracket Bolts on right and left side (see Figure 1-5).

Step 4: loosen Adjustment Bolts on right and left side (see Figure 1-6).

Step 5: place Belt gauge on Drive Belt (Figure 1-7). Note: Suggested belt gauge is a Kent-Moore #BT-33-73-F.

Step 6: Tighten the adjustment bolts (see Figure 1-6) and watch the gauge until it reads 110-120 pounds. Note: The belt will stretch slightly after a short period of normal

operation. The tension should not go below 85 pounds.

Step 7: Retighten Bracket Bolts on right and left side (see Figure 1-5).

Step 8: place Belt gauge on Alternator Drive Belt (Figure 1-8).

Step 9: Tighten the Alternator Adjustment Bolt (see Figure 1-9) and watch the gauge until it reads 50-60 pounds. Note: The belt will stretch slightly after a short period of normal

operation. The tension should not go below 45 pounds.

Step 10: Reattach the Resistor Assembly and all covers securely.figure 1-6

figure 1-7 figure 1-8 figure 1-9

figure 1-5

figure 1-4

Resistor & BracketResistor & Bracket

Bracket Bolts

Adjustment Bolts

Drive Belt

Alternator Drive Belt

Alternator Adjustment BoltAlternator Adjustment Bolt

�7Nautilus® Commerical Series Elliptical Service Manual


BElT REplACEMENT

Tools needed: • Ratchet• Cordless drill• 9/16 Socket • 7/16 Socket • phillips bit• Belt gauge (Kent Moore BT-33-73-F or equivalent) • 1/8 Allen bit• 9/16 wrench • 15/16 Socket

Step 1: Remove the outer covers of the frame. Model: E916 -

1-1 Remove attaching screws to Drivetrain Cover. See Figure 2-1. Set the screws aside for Step 10.

1-2 place left Footlink pod in upswing position (see Figure 2-2).

1-3 Remove the attaching screws to the left Drivetrain Cover, and carefully move the cover over the pod toward the front of the machine (see Figure 2-3).

1-4 Repeat steps 1-2 and 1-3 on the Right Drivetrain Cover.

Model: EV916 - 1-1 Remove attaching screws to Drivetrain Cover (see

Figure 2-1). 1-2 place left Footlink pod in upswing position (see

Figure 2-2). 1-3 Remove the attaching screws to the left Rear Back

Cover and set aside. 1-4 Repeat steps 1-2 and 1-3 on the Right Rear Back

Cover.

Step 2: Remove attaching screws to Assembly, Resistor and Bracket (see Figure 2-4).



figure 2-1

figure 2-2

figure 2-3

figure 2-4

Resistor & BracketResistor & Bracket

�8


Step 3: loosen Bracket Bolts on right and left side (see Figure 2-5).

Step 4: loosen Adjustment Bolts on right and left side (see Figure 2-6).

Step 5: loosen Alternator Belt adjustment nut and push Alternator downward to loosen the belt (see Figure 2-7). Remove the loosened Alternator Belt from the Flywheel grooves.

Step 6: Remove the old Flywheel using a 15/16 socket, and replace with new smaller mass Flywheel. See Figure 2-8.

Step 7: Using a 1/8 Allen bit, untighten the Set Screws holding the Intermediate pulley in place (see Figure 2-9).

Step 8: From the right side, tap the Shaft back through the bracket and spacer, into the pulley. Remove the Drive Belt and Alternator Belt from the Intermediate pulley grooves.

Step 9: Remove the pillow Block bolts on both left and right side of the Drive pulley with a 9/16 socket and wrench (see Figure 2-10).

Step 10: lift the Drive Belt off the grooves and over the pillow Block to remove from the Drive pulley.

figure 2-6

figure 2-5

Bracket Bolts

Adjustment Bolts

figure 2-7

Alternator Adjustment BoltAlternator Adjustment Bolt

Figure 8 Figure 9 Figure 10



Step 11: place the new Alternator Belt onto the Intermediate pulley and Flywheel grooves. Then place new Drive Belt onto the Drive pulley and the Intermediate pulley grooves.

Step 12: Reattach the Drive pulley and pillow Blocks to the frame. Use the manufacturer’s marking on the frame to determine placement of the pillow Blocks, then tighten. (See Figure 2-10.)

Step 13: From the left side, tap the Shaft back through the Intermediate pulley, spacer, and bracket.

Step 14: Retighten the Set Screws attaching the Shaft (see Figure 2-9).

Step 15: Center the Drive pulley Belt on the Drive pulley and Intermediate pulley; tighten slightly. Note: It is very important that the belt is centered on

both pulleys (see Figure 2-11 and 12).

Step 16: place Belt gauge on Drive Belt (Figure 2-13). Note: Suggested belt gauge is a Kent-Moore

#BT-33-73-F.

Step 17: Tighten the adjustment bolts (see Figure 2-6) and watch the gauge until it reads 110-120 pounds. Note: The belt will stretch slightly after a short

period of normal operation. The tension should not go below 85 pounds.

Step 18: Retighten Bracket Bolts on right and left side (see Figure 2-5).

Step 19: place Belt gauge on Alternator Drive Belt (Figure 2-14).

Figure 12

Figure 11

figure 14

figure 13

Drive Belt

Alternator Drive Belt

40


Step 20: Tighten the Alternator Adjustment Bolt (see Figure 2-7) and watch the gauge until it reads 50-60 pounds. Note: The belt will stretch slightly after a short

period of normal operation. The tension should not go below 45 pounds.

Step 21: Reattach the Resistor Assembly and all covers se-curely.

Step 22: Retest the machine and adjust as needed.

UppER pIVOT ShAFT lUBRICATION

Tools needed: • (Two) 3/4 inch wrenches• Snap Ring pliers• long Shaft phillips Bit • Cordless Drill • Rust Inhibitor cloth (Corwipe® 500 - p/N 40040-001)• petroleum based lubricant (lubriplate made by Fiske

Brothers Refining Company)

On the LEFT SIDE of the machine:

Step 1: Remove the Swing Arm Assembly from the Mast, exposing the Upper pivot Shaft.





42




44


Appendixes

Contents

Appendix A—Required Tools ..................................................................... 68

Appendix B—International Power Plug Configurations ............................. 68

46

Appendix

Required ToolsThis is a list of the most common tools you will need to service the E916 and EV916 Ellipticals.

Table A–1. Required Tools and Uses

Tool Purposes

Socket wrench General

3/4" socket (deep well) Removing and installing misalignment nut

3/4" open-end box wrench Removing and installing nut on swing arm and foot link assembly

1/4" Allen wrench Hex cap screws on crank arms

9/16" wrench Adjusting belt tension

9/16" Allen wrench Removing and installing screws on crank cover

7/16" Allen wrench Adjusting belt tension

#2 Philips screwdriver Removing and installing screws on pod and drivetrain covers

Snap Ring Pliers Connecting arm and eccentric crank arm

Tape Measure Adjusting belt tension

Diagonal cutters General

Multimeter Electrical troubleshooting

International Power Plug Configurations

Table B–1. International Power Plugs

Powercords System country

G UK

C, E, F Europe

J Swiss

K Australia

L


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. (“Nautilus”) will void any warranty coverage set forth by Nautilus® warranty policies and procedures.

Time Period Frame: 15 years Mechanical and electrical parts : 3 years labor: 1 year wear Items: 1 year

Note – Warranty only applies to use of product in non-dues paying facility settings.

What This Warranty Does Not Cover1. Any component on original equipment which carries a

separate consumer warranty of the parts supplier.

2. Users weighing more than 400 lbs.

3. 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, or disaster (such as floods or power surges).

4. Use of product in an application not recommended by Nautilus, Inc. or in a manner or environment for which it was not designed.

5. Damage due to normal wear and tear.

Limitations

The preceding warranties are the sole and exclusive express warranties made by Nautilus. They supersede any prior, contrary or additional representations, whether oral or written. No agent, representative, dealer or employee has the authority to alter or increase the obligation or limitations of this warranty. Any implied warranties, including the wARRANTy OF MERChANTABIlITy and any wARRANTy OF FITNESS FOR A pARTICUlAR pURpOSE, are limited in duration to the term of the applicable express warranty provided above, whichever is longer. Some

states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

What Nautilus Will Do

Nautilus’s liability hereunder is expressly limited to the replacement of goods not complying with this warranty or, at Nautilus’s election, to the return of the purchase price of the exercise product in question. ThESE REMEDIES ARE ThE EXClUSIVE AND SOlE REMEDIES FOR ANy BREACh OF wARRANTy. Nautilus shall in no event be liable for incidental or consequential losses, damages or expenses in connection with its exercise products. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

Procedureswarranty 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 will have the option to repair or replace any exercise product, which requires service. Nautilus reserves the right to refund the purchase price.

2. Nautilus 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 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, Nautilus shall not be liable for any cost, damage, failure or loss caused by the use of such unauthorized service or parts.

Warranty

Warranty Information

48

ImPoRTAnT ConTACT numbeRS

If you need assistance, please have both the serial number of your machine and the date of purchase available when you contact the appropriate Nautilus office listed below.

© 200�. Nautilus, Inc. All Rights Reserved. Nautilus, the Nautilus Logo, Be Strong, MyStride, SyncLynk are either registered trademarks or trademarks of Nautilus, Inc. Polar is a registered trademark of its respective company.

WoRLDWIDe CuSTomeR SeRVICe

• noRTH AmeRICA offICe Nautilus, Inc.

world headquarters 16400 S.E. Nautilus Drive Vancouver, washington, USA 98683 phone: 800-NAUTIlUS e-mail: [email protected]

• nAuTILuS InnoVATIon CenTeR Nautilus, Inc.

1886 prairie way louisville, Colorado, USA 80027 phone: 800-864-1270 Fax: 800-898-9410

• CoRPoRATe HeADQuARTeRS Nautilus, Inc.

world headquarters 16400 S.E. Nautilus Drive Vancouver, washington, USA 98683 phone: 800-NAUTIlUS

InTeRnATIonAL CuSTomeR SeRVICe

• SWITZeRLAnD offICe Nautilus International S.A.

Rue jean prouve 6 1762 givisiez / Switzerland Tel: +41-26-460-77-77 Fax: +41-26-460-77-70

INTERNATIONAl OFFICES:

• SWITZeRLAnD offICe Nautilus International S.A.

Rue jean prouve 6 1762 givisiez / Switzerland Tel: +41-26-460-77-77 Fax: +41-26-460-77-70 web: www.nhfg-intl.com

• GeRmAny and AuSTRIA offICe Nautilus gmbh

Tel: 02204-61027 Fax: 02204-62890

• ITALy offICe Nautilus Italy s.r.l.

Tel: 031-51-10-86 Fax: 031-34-24-97

• unITeD KInGDom offICe Nautilus UK ltd.

Tel: 01-908-267-345 Fax: 01-908-267-346


Documents

Service Manual Commercial Series Elliptical · authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty. If you are a consumer and require