Be Strong. Service Manual Commercial Series Elliptical. Model: E916 & EV916. PN 40478A Rev B (8/2006)

Transcription

1 Be Strong. Service Manual Commercial Series Elliptical Model: E916 & EV916 PN 40478A Rev B (8/2006)

2 Important Please Read 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 (USA) or (outside USA). 2

3 Table of Contents Important Safety Information...5 Product Specifications EV916 Elliptical Trainer...6 E916 Elliptical Trainer...7 Console Codes Overview...11 Defaults...11 Customize...11 Machine Status...12 Diagnostics...13 Maintenance Logs...14 Machine Configuration...16 Wiring Schematics 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 Troubleshooting EV916 Top Level Wiring Diagram...18 Appendixes Required Tools...68 International Power Plug Configurations...68 Warranty Information...69 Contact Numbers...70 Nautilus Commerical Series Elliptical Service Manual

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5 Safety Requirements 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. 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. 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. Nautilus Commerical Series Elliptical Service Manual

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) (North America) or (International office). Label 1 Label 1 6

7 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 (North America) or (International office) to obtain a new label. Label 1: See Figure 1 for connector warning label for the battery charger plug. Figure 1 Location: The warning label in Figure 1 is located on the back of the machine above the battery charger plug. Nautilus Commerical Series Elliptical Service Manual 7

8 Specifications - EV916 Elliptical Trainer with MyStride Technology Electrical Power Battery Type Battery Charge Time Display Cordless, or VAC, 50/60 Hz, 20 watts maximum (operation with charger connected) 6VDC sealed lead-acid 8 hours to full charge, starting with discharged battery C51 blue/white LCD with backlight Tactile membrane keypanel Physical Length Width Height Weight Max User Weight Supported Belt(s) 94 in. (239 cm) 28 in. (71 cm) 62 in. (157.5 cm) 350 lb. (147 kg) 400 lb. (181 kg) Two: 10-groove drive belt and 6-groove alternator belt Functionality Ellipse Stride Length Number of Functions Heart Rate Monitoring Workout Programs Resistance Range Language Options C-Safe Compatible Dynamically variable up to 30 (76 cm) Ten: Heart rate, elapsed time, calories burned, calories burned per hour, watts, METS, resistance level, rpm, distance, and workout profile Integrated heat rate monitoring system with polar-compatible wireless and contact HR Twelve: Quick Start, Manual, Fat Burner, Calorie Burner, Intervals, HR Zone Trainer, multi-stage Fit Test. Custom Intervals, HR Intervals, Random Play Twenty: 20 watts (level 1, 20 rpm) to 300 watts (level 20, 100 rpm) English, German, French, Spanish, Italian, Dutch, Portuguese Level 2 compatible. Owner/manager will be able to customize console. Environmental Operating Temperature o F (10 32 o C) Storage Temperature o C Operating Humidity (non-condensing) 3 95% relative humidity Storage Humidty (non-condensing) 3 95% relative humidity 8

9 Specifications - E916 Elliptical Trainer with SyncLink Stride Technology Electrical Power Battery Type Battery Charge Time Display Cordless, or VAC, 50/60 Hz, 20 watts maximum (operation with charger connected) 6VDC sealed lead-acid 8 hours to full charge, starting with discharged battery C51 blue/white LCD with backlight Tactile membrane keypanel Physical Length Width Height Weight Max User Weight Supported Belt(s) 82 in. (208 cm) 28 in. (71 cm) 62 in. (157.5 cm) 325 lb. (147 kg) 400 lb. (181 kg) Two: 10-groove drive belt and 6-groove alternator belt Functionality Ellipse Stride Length Number of Functions Heart Rate Monitoring Workout Programs Resistance Range Language Options C-Safe Compatible 18 (46 cm) Ten: Heart rate, elapsed time, calories burned, calories burned per hour, watts, METS, resistance level, rpm, distance, and workout profile Integrated heat rate monitoring system with polar-compatible wireless and contact HR Twelve: Quick Start, Manual, Fat Burner, Calorie Burner, Intervals, HR Zone Trainer, multi-stage Fit Test. Custom Intervals, HR Intervals, Random Play Twenty: 20 watts (level 1, 20 rpm) to 300 watts (level 20, 100 rpm) English, German, French, Spanish, Italian, Dutch, Portuguese Level 2 compatible. Owner/manager will be able to customize console. Environmental Operating Temperature o F (10 32 o C) Storage Temperature o C Operating Humidity (non-condensing) 3 95% relative humidity Storage Humidty (non-condensing) 3 95% relative humidity Nautilus Commerical Series Elliptical Service Manual

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11 1 Console Codes Contents Overview Defaults Customize Machine Status Diagnostics Maintenance Logs Reset Maintenance Hours Error Log Machine Configuration Nautilus Commerical Series Elliptical Service Manual 11

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13 Customization Overview To 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. Defaults You 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 ( lbs. or 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 Customize You 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) Nautilus Commerical Series Elliptical Service Manual 13

14 Machine Status 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 Step No. Press Keys Display (What you will see) 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 Status Use 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 14

15 Diagnostics Refer to the following table to scan through and customize the settings: Table 2 3. Machine Status Step No. Press Keys Display (What you will see) 1, 4, ENTER MACHINE STATUS 2 or MAINT HOURS, ELLIPTICAL [or other], CONS, DISTANCE, WORKOUTS, RUN HOURS 3 CLEAR SELECT WORKOUT 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. Diagnostics Use 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 Nautilus Commerical Series Elliptical Service Manual 15

16 Maintenance Logs Refer to the following table to scan through the diagnostic tests and view diagnostic information: Table 2 4. Diagnostics Step No. Press Keys Display (What you will see) 1, 6, ENTER DIAGNOSTICS 2 or TACH TEST, ALT TEST, I/O TEST, A SENSOR B, SERIAL PORTS, KEY TEST, DISPLAY TEST 3 ENTER Selected choice 4 CLEAR DIAGNOSTICS 5 CLEAR SELECT WORKOUT 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 Logs The 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. 16

17 Maintenance Logs Refer to the following table to scan through the Maintenance Logs tests and view diagnostic information: Table 2 5. Maintenance Logs Step No. Press Keys Display (What you will see) 1, 7, ENTER MAINTENANCE LOGS 2 or QA ID NUMBER*, MAINT HOURS, ERROR LOG 3 ENTER Selected choice 4 CLEAR after viewing (or reset) MAINTENANCE LOGS 5 CLEAR SELECT WORKOUT * 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 Step No. Press Keys Display (What you will see) 1, 7, ENTER MAINTENANCE LOGS 2, MAINT HOURS 3 ENTER MAINT HOURS #### 4 CLEAR to exit after viewing, or 0, ENTER to reset MAINTENANCE LOGS 5 CLEAR SELECT WORKOUT Maint Hours lets the service technician enter a value representing the maintenance hours. Table 2 7. Error Log Step No. Press Keys Display (What you will see) 1, 7, ENTER MAINTENANCE LOGS 2,, ERROR LOG 3 ENTER NO ERROR or the highest priority error 4 or Scrolls through the error log list 5 CLEAR SELECT WORKOUT Error Log displays fatal errors accrued on the system. The log holds up to 8 error entries. Errors are handled in two ways: n 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. 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. Nautilus Commerical Series Elliptical Service Manual 17

18 Machine Status 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 Configuration Use 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 Step No. Press Keys Display (What you will see) 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. 18

19 2 Electrical Troubleshooting Contents Common Electrical Problems and Potential Causes Troubleshooting Flowcharts No Display Resistance Problem Wiring Schematics EV916 Power and Alternator Wiring Diagram EV916 Top Level Wiring Diagram E916 Main Power Wiring Diagram E916 Console Heart Rate Wiring Diagram Nautilus Commerical Series Elliptical Service Manual 19

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21 Common Electrical Problems and Potential Causes 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. Table 2 1. Tachometer Problem Potential Causes Remedy Does not maintain 2000 rpm during diagnostic test when pedals are in motion. Alternator is bad. Field wire is loose or open. Inductive switch is open. Main cable is open. Replace the alternator. Tighten screws on field wire. Replace field wire. Adjust the gap on the inductive switch. Replace the inductive switch. Replace the cable. Table 2 2. Alternator Problem Potential Causes Remedy There is no resistance to the pedals. Alternator may be bad. Alternator drive belt is loose. Replace the alternator. Adjust the alternator drive belt tension. Table 2 3. Remote Control Problem Potential Causes Remedy Remote control buttons on the swing arms do not work. 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 cables are not plugged into the back of the console. The cable is not plugged into the elliptical swingarm PCBA. A screw has pierced through the cable(s). There is a short in the membrane switch. The right and left cables are reversed in back of the console. Plug the cables into the back of the console. Plug the cable into the elliptical swingarm PCBA. Replace the cable(s). Replace the elliptical swingarm PCBA. Reverse the cables in the back of the console. Nautilus Commerical Series Elliptical Service Manual 21

22 Common Electrical Problems and Potential Causes Table 2 4. Contact Heart Rate Monitor (CHR) Problem Potential Causes Remedy CHR on a swingarms does not work. CHR on the fixed handle assembly does not work. The cables not plugged into the back of the console. The cables are incorrectly plugged into the back of the console. The cable is not plugged into the contact plate on the grip. A screw has pierced through the cable(s). The contact heart rate board is not functioning. The cables not plugged into the back of the console. The cables are incorrectly plugged into the back of the console. The cable is not plugged into the contact plate on the grip. A screw has pierced through the cable(s). The Contact Heart Rate (CHR) board is not functioning. Plug cables into the back of the console. Check to make sure cables are plugged in correctly. Plug the cable into the contact plate. Replace the cable(s). Replace the CHR board in the console. Plug the cables in the console. Make sure the cables are properly connected to the console. Plug the cable into the contact plate. Replace the cable. Replace the CHR board. 22

23 Common Electrical Problems and Potential Causes Table 2 5. Console Problem Potential Causes Remedy The console does not power up (dead). The console powers up but locks up or flashes on and off. The console is not plugged into the main cable. The main cable is not plugged into the power board. A screw has pierced through the CHR/ Remote Button cable. A screw has pierced through the main cable, or the main cable is pinched. The battery is dead. The speed sensor is too far from the speed disk. The console is bad. A screw has pierced the CHR/ Remote Button cable. A screw has pierced the main cable, or the main cable is pinched. The console is bad. The battery is below 6.0V. Plug the main cable into the console. Plug the main cable into the power board. Remove the CHR cables from the console. If the console powers up, the screw is the problem. Replace the cable. 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. Charge the battery using the suppied charger. Replace the battery. Readjust the gap. Replace the console. Remove the CHR cables from console. If the console powers up, a screw is the problem. Replace the cable. 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. Replace the console. Refer to the electronic troubleshooting flowchart. Verify that the battery is bad with no secondary problem occurring. Nautilus Commerical Series Elliptical Service Manual 23

24 Troubleshooting Flowcharts No Display Short TP7 to TP10 on the Power Board. Does the Console display light? No Replace the Battery. Yes Unplug J6 and check that the voltage between the two contacts on the plug is 3 3.5VAC while rotating the crank arms. End Is the voltage good? No Check that the gap in the Speed Sensor is no greater than 1/16 of an inch. Yes Check that the voltage between TP12 (GND) and pin 1 of J3 on the Power Board reads 6VDC when the pedals move. Is the gap good? No Readjust the Speed Sensor gap. Yes Is the voltage good? No Replace the Power Board. Replace the Speed Sensor. Yes Next Page End End 24

25 Troubleshooting Flowcharts Previous Page Check that the voltage between U1 heatsink (GND) and pin 1 reads 6VDC. Is the voltage good? No Replace the cable. Yes Check that the voltage between U1 heatsink (GND) and pin 3 reads 5.5 to 6VDC. End Is the voltage good? No Replace the Processor/ Controller PCBA. Yes Replace the lens. End Nautilus Commerical Series Elliptical Service Manual 25

26 Troubleshooting Flowcharts No Resistance Disconnect the plug from J2 on the Power Board, and check the resistance between the plug s contacts. Does resistance read.5 ohms? No Replace the Load Resistor. Yes Verify the voltage between TP5 and TP9 varies between 4.4VDC and -3VDC as the workout level changes from 1 20 respectively. End Is the voltage good? No Check that the level changes on the Console display. Yes Remove the plug on J1, short pins 1 and 3, and pedal. Workout level changes on the display? No Replace the Processor/ Controller PCBA. Yes Is there full resistance when you pedal? No Replace the Alternator. Replace the keypad. Yes End Replace the Power Board. End 26

27 Main Power Wiring Diagram Wiring Schematics Overview Use the schematics on the following pages to assist you in isolating and correcting electrical and electronic problems (40471) (40844) WHITE BLACK - + BATTERY BROWN BLACK (GROUND) (40677) (21445) POWER SPEED SENSOR WHITE(B+) ALTERNATOR EV916 Elliptical Power Electronics and Alternator Wiring Diagram (13572) (40603) RESISTOR Notes: Place field diode assembly (21204) between field and ground terminals on the alternator (22661). Nautilus Commerical Series Elliptical Service Manual 27

28 Console Heart Rate Wiring Diagram (40680) (40465) LEFT SWINGARM (40466) RIGHT SWINGARM "DISPLAY LOCK QUICKSTART" "LEVEL (UP) - (DOWN)" (40680) (40692 SWINGARM PCBA) (40692 SWINGARM PCBA) GREEN RED FRONT GRIP BLACK REAR GRIP BLACK REAR GRIP RED FRONT GRIP EV916 Elliptical Top Level Wiring Diagram (40835) (40801 CONSOLE) RIGHT LEFT (40679) FROM BOTTOM OF MAST RED BLACK WHITE FIXED "T-BAR" CONTACT HEART RATE GRIPS TO ELLIPTICAL POWER ELECTRONICS AND ALTERNATOR (40471) (40844) (40836) (40834 STRIDE SENSOR) (25165 POLAR SENSOR) CABLE #17841 TO T.V. (T.V. COMPATIBLE ONLY) 28

29 Main Power Wiring Diagram (21204) (40678) WHITE + - BLACK BATTERY BROWN BLACK (GROUND) WHITE(B+) ALTERNATOR E916 Elliptical Main Power Wiring Diagram (21445) POWER (13584) (40710) (40844) SPEED SENSOR (40603) RESISTOR Notes: Place field diode assembly (21204) between field and ground terminals on the alternator (22661). Nautilus Commerical Series Elliptical Service Manual 29

30 Console Heart Rate Wiring Diagram NAUTILUS E916 ELLIPTICAL TOP-LEVEL WIRING (41531 CONSOLE) (40680) RIGHT (40465) LEFT SWINGARM (40466) RIGHT SWINGARM "DISPLAY LOCK QUICKSTART" "LEVEL (UP) - (DOWN)" (40680) (40692 SWINGARM PCBA) (40692 SWINGARM PCBA) GREEN RED FRONT GRIP BLACK REAR GRIP BLACK REAR GRIP RED FRONT GRIP BLACK WHITE FIXED "T-BAR" CONTACT HEART RATE GRIPS E916 Elliptical Console Heart Rate Wiring Diagram (40679) LEFT FROM BOTTOM OF MAST RED TO ELLIPTICAL POWER ELECTRONICS AND ALTERNATOR (40710) (40844) (40836) (25165 POLAR SENSOR) CABLE TO T.V. (T.V. ONLY) 30

31 3 Mechanical Troubleshooting Contents Common Mechanical Problems and Solutions EV916 Top Level Wiring Diagram EV916 Power and Alternator Wiring Diagram E916 Console Heart Rate Wiring Diagram E916 Main Power Wiring Diagram Nautilus Commerical Series Elliptical Service Manual 31

32 32 Mechanical Troubleshooting

33 Mechanical Troubleshooting Common Mechanical Problems and Solutions Table 3 1. Foot Pedals Problem Potential Causes 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. Table 3 2. Connecting Arm Problem Potential Causes Solutions 1 The connecting arm is making contact inside the rear pod cover, causing squeaking noise. 2 The seal is coming out of the self-aligning bearing (rear of the connecting arm). 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. Table 3 3. Pod Covers Problem Potential Causes Solutions 1 The pod cover is loose. The pod cover inserts are pulled out or stripped. 2 There is a rubbing noise. The pod cover is hitting the drivetrain cover. Replace the pod 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. Table 3 4. Noises Problem Potential Causes Solutions 1 There is a clanking noise at the foot pedal(s). Screws holding the foot pedal in place have come loose. There is too much play between the foot support and the pivot shaft. The foot support is broken. Remove the foot pedal to verify. Tighten the screws attaching the foot pedal to the foot support. Tighten the 5/16" button head screws attaching the foot support to the pivot shaft. Replace the foot support. Nautilus Commerical Series Elliptical Service Manual 33

34 Mechanical Troubleshooting Table 3 4. Noises Problem Potential Causes Solutions 2 There is a clunking feeling or noise when running on the machine (once per revolution). The crank arm is loose. Set screws in the drive pulley are loose. 3 There is a rubbing noise. The pod cover is hitting the drivetrain cover. 4 There is a squeak where the the connectig arm and swing arm join. 5 Noise is coming from the drive belt. The crank cover is hitting the drivetrain cover. There is possible rust on the swing arm shaft. The drive belt is not tracking correctly on either the drive pulley or the intermediate pulley. Tighten the screws securing the crank arm and foot plate. Replace if the screws are broken. Tighten the set screws. Verify that the snap ring securing the eccentric crank arm to the crank arm is flush against the back side of the crank arm. Tighten the srews securing the crank cover to the crank arm. Clean the rust off the shaft using #000 steel wool. 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. The intermediate pulley is cracked, causing the drive belt not to track correctly. Replace the drive belt. Replace the intermediate pulley. Table 3 5. Resistance Problem Potential Causes Solutions 1 There is no resistance. The drive pulley is loose. The belt has come off the drive or the alternator. See the Electrical Troubleshooting guide. The alternator is bad. 34

35 Mechanical Procedures 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. 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 F or equivalent) To avoid damage to the unit or electrical shock, unplug the E/EV9 machine before disassembling the console or removing covers. Step 1: Remove the outer covers of the frame. Model: E Remove attaching screws to Drivetrain Cover. See Figure 1-1. Set the screws aside for Step 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: EV 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. Figure 1-1 Figure 1-2 Step 2: Remove attaching screws to Assembly, Resistor and Bracket (see Figure 1-4). Figure 1-3 Nautilus Commerical Series Elliptical Service Manual 35

36 Mechanical Procedures 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). Resistor & Bracket Note: Suggested belt gauge is a Kent-Moore #BT F. Step 6: Tighten the adjustment bolts (see Figure 1-6) and watch the gauge until it reads pounds. Figure 1-4 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). Bracket Bolts Step 8: place Belt Gauge on Alternator Drive Belt (Figure 1-8). Figure 1-5 Step 9: Tighten the Alternator Adjustment Bolt (see Figure 1-9) and watch the gauge until it reads 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 Adjustment Bolts Alternator Adjustment Bolt Drive Belt Alternator Drive Belt Figure 1-7 Figure 1-8 Figure

37 Mechanical Procedures Belt Replacement Tools needed: Ratchet Cordless drill 9/16 Socket 7/16 Socket Phillips bit Belt Gauge (Kent Moore BT F or equivalent) 1/8 Allen bit 9/16 Wrench 15/16 Socket To avoid damage to the unit or electrical shock, unplug the E/EV9 machine before disassembling the console or removing covers. Step 1: Remove the outer covers of the frame. Model: E Remove attaching screws to Drivetrain Cover. See Figure 2-1. Set the screws aside for Step 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: EV 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. Figure 2-1 Figure 2-2 Step 2: Remove attaching screws to Assembly, Resistor and Bracket (see Figure 2-4). Figure 2-3 Resistor & Bracket Figure 2-4 Nautilus Commerical Series Elliptical Service Manual 37

38 Mechanical Procedures 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. Figure 2-5 Bracket Bolts 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). Figure 2-6 Adjustment Bolts 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. Alternator Adjustment Bolt 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). Figure 2-7 Step 10: lift the Drive Belt off the grooves and over the Pillow Block to remove from the Drive Pulley. Figure 8 Figure 9 Figure 10 38

39 Mechanical Procedures 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.) Figure 11 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. Figure 12 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). Drive Belt Note: Suggested belt gauge is a Kent-Moore #BT F. Step 17: Tighten the adjustment bolts (see Figure 2-6) and watch the gauge until it reads pounds. Figure 13 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). Alternator Drive Belt Figure 14 Nautilus Commerical Series Elliptical Service Manual 39

40 Mechanical Procedures Step 20: Tighten the Alternator Adjustment Bolt (see Figure 2-7) and watch the gauge until it reads 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 securely. 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 P/N ) petroleum based lubricant (Lubriplate made by Fiske Brothers Refining Company) To avoid damage to the unit or electrical shock, unplug the E/EV9 machine before disassembling the console or removing covers. On the LEFT SIDE of the machine: Step 1: Remove the Swing Arm Assembly from the Mast, exposing the Upper Pivot Shaft. 40

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45 Appendixes Contents Appendix A Required Tools Appendix B International Power Plug Configurations Nautilus Commerical Series Elliptical Service Manual 45

46 Appendix Required Tools This 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 Socket wrench Purposes 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 Tape Measure Diagonal cutters Multimeter Connecting arm and eccentric crank arm Adjusting belt tension General Electrical troubleshooting International Power Plug Configurations Table B 1. International Power Plugs Power Cords System Country G UK C, E, F Europe J K Swiss Australia L 46

47 Warranty 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. ( 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 Cover 1. 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. 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 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. Nautilus Commerical Series Elliptical Service Manual 47

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. WORLDWIDE CUSTOMER SERVICE north AMERICA OFFICE Nautilus, Inc. World Headquarters S.E. Nautilus Drive Vancouver, Washington, USA Phone: 800-NAUTILUS INTERNATIONAL CUSTOMER SERVICE SWITZERLAND OFFICE Nautilus International S.A. Rue Jean Prouve Givisiez / Switzerland Tel: Fax: INTERNATIONAL OFFICES: nautilus INNOVATION CENTER Nautilus, Inc Prairie Way Louisville, Colorado, USA Phone: Fax: CORPORATE HEADQUARTERS Nautilus, Inc. World Headquarters S.E. Nautilus Drive Vancouver, Washington, USA Phone: 800-NAUTILUS SWITZERLAND OFFICE Nautilus International S.A. Rue Jean Prouve Givisiez / Switzerland Tel: Fax: Web: GERMANY and AUSTRIA OFFICE Nautilus GmbH Tel: Fax: ITALY OFFICE Nautilus Italy s.r.l. Tel: Fax: united KINGDOM OFFICE Nautilus UK Ltd. Tel: Fax: 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. 48

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