Be Strong. assemblymanual TreadClimber Model TC916 Commercial Series. P/n: revb(11/09/2006)

Transcription

1 Be Strong. assemblymanual TreadClimber Model TC916 Commercial Series P/n: revb(11/09/2006)

2 For detailed instructions and information on how to use and care for your treadclimber Commercial series exercise machine, model tc916, refer to the owner s manual.

3 Table of contents Treadclimber Features... 4 PRODUCT Specifications... 5 Important Safety precautions... 6 Warranty Information: Time Period... 8 What this Warranty Does Not Cover... 8 Limitations... 8 Procedures... 8 Getting Started: Select Your Workout Area... 9 Power Plug Receptacle... 9 Turning on the Power... 9 Understanding the Display and Controls... 9 Limited Access Control/Magnetic Safety Stop Magnetic Key Safety Stop Activation Quick start guide Moving instructions: Moving instructions for fully assembled unit: moving Your treadclimber tc removing machine from pallet moving unit into position in facility Disassembly of Upright Unit: Important information to read before disassembling upright unit.. 16 Removing Rear Step Removing Uprights Removing Base Plastic moving tool information Assembly instructions for crated unit: before YOU ASSEMBLE basic assembly principles hardware AND tool list parts list reference guide unpacking GUIDE assembly guide BELT TENSION AND ALIGNMENT Important contact numbers: Nautilus TreadClimber Model TC916 Assembly Manual

4 TReaDclIMbeR features console ergo bar Power on/off switch Model: Tc916 adjustable feet 4

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

6 Important safety Precautions SAVE THESE INSTRUCTIONS: The following definition applies to the word Warning found throughout this manual: Used to call attention to POTENTIAL hazards that could result in personal injury or loss of life. WHEN USING ELECTRICAL EQUIPMENT ALWAYS FOLLOW THESE BASIC PRECAUTIONS: To reduce the risk of electrical shock, always unplug the external power supply from the electrical outlet before cleaning, maintaining, or repairing. To reduce the risk of burns, electric shock or injury to persons read and follow all safety warnings and instructions in this manual. Secure long hair and loose clothing before use. Do not use near water! 6 READ ALL INSTRUCTIONS BEFORE USING THE MACHINE. Read this manual in full before operating the TreadClimber machine. Failure to follow these guidelines can produce a serious or possible fatal electrical shock hazard or other serious injury. Consult a qualified electrician as required. 1. The controller Stop Key does not turn off the electrical current to the TreadClimber exercise machine. The TreadClimber machine continues to draw power, even when the controller is off. To avoid electric shock, do not remove TreadClimber hood or place hands beneath the TreadClimber exercise machine while the machine is plugged into a power source. 2. Do not start the TreadClimber machine when someone else is standing on the walk belts. 3. Keep walk speed and treadle displacement at the lowest settings when getting on and off the TreadClimber machine. 4. Keep the area underneath and around the TreadClimber exercise machine clear. 5. Never position the TreadClimber exercise machine with the back end (direction of belt travel) facing a wall or any other objects such as furniture or other pieces of fitness equipment. Failure to keep the rear space of the machine clear can prevent safe exit of the TreadClimber machine in an emergency situation such as falling. Allow a minimum of four feet behind the TreadClimber exercise machine.

7 Important safety precautions 6. Before each use of this equipment, check the power receptacle for signs of damage. Do not operate the equipment if the integrity of the power receptacle is in question. 7. To avoid potential safety and electrical problems, replace with manufacturer s specified parts only. 8. This equipment is classified Class I, Type B, ordinary equipment. Not protected against fluid ingress. Rated for continuous operation. Do not operate this equipment in the presence of flammable anesthetic mixtures. 9. Do not let liquid enter the controller. If it does, the controller must be inspected and tested for safety by an approved technician before it can be used again. 10. Increased risk due to leakage current can result if this equipment is not grounded properly. 11. The TreadClimber machine must be on an appropriate, dedicated electrical circuit. Nothing else should be connected to the circuit. 12. Do not stand on the TreadClimber TC916 s hood or front trim cover. 13. Close supervision is necessary whenever the machine is used by or near children, invalids, or disabled persons. Failure to follow the conditions set forth below shall limit, to the extent allowed by law, Nautilus Inc. s responsibility for the safety, reliability, and performance of this equipment. The operator manual must be read in full by each owner and trainer before the product is first used. Each user must be instructed in the proper use of the TreadClimber machine and its accessories. Do not remove the TreadClimber hood: dangerous voltages are present. Components are serviceable only by qualified service personnel. The electrical wiring within the TreadClimber equipment setting and the electrical installation of the TreadClimber machine must comply with the applicable local or provincial requirements. The equipment must be used in accordance with the instructions for use. For further information or instruction on use, maintenance or specifications, please contact your Authorized Nautilus Fitness Dealer or Service Technician. Nautilus TreadClimber Model TC916 Assembly Manual

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

9 Getting Started Getting Started Select Your Workout Area Select the location where you are going to put your Nautilus TreadClimber exercise machine carefully. The best place for your TreadClimber machine is on a hard, level surface. You will need at least two feet (61 cm) on each side and in front of your TreadClimber machine, and at least four feet (122 cm) behind it for dismount. Make sure that the location you choose has a grounded, 3-prong power outlet within reach of the TreadClimber machine power cord, preferably to the front of the machine where you will be less likely to step on the cord during dismount. Figure 1: On/Off Switch & Power Plug NOTE: The TreadClimber machine is designed to plug into grounded, non-gfi outlets only. To determine if your outlet or circuit breaker is GFI, look for a test and reset button on them. If they have the test and reset button it is a GFI outlet or circuit breaker, and therefore not suitable for plugging the TreadClimber machine into. Power Plug Receptacle The Commercial Series TreadClimber TC916 has one power plug receptacle located on the front side of the motor pan (see Figure 1). Turning on the Power The TreadClimber exercise machine can be turned on by moving the power switch located at the front of the machine, to the ON position (see Figure 1). Understanding the Display and Controls The TreadClimber console display is a computerized panel used to operate the TreadClimber exercise machine and see all workout data and operational status. You should familiarize yourself with the operation of the TreadClimber machine and location of all keys before beginning use. Detailed descriptions and usage information is available in the TreadClimber Commercial Series, Model TC916, Owner s Manual. Nautilus TreadClimber Model TC916 Assembly Manual 9

10 Getting Started Limited Access Control/Magnetic Safety Stop Limited-access control lets you restrict TreadClimber machine use to authorized personnel. It also lets you stop the TreadClimber machine in an emergency. The magnetically-activated control is located on the bottom of the display as shown (see Figure 2). The limited-access control is deactivated on machines shipped from the factory. Magnetic Key Safety Stop Activation To activate the limited-access control and restrict access, place the magnetic safety stop key supplied with the TreadClimber machine in the designated area located below the display (see Figure 3). Figure 2 The magnetic key will activate the control. If you remove the key, the TreadClimber treadle belts will stop and the console controller will not respond to any key presses. Accumulated values will remain on the display until you turn off the power, or press [CLEAR]. The console will display a message, REPLACE MAGNET when you remove the magnetic key from its designated area. You must replace the key or deactivate the control to start the walk belt. Figure 3 10

11 Getting Started Quick Start Guide To Start: Insert the Magnetic Safety Stop Key 1 and press the [QUICK START] key 2, or select a program key 3. To Stop: Press [STOP] 4 to pause the workout. Press [STOP] 4 again to end the workout. During the workout: After selecting a program, follow the Display 5 prompts and use the numeric keypad 6 to enter information. Walk speed may be changed at any time during the workout by pressing the [Speed: UP] key 7 to increase the walk speed, or the [Speed: DOWN] key 8 to decrease the walk speed. Treadle displacement may be changed at any time during the workout by pressing the [Treadle: MAX] key 9 to increase the height, or the [Treadle: MIN] key 10 to decrease the height. WARNING: For detailed information on use and safety, refer to your Owner s Manual file located on CD ROM Nautilus TreadClimber Model TC916 Assembly Manual 11

12 MOVING instructions Moving your Fully Assembled TreadClimber TC916 To reduce the risk of injury to persons read and follow all safety warnings and instructions in this manual. Two people are required to unload and move the TreadClimber TC916 exercise machine into position in the facility. Delivery Logistics The TreadClimber TC916 may be delivered fully-assembled, shipped on a pallet crate, and blanket wrapped; Pallet crate shipping weight: 806 pounds Unit weight: 684 pounds - OR - Delivered in a one box configuration, requiring assembly. Boxed Unit shipping weight: 850 pounds Unit weight: 684 pounds Moving Instructions for fully assembled unit Include: 1. Taking unit off pallet crate. 2. Moving unit into position in facility, if door ways are greater than 40 inches (101 cm) wide. 3. Disassembly of Upright Unit Instructions, if door ways are less than 40 inches (101 cm) wide. 4. Moving Tool Information to assist with moving fully assembled TreadClimber unit. Assembly Instructions for ONE box configuration unit Include: 1. Unpacking Instructions. 2. Assembly Instructions. 12

13 MOVING instructions Removing Machine from Pallet Tools Needed: 7/16 Socket Ratchet Figure 1 Step 1: Remove TC916 from pallet by removing restraining stabilizer brackets with socket and ratchet from stabilizer feet (see Figure 1). Step 2: Manually slide TC916 to one side of the pallet - over hanging approximately 12 to 15 inches off the side of the pallet (see Figure 2). Step 3: Tilt unit to side and slide edge of frame to ground (see Figure 3). Figure 2 Step 4: Tilt to 40 degrees and move pallet out of the way, lowering TC916 to ground (see Figure 4). NOTE: If removing the TreadClimber TC916 from pallet you should be placing the unit in its final position in the facility when removing it from the pallet. Figure 3 Figure 4 Nautilus TreadClimber Model TC916 Assembly Manual 13

14 MOVING instructions Moving Unit into Position in Facility NOTE: Perform the following moving procedure to position your TreadClimber Model TC916 in your facility if your door ways are greater than 40 inches wide. Figure 1 Tools Needed: 7/16 Socket Ratchet Moving Dolly Lift Bar Step 1: Remove TC916 from pallet by performing steps in section Removing Machine from Pallet in this manual. Figure 2 Step 2: Tilt to 40 degrees (see Figure 1). While tilted place 4-wheel moving dolly under center of TreadClimber frame (see Figure 2). When lowering the TreadClimber unit onto dolly be sure that the castors are locked so that it does not move out from under the TreadClimber unit. Figure 3 Step 3: Carefully, lower the TreadClimber Model TC916 onto 4-wheel moving dolly (see Figure 3). Step 4: Once in position in the facility, prepare to remove unit from 4-wheel dolly by locking castors. Figure 4 14

15 Moving instructions Step 5: Carefully tilt TreadClimber machine onto one-side of frame towards ground (see Figure 4). Step 6: Tilt unit to 40 degrees and remove moving dolly. Step 7: Place Moving Tool under the machine according to the Moving Tool Instructions section located in this manual and wheel the unit into position. Nautilus TreadClimber Model TC916 Assembly Manual 15

16 moving instructions Disassembly of Upright Unit Important information to read before disassembling upright unit. During delivery of this unit it may become necessary to disassemble the upright portion of the unit to reduce the size and weight. The upright portion of the unit has wheels integrated into it, making it possible to wheel it away from the base and handle it as a separate unit. Only use this option if delivery of the unit is not possible using one of the two preferred moving options: Moving unit into position in facility, if door ways are greater than 40 inches (101 cm) wide, or One boxed configuration, requiring assembly before use. To avoid electrical shock or damage to the unit you must power off the unit and make sure all power has been drained from the unit and capacitors by ensuring there are no lighted leds on the console. Detaching and moving the upright portion of this product requires two people! You must have a minimum of two people to properly support the heavy upright structure so the console does not fall and cause damage to the unit. 16

17 MOVING instructions 1.0 Removing Rear Step Tools Needed: Phillips head screw driver Magnetic 3/8 Nut Driver with long shaft Magnetic 3/8 socket Ratchet Figure 1-1 Step 1: Unplug the unit from the power source and ensure that all power has been drained from the unit. Step 2: Remove two (2) middle screws (see Figure 1-1). Step 3: Slide step cover plate back to remove (see Figure 1-2). Step 4: Depending upon the Step Weldment style of the unit: Figure 1-2 4A: Remove the four corner screws and slide the weldment outward (see Figure 1-3). - OR - 4B: Remove the two side screws. One screw on left and right, then slide the weldment outward (see Figure 1-4). Removing the step cover plate provides access to the I/O cables needed for the next step. Figure 1-3 Four Screws To avoid electrical shock or damage to the unit you must power off the unit and make sure all power has been drained from the unit and capacitors by ensuring there are no lighted leds on the console. Figure 1-4 Two Screws Nautilus TreadClimber Model TC916 Assembly Manual 17

18 MOVING instructions 2.0 Removing Uprights Tools Needed: Phillips head screw driver 5/32 Allen wrench 3/4 inch wrench or socket 1/2 inch drive Ratchet 1/2 inch drive Torque wrench Step 1: Remove for the four Button head screws attaching the console to the Upright weldment, disconnect the cables and remove the console from the machine. Step 2: Remove the Rear Step as directed in Section 1: Removing Rear Step. Step 3: Disconnect the Base Cable (P/N ) from the Handrail Cable (P/N ) located in the lower left hand corner (see Figures 2-1 and 2-2). Step 4: Remove rear plastic cover by loosening six (6) screws (see Figure 2-3 and Figure 2-4). Step 5: Remove right and left lower plastic parts by removing seven (7) screws located on the right and left upright inside panels (see Figure 2-5 and Figure 2-6). Step 6: Remove the four (4) upright bolts (see Figure 2-7) Step 7: Wheel upright structure away to safe location (wheels are integrated into upright portion of unit). NOTE: To replace the upright unit, reverse the directions. The four handrail screws are to be torqued to a setting of 75 ft. lbs. Detaching and moving the upright portion of this product requires two people! You must have a minimum of two people to properly support the heavy upright structure so the console does not fall and cause damage to the unit. Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4: Rear plastic cover off. Figure 2-5: Lower plastic parts. Figure 2-7 Figure

19 MOVING instructions NOTE: You should only use this step if you need to rotate the lower base unit up onto its side to transport it. 3.0 Removing Base Plastic Figure 3-1 Tools Needed: 1/8 Allen bit Step 1: Remove three (3) front plastic screws (see Figure 3-1). Step 2: Remove right and left side plastic covers - four (4) screws each side (see Figure 3-2). Step 3: Remove right and left side pan covers - two (2) screws each side (see Figure 3-3 and Figure 3-4). Figure 3-2 Figure 3-3 Figure 3-4: Pan without covers. Nautilus TreadClimber Model TC916 Assembly Manual 19

20 MOVING instructions Moving Tool Information moving tool Parts: CLEVIS CLIP FRAME WHEEL The following parts are shown in the figure to the right, in order listed: Wheel Bar one frame, two wheels, two clevis clips Caster Cart one base, two wheels Lifting Tool one piece Two 4x4x6 inch (ca. 10x10x15.5 cm) Blocks of Wood - not pictured Before moving the Tc916 UNIT: 1 - Make sure the power cord is not running under the machine. Usage Directions: Step 1: Lift the right side of the TC916 and brace with a 4x4x6 inch (ca. 10x10x15.5 cm) block of wood near the middle of the machine. Caster Cart Step 2: Lift the left side of the TC916 and brace with a 4x4x6 inch (ca. 10x10x15.5 cm) block of wood near the middle of the machine. Wheel Bar Figure 1 Step 3: Slide the Wheel Bar under the machine near the front of the TC916. Tilt the TC916 towards the rear, raising the front of the machine to provide room to slide the Wheel Bar underneath. Step 4: Tilt the machine forward, towards the Console and slide the Caster Cart under the rear of the machine (see Figure 1). Position the Caster Cart under the machine flush with the bottom of the frame so that it hooks between the frame and the leveling pads. Figure 2 20

21 MOVING instructions Step 5: On the right side, lift the machine and remove the block of wood, lowering the machine onto the Caster Cart and Wheel Bar, ensuring the wheels are straight. Step 6: On the left side, lift the machine and remove the block of wood, lowering the machine onto the Caster Cart and Wheel Bar, ensuring the wheels are straight (see Figure 2). Step 7: The machine is now ready to move. a. This moving tool is designed to move the TC916 in and out of a row of machines. It is not intended to move the machine long distances or over obstacles. b. Once the machine is out of the row other moving methods can be employed to move the machine to another room or in/out of the club. c. This tool is designed as a service aid and not for transportation. d. DO NOT operate the TC916 while it is on the Caster Cart. Step 8: When service is completed or the machine needs to be operated place the machine where it is desired and reverse the steps removing the Caster Cart and Wheel Bar. Nautilus TreadClimber Model TC916 Assembly Manual 21

22 Assembly instructions Before You Assemble Basic Assembly Principles Here are a few basic assembly tips that can make assembly of your Nautilus Commercial TreadClimber exercise machine quick and easy. 1. you can make the assembly process go faster by gathering the pieces you need for each step prior to starting the step. 2. as a general rule, and for all bolts and locknuts on your Nautilus TreadClimber exercise machine, turning toward the right will tighten, turning towards the left will loosen. An easy way to remember this is by remembering the expression, Lefty loosey, righty tighty. 3. gather all of the tools needed for assembly before beginning. The tools are listed in the Hardware and Tools list of this manual. You may find the use of a utility knife or scissors beneficial during the unpacking and assembly process. To reduce the risk of injury to persons read and follow all safety warnings and instructions in this manual. Two people are required to unload, unpack, assemble and move the TreadClimber TC916 exercise machine into position. 22

23 Assembly instructions Hardware and Tool List Tools needed: (not provided) 3/4 inch Socket, for a 1/2 inch Drive Ratchet 1/2 inch drive Ratchet 7/32 Allen bit 5/32 Allen bit 1/8 Allen bit Torque wrench with 1/2 inch drive Phillips screw driver *Hardware not illustrated to actual size. Qty: 4 Descr: Screw, x 3.25 HHC Part Number: Qty: 4 Descr: Screw, 1/4-20 x 3/8 Button, HD, SO Part Number: Qty: 8 Descr: Screw, x 1.00, BH, SS Part Number: Qty: 36 Descr: Screw, Button HD Cap, x 5 / 8L Part Number: Qty: 4 Descr: Washer,.50 SAE Flat Part Number: Qty: 2 Descr: Screw, #10-32 x Flat Hd Phillips Part Number: Qty: 4 Descr: Washer, Split Lock.50 Part Number: Qty: 36 Descr: Washer, Lock, Int. Star, #10, SS Part Number: Qty: 8 Descr: Internal/External Washer.375 Part Number: Nautilus TreadClimber Model TC916 Assembly Manual 23

24 Assembly instructions Parts List Reference Guide NOT ILLUSTRATED: Qty: 1 Descr: Assembly/Owner s Manual Kit and Hardware Kit Bag Qty: 1 Descr: Power cord Part Number: DEPENDING UPON YOUR COUNTRY AND REGION YOU WILL HAVE A POWER CORD CONFIGURED TO YOUR COUNTRY S/REGION S POWER SUPPLY. IF THE POWER CORD IS MISSING OR NOT COMPATIBLE CONTACT A NAUTILUS REPRESENTATIVE FOR A REPLACEMENT. Qty: 1 Descr: Console Assembly Part Number: Domestic TV, Domestic TV, International Qty: 1 Descr: Rear Step Cover Part Number: Qty: 1 Descr: Left Upright Plastic Cover Part Number: Qty: 1 Descr: Right Upright Plastic Cover Part Number: Qty: 1 Descr: Rear Step Weldment Part Number: Qty: 1 Descr: Left Bottom Plastic Pivot Cover Part Number: Qty: 1 Descr: Right Bottom Plastic Pivot Cover Part Number: Qty: 1 Descr: One Rear Motor Cover Part Number:

25 Assembly instructions Qty: 1 Descr: TC916 TreadClimber Base Assembly Part Number: Qty: 1 Descr: TC916 TreadClimber Handrail Assembly Part Number: Qty: 1 Descr: TC916 TreadClimber Handrail Upright Support Assembly Part Number: Nautilus TreadClimber Model TC916 Assembly Manual 25

26 Assembly instructions Unpacking Guide The following instructions provide direction in unpacking the boxed unit for the Nautilus Commercial Series TreadClimber model TC916. Step 1: Opening Crate Tools: Scissors or utility knife 1-1 remove the outer cardboard to reveal the contents of crate. Step 2: Unpacking Crate Tools: Upper Upright Weldment Scissors or utility knife 2-1 remove the three enclosed boxes within the crate and place to the side. 2-2 remove the Upper Upright Weldment and Lower Upright Weldment. Lower Upright Weldment 26

27 Assembly instructions Step 3: Verifying Box Contents Locate the following for this step: Box 1 - Parts Master Carton Box 2 - Top Plate Carton Box 3 - Short Side Panel Carton BOX 1 BOX 2 Tools: BOX 3 Scissors or utility knife 3-1 verify the contents of Box 1: PARTS MASTER CARTON. The carton should contain the following: box #1A - Left and right top Upright Covers. Marked Long Side Panels on the box. box #1B - Console. Marked Control Panel on the box. Figure 1 Rear Step weldment (see Figure 1). hardware Bag containing: TV Cable (if applicable), Owners Manual, Magnet, Cord Clamp, Grounding Harness, 5/16 Allen Wrench, Service Bulletin, and hardware for attaching the Weldment, Console, and Covers. 3-2 verify the contents of Box 2: TOP PLATE CARTON. Figure 2 Rear Step, insert molded (see Figure 2). Lower Front Cover (see Figure 3). Figure verify the contents of Box 3: SHORT SIDE PANEL CARTON. Left and Right Pivot Covers (see Figure 4). Figure 4 Nautilus TreadClimber Model TC916 Assembly Manual 27

28 Assembly instructions Step 4: Dismantling Crate Tools: Hammer 4-1 Carefully dismantle the wooden crate to allow access to the bottom half of the TreadClimber TC916 frame. NOTE: The TreadClimber TC916 base frame should be close to the final location for the fully assembled machine during this step. Remove wooden supports around base assembly. Step 5: Removing from Pallet Tools: 7/16 Socket Ratchet Figure remove TC916 from pallet by removing restraining stabilizer brackets with socket and ratchet from stabilizer feet (see Figure 1). 5-2 manually slide TC916 to one side of the pallet - over hanging approximately 12 to 15 inches off the side of the pallet (see Figure 2). 5-3 Tilt unit to side and slide edge of frame to ground (see Figure 3). Figure Tilt to 40 degrees and move pallet out of the way, lowering TC916 to ground. NOTE: When removing the TreadClimber TC916 from pallet you should be placing the unit in its final position in the facility. Figure 3 28

29 Assembly instructions Assembly Guide The following instructions provide direction in assembling the boxed units for the Nautilus Commercial Series TreadClimber model TC916. All instructions in the manual are given with the orientation of standing on the TreadClimber facing the console. The console is the front, while the rear roller is the back. Step 1: Connecting Wiring Harness Locate the following for this step: Parts: Figure 1: Connecting Wiring Harness Handrail Upright Support Assembly Base Assembly (P/N ) Handrail Upright Support Assembly (P/N ) 1-1 Locate the three Ground Wire Straps on either side of the Base Assembly, making sure that the wire is extended towards the front of the unit and doesn t become hidden behind the Handrail Upright Support during Step With the help of another person, connect wiring harness (P/N ) from the TreadClimber TC916 Base Assembly to the wiring harness (P/N ) in the Handrail Upright Support Assembly. See Figure 1. Ground Wire Strap Locations Base Assembly Wiring Harness Connection Nautilus TreadClimber Model TC916 Assembly Manual 29

30 Assembly instructions Step 2:connecting Handrail Support to Base Assembly Locate the following for this step: Figure 2: Connecting Handrail Support to Base Assembly Parts: Assembly from Step 1 Handrail Upright Support Assembly Hardware: 4 bolts (P/N 17683) 4 Lock Washers (P/N ) 4 Washers (P/N 22091) Tools: 3/4 inch socket for 1/2 drive Torque wrench (1/2 inch), set at 75 ft. lbs. (100 NM) 1/2 inch drive Ratchet Base Assembly 2-1 on right side, connect Handrail Upright Support Assembly to TreadClimber Base Assembly using 2 bolts, 2 lock washers, and 2 washers. Finger tighten only, being careful not to pinch wiring harness. See Figure 2 and Figure 2A. 2-2 Repeat Step 2-1 on the left side. 2-3 using the drive ratchet, tighten the 2 lower bolts on each side first, and then the 2 upper bolts on each side installed in Step 2-1 and Step 2-2. Then use the Torque wrench to set the tightness for all 4 bolts to 75 ft. lbs. (100 NM) Bolt Washer Lock Washer IMPORTANT! Make sure that the wiring harness cables Do not become pinched. Figure 2A: Close-up of hardware stack. 30

31 Assembly instructions Step 3:connecting Ground Wire Straps to Base Assembly Locate the following for this step: Parts: Assembly from Step 2 3 Grounding Straps Figure 3: Connecting Ground Wire Straps Ground Wire Strap - #3 Hardware: 4 Self-tapping screws -.25 x.50 (P/N 22139) 5 Lock Washers (P/N ) Tools: Phillips screw driver 3-1 remove the 3 Grounding straps, 4 Self-Tapping Screws, and 5 Lock Washers from the parts bag. Ground Wire Strap - #2 Ground Wire Strap - #1 3-2 attach one end of a grounding strap to the right side of base frame with one screw and lock washer. (See Figure 3 - Grounding Strap #1.) IMPORTANT! Place ring terminal of the cable bet ween the screw and lock washer. Figure 3A: Connecting Ground Wire Straps #2 & #3 3-3 attach the other end of grounding strap to the cross bar of the lower Upright weldment with a screw and lock washer. (See Figure 3 - Grounding Strap #1.) 3-4 attach one end of second grounding strap to the left side of base frame with one screw and washer. (See Figure 3 - Grounding Strap #2.) 3-5 attach the other end of second grounding strap with one end of third grounding strap to the cross bar of the lower Upright weldment with a screw and two washers. (See Figure 3 - Grounding Strap #2 and #3, and Figure 3A.) Ground Wire Strap - #3 Ground Wire Strap connection between - #2 & #3. Ground Wire Strap - #2 IMPORTANT! Leave other end of third grounding strap free. It will be installed in step 10 of assembly process. Nautilus TreadClimber Model TC916 Assembly Manual 31

32 Assembly instructions Step 4:connecting Wiring Harness from Upright Supports to Handrails Locate the following for this step: Figure 4: Connecting Wiring Harness to Handrail Parts: Assembly from Step 3 Handrail Assembly (P/N ) Handrail Assembly 4-1 Connect the wiring harness (P/N ) from the Handrail Upright Support Assembly (P/N ) to the Handrail Assembly. See Figure 4. Wiring Harness Connection NOTE: Carefully slide the Upper Upright Cables (TV Cable if applicable) inside Handrail Upright Support Assembly, until they come out the bottom as you place the Handrail Assembly on. Base Assembly 32

33 Assembly instructions Step 5:connecting Handrail Support to Base Assembly Locate the following for this step: Parts: Assembly from Step 4 Hardware: 8 screws (P/N 25796) 8 washers (P/N ) Tools: Figure 5: Connecting Handrail Support to Base Assembly Handrail Assembly Screw Washer 7/32 Allen bit 5-1 bolt Handrail Assembly (P/N ) to Handrail Upright Support Assembly (P/N ) using 8 screws and 8 washers. See Figure 5. IMPORTANT! Make sure that the wiring harness cables Do not become pinched. Base Assembly Nautilus TreadClimber Model TC916 Assembly Manual 33

34 Assembly instructions Step 6:connecting Wiring Harness to Console Locate the following for this step: Parts: Assembly from Step 5 Console (P/N 17670) Figure 6: Connecting Wiring Harness to Console Console Handrail Assembly 6-1 Connect the wiring harness from the Handrail Upright Support Assembly (P/N ) to Console (P/N ) on the left and right side. See Figure 6. NOTE: if TV Cable present, connect to mating cable from the console. 6-2 being careful not to pinch the wiring harness, slide the console into the open tubes of the handlebar. IMPORTANT! Make sure that the wiring harness cables Do not become pinched. Base Assembly Wiring Harness Connection 34

35 Assembly instructions Step 7: Securing Console Locate the following for this step: Parts: Assembly from Step 6 Hardware: Figure 7: Securing Console Console Handrail Assembly 4 screws (P/N 24162) Tools: Screws 5/32 Allen bit 7-1 align the holes on the tubing of the console with the holes on the handrail and secure Console (P/N ) in place using 4 screws (P/N ). See Figure 7. Base Assembly Step 8: Attaching Lower Plastic Covers Locate the following for this step: Parts: Assembly from Step 7 Right Bottom Plastic Pivot Cover (P/N 17919) Left Bottom Plastic Pivot Cover (P/N 17918) Hardware: Figure 8: Attaching Lower Plastic Covers Left Bottom Plastic Pivot Cover Screws Washers 14 screws (P/N 17815) 14 washers (P/N 17578) Tools: 1/8 Allen bit 8-1 on the right side, attach Right Bottom Plastic Pivot Cover (P/N ) using the 7 screws (P/N ) and 7 washers (P/N ). See Figure Repeat Step 8-1 on the left side. Base Assembly Right Bottom Plastic Pivot Cover Nautilus TreadClimber Model TC916 Assembly Manual 35

36 Assembly instructions Step 9: Attaching Rear Motor Cover Locate the following for this step: Figure 9: Attaching Rear Motor Cover Parts: Assembly from Step 8 Rear Motor Cover (P/N 17874) Hardware: 6 screws (P/N ) 6 washers (P/N 17578) Tools: Phillips screw driver Screws 9-1 attach the Rear Motor Cover using 6 screws and 6 washers. See Figure 9. IMPORTANT! Make sure that free end of grounding strap installed in step 3 is above rear motor cover. It will be installed in step 10 of assembly process. Washers Rear Motor Cover Base Assembly 36

37 Assembly instructions Step 10:attaching Rear Step Assembly Locate the following for this step: Figure 10: Attaching Rear Step Cover Parts: Assembly from Step 9 Rear Step Weldment (P/N 17591) Rear Step Cover (P/N 17733) Hardware: 2 screws (P/N ) 2 washers (P/N ) 2 screws (P/N ) 1 Self-tapping screws -.25 x.50 (P/N 22139) 1 Lock Washers (P/N ) Rear Step Cover Screws Tools: Phillips screw driver 3/8 Socket driver 10-1 attach the Rear Step Weldment to the Base Assembly using two screws (P/N ) and two washers (P/N ). NOTE: due to the tight spacing a magnetic tool is recommended during this step. Rear Step Weldment Figure 10-A: Attaching Grounding Strap Base Assembly 10-2 secure the loose end of third grounding cable that was installed in Step 3 to the Step weldment on the left side with a Self-tapping Screw and Lock Washer. (See figure 10-A.) 10-3 attach the Rear Step Cover to the Rear Step Frame (P/N ) using two screws (P/N ). See Figure 10. Ground Wire Strap - #3 Rear Step Weldment Third Ground Wire Strap connection to Rear Step Weldment Nautilus TreadClimber Model TC916 Assembly Manual 37

38 Assembly instructions Step 11:attaching Upright Plastic Covers Locate the following for this step: Figure 11: Attaching Upright Plastic Covers Parts: Assembly from Step 10 Right Upright Plastic Cover (P/N ) Left Upright Plastic Cover (P/N ) Hardware: Left Upright Plastic Cover Washer Screw 16 screws (P/N ) 16 washers (P/N ) Tools: 1/8 Allen bit 11-1 on the right side, attach the Right Upright Plastic Cover using 8 screws (P/N ) and 8 washers (P/N ). See Figure Repeat Step 11-1 on the left side of the unit. Right Upright Plastic Cover Step 12: Installing Power Cord Locate the following for this step: Figure 12: Installing Power Cord Parts: Assembly from Step 11 Power Cord 12-1 Locate the power cord for your region attach the power cord to the AC Inlet on the Front Motor Pan and then to the wall outlet (see Figure 12). Power Cord Outlet 38

39 Assembly instructions Step 13: Turning on the Power Locate the following for this step: Figure 13: Turning on Power Parts: Assembly from Step Locate the power switch at the front of the machine move the power switch to the ON position (see Figure 13). IMPORTANT! Refer to the owner s manual For detailed instructions and information on how to use and care for your treadclimber Commercial series exercise machine, model tc916. Power Switch Step 14:inspecting Assembly Congratulations! Now that you have assembled your Nautilus TreadClimber Model TC916, it is VERY IMPORTANT to tighten all screws and bolts, and visually inspect the TreadClimber exercise machine. If your TreadClimber machine sits unevenly you may adjust the leveling feet on each corner of the machine by hand to make the unit stable on your floor. Make sure that your TreadClimber exercise machine has been assembled correctly and securely, and that there are no loose, uncovered, or unattached parts prior to use. Failure to visually check and test assembly before use can cause damage to the Nautilus TreadClimber Model TC916 exercise machine and serious injury to users and bystanders and can also compromise the effectiveness of your exercise program. Nautilus TreadClimber Model TC916 Assembly Manual 39

40 BELT TENSION AND ALIGNMENT During initial installation, within the first 1- to -4 hours of use, and daily for the first week of use, the treadle belts on the TreadClimber TC916 need the tension and alignment inspected and adjusted. As the TreadClimber treadle belts stretch through use it will become necessary to tension the belts. Adjust the belt tension whenever the belt slips or moves unsteadily during operation. Failure to follow these instructions could seriously impact performance. IMPORTANT- Do not over tighten treadle belts! The belt need only be tight enough to prevent it from slipping during use. Excessive belt tension will decrease belt life and can damage the TreadClimber rollers and drive system. Alignment adjustment Tensioning adjustment Figure 1 Tools Needed: 5/16 Allen wrench Belt alignment and tensioning adjustments (see Figure 1). NOTE: The adjustments are the same on the right and left side of the machine. To check for proper belt alignment: Step 1: Operate TreadClimber machine so belt is running at mph ( km/h). Step 2: Belt is aligned when 1/8 of roller is showing (see Figure 2). Step 3: Tightening alignment screw clockwise moves belt out, loosening screw counter-clockwise moves belt in. Figure 2: Belts are correctly aligned when 1/8 inch of roller is showing. To check for proper belt tension: Step 1: Tension is correct when gap between treadles is even and centered. See Figure 3 for an example of INCORRECT tension. Step 2: Tighten (clockwise turn) or loosen (counterclockwise turn) tensioning adjustment located at the end of the treadle. Tension is slightly off. To completely loosen belt if you want to start from scratch: Step 1: Totally loosen off alignment screw by turning counter-clockwise. Step 2: Loosen tensioning screw by turning counterclockwise. Figure 3: Tension is too tight, treadle guards are rubbing. To correct loosen tensioning adjustment screw. 40

41 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. For technical assistance and a list of distributors in your area, please call or fax one of the following numbers. OFFICES IN THE UNITED STATES: INTERNATIONAL CUSTOMER SERVICE: TECHNICAL/CUSTOMER SERVICE Nautilus, Inc. World Headquarters SE Nautilus Drive Vancouver, Washington, USA Phone: 800-NAUTILUS ( ) customerservice@nautilus.com Fax: international Office Nautilus International S.A. Rue Jean Prouvé Givisiez / Switzerland Tel: Fax: technics@nautilus.com corporate HEADQUARTERS Nautilus, Inc. World Headquarters SE Nautilus Drive Vancouver, Washington, USA Phone: 800-NAUTILUS ( ) International Offices: Switzerland Office Nautilus Switzerland S.A. Tel: Fax: 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: china OFFICE Nautilus Representative Office Tel: Fax: Nautilus TreadClimber Model TC916 Assembly Manual 41

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44 Model TC Nautilus, Inc. All rights reserved. Nautilus, the Nautilus logo, TreadClimber, and Be Strong are either registered trademarks or trademarks of Nautilus, Inc. Nautilus, Inc. World Headquarters SE Nautilus Drive, Vancouver, Washington, USA NAUTILUS