Nautilus Be Strong Commercial Series U916 User Manual Download

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Be Strong.

®

003-3376-060309A

Rework Manual

Commercial Series Bike U916

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Summary of Contents for Be Strong Commercial Series U916

Page 1: ...Be Strong 003 3376 060309A Rework Manual Commercial Series Bike U916 ...

Page 2: ...quiring Work 3 Tools Required 3 Parts 4 Parts List 6 Hardware 7 Assembly 8 Software Upgrade 11 Shield Spacer Installation 14 Flywheel Intermediate Hub Assembly Belt and Pulley Replacement 15 Final Inspection 20 Final Packaging 22 Appendix 32 2 ...

Page 3: ...U09030001 100155ACU09030030 Tools Required FISP s Phillips head screw driver 2 drive s Vice grips s Cloth towel rag s 15 16 socket and socket torque wrench s 13mm socket and wrench s 4 5 6 mm Metric Hex wrenches s Snap ring pliers for 25mm shaft s Rubber mallet s Bearing puller for pulley removal s Adjustable Crescent wrench for all nuts s 6mm hex drive bit and torque wrench may be same torque wre...

Page 4: ...ike Kit 1 002 6845 Shroud Spacer 1 2 41375 021 D51 Display Firmware 1 Firmware 3 002 6840 Intermediate Hub Assembly 1 4 000 6432 Belt Alternator U R916 1 5 000 6214 Assembly Overmold Intermediate 8V Pulley 1 6 SM40329 Flywheel Cast 5300 1 4 ...

Page 5: ... 4 8 902 4274 SCW GHCS M8x1 25x25 SS 1 9 902 4141 NUT NL M8 1 25 G2 BlkZ 3 10 902 4140 NUT NL M6 1 0 G2 Blk Z 2 11 002 6858 U916 Rework Sticker Blue 1 12 003 3375 060309 R916 Rework Manual 13 003 3376 060309 U916 Rework Manual 5 ...

Page 6: ...TS LIST BOX CONTENTS H REF DESCRIPTION QTY A Console 1 B Console Mast 1 C Main Frame 1 D Seat assembly 1 E Handlebar 1 F Right Mast Shroud 1 G Left Mast Shroud 1 H Water Bottle Holder 1 I Hardware Pack not shown 1 A B C D E F G 6 ...

Page 7: ... Ref 1 Allen Head Bolt M10x25 Qty 4 Ref 2 Spring Washer M10 Qty 4 Ref 3 Flat Washer M10 Qty 4 Ref 8 Phillips Head Screw 10 32 x 3 4 Qty 6 Ref 4 Phillips Head Screw 1 4 x20 Qty 4 Ref 5 Spring Washer M6 Qty 4 Ref 6 Allen Head Bolt M8x20 Qty 4 Ref 7 Spring Washer M8 Qty 4 Ref 10 8mm Allen Wrench Ref 9 6mm Allen Wrench Phillips Screwdriver 7 ...

Page 8: ...ustment Lever J to allow the locking pin to to clear the Main Frame and release the Adjustment Lever when the seat is at the desired height Note Make sure that the plastic seat sliders inside the seat tube are in the correct position to prevent any damage If the seat slider plastic tabs have fallen out of slots at the bottom of the seat post carefully push the seat slider plastic back into holes p...

Page 9: ...Washer M8 Qty 4 Tools s 6mm Allen Wrench 2 1 Connect the attached long Wire Tie L to the handlebar cables M and use it to pull the cables out through the Mast B as shown in ﬁg 3 Keep the wire to attach the cable again 2 2 Align the Handlebar with the holes in the Mast 2 3 Install and completely tighten the hardware Figure 2 E 7 B 6 L R 9 ...

Page 10: ... Console Figure 5 6 3 2 The Right Heart Rate Wire O is labeled with an R Plug the Right Heart Rate Wire into the connector labeled P1 on the back of the console Figure 5 6 3 3 Plug the Left Heart Rate Wire P into the P2 connector Figure 5 6 3 4 Plug the Center Heart Rate Wire T into the P3 connector Figure 5 6 3 5 Gently push the excess wires back down into the mast 3 6 Align the Console with the ...

Page 11: ...03 The kit includes e ce of XX when ordering For example OR P N 41376 7XX programmed with the correct C52 program version T9 16 TC9 16 etc The version number should b used in pla if you need revision 3 then you would order p n 41376 703 The kit includes are available separate from the kit use p n 27834 1 x Programming Instructions this document arts needed 1 x F I S P 1 x F I S P programming cable...

Page 12: ...ibbon cable and locate the keyed side Remove the plastic access plate on non TMs or the steel plate on the T9 xx or TC9 xx and match the keyed side o cable connector with the corresponding side of the 10 pin connector on the b ORCED THE CONNECTOR CAN FIT THE WR 4 There is one Light Emitting Diode LED that can turn three different colors depending on the programming status Power ON the console cont...

Page 13: ...se device and verify that the software has been upgraded Non treadmill machines 5 Wait for the F I S P LED to turn GREEN 6 Once the programming is complete the green LED will turn on Remove the F I S P programm 7 Configure t TER on the C5X console The console will display CHANGE MACHINE Press ENTER again 2 Press until BIKE Rev B shows on the display Press ENTER to select that machine type 4 ENTER ...

Page 14: ...ead screwdriver remove the left cover Step 2 Adding spacer to standoff Push the right side cover away from the frame Add part 002 6845 to the standoff as shown in the picture Add a drop of CA adhesive to part 002 6845 before attaching to the standoff Step 3 Reattach cover 14 ...

Page 15: ...iate shaft 5mm hex wrench this will allow the belt to removed as well interm using a Step 2 Removing pulley from the inter Remove the 8M 1 25 x 20 allen cap screws 902 4725 from pulley 000 6229 using a 6mm hex wrench After socket head cap has been broken loose remove the belt from the crank pulley by turning the crank clockwise and working the belt off the edge 15 ...

Page 16: ...diate shaft with puller or pry bar Step 4 Removing intermediate shaft Beware of sharp edges on intermediate shaft Remove external snap ring from intermediate shaft located behind 000 6214 pulley Using a rubber mallet and punch drive the shaft from the bearing housing in the frame 16 ...

Page 17: ...rings until snap ring grove is exposed on the opposite side Important mallet must only contact the end of the shaft Make sure the Snap Ring is closed and seated in the groove Step 7 Reattaching intermediate Get 002 0631 Woodruff Key and 000 6229 Intermediate Pulley and place them on the Shaft with a rubber mallet drive the pullet back onto the shaft Get 902 4725 Screw 902 6024 Flat Washer 902 6027...

Page 18: ...Hand start the Screws and Washers into the Pulley Tighten using a 5mm hex wrench Get a 000 6291 Alternator Belt and install by placing the Belt on the Alternator centered in the hand NOTE the pulley has a hole that can be used to keep the belt on the pulley while installing the belt by using a wire tie through the hole and around the belt remove wire tie after belt is installed grooves and then ov...

Page 19: ...Step 12 Step 11 Reattach cover When the Belt is installed correctly there is a groove visible on each side of the Pulley 19 ...

Page 20: ... With Pull Test Verify All Alternator Wires Secure With Pull Test Verify Ground Wire Secure With Pull Test Verify Mounting Hardware For Intermediate Pulley Alternator And Tension Bolt Secure Verify HTD Belt Not Damaged And Tracking Across Sprockets And Pulley By Turning Crank PASSED NAME DATE M ECHANICAL R UN T EST Console Should Turn On With One Crank Of Pedals Verify Quick Start And Level Keypad...

Page 21: ... Pedals Secure After Shrouds Installed Run Test After Shrouds Installed To Ensure Proper Fit Verify Water Bottle Holder Secure U916 Only Verify CHR Plates Stretch Wrapped Check All Decals And Console Overlay For Scratches Air Pockets Alignment Etc Verify Serial Number Matches Work Order Paperwork Verify Shipping Box Content Correct See BOM PASSED NAME DATE Step 2 Apply rework sticker to Serial Num...

Page 22: ... bar from mast being careful in pulling the wires out of the neck Screws are used over and new mounting screws are placed in hard ware kit Wrap quick silver around mounting and where wires handle bar is mounted Wrap quick silver around CHR grips 22 ...

Page 23: ...bar in xxx bag Place wrapped handle bar in carton Wrap console in bubble wrap and place in box Close up box Close and tape shut the carton The carton will be put in with the bike at later time Break screws loose 23 ...

Page 24: ...se dewalt to remove screws holding mast Use care when pulling wires thru mast off Pull wire tie back through and reattach The customer pulls the cables up the mast Get 000 4897 bag and place over mast 24 ...

Page 25: ...Place mast in carton Remove seat from bike Get 000 4897 bag and place over seat assembly 25 ...

Page 26: ...Place seat post in carton and block with foam from the console Wrap up cables and stuff into the mast mounting opening using care not to cut insulation on cables Wrap quick silver on legs and pedals 26 ...

Page 27: ...Get bag 17885 and place over bike Get 002 0587 tube and place over bike Place hardware bag in carton with mast and fold top down and tape 27 ...

Page 28: ...Place Battery Charger in carton Intl 21756 Dom 002 0677 Close carton and tape Place handle bar and console box inside tube 28 ...

Page 29: ...Place mast and hardware bag on top of mast and console box Get 4 2x4 upright supports and place in box on both ends Get 2 cross boards and place on supports Place seat carton inside tube 29 ...

Page 30: ...Staple 2x4 upright supports to side of box using BOSTICH gun 1 staples gun Close carton and staple top flap Staple 4 xxx corner protectors to carton 30 ...

Page 31: ...Band box shut on both ends Place bands where the upright supports are in box 31 ...

Page 32: ... the former extension setup files but will save to a new 4dx format The person programming the FISPs may need to change the program s file locations if so upon saving this changed program an extension change will be realized This impacts application versions of 2 X X X that are pre 3 x x x The FISP may be setup to contain multiple programs the limitation is that only programs of different processo...

Page 33: ...The Multi Build FISP Load screen should look something like this OR 33 ...

Page 34: ...umber SNo24010622 is displayed 4 Center bottom shows that the FISP is NOT connected to the Target processor Console or VSD 5 At the top the Project Dot is checked and shows that the correct program is loaded onto the PC awaiting download to the FISP 6 DO NOT CHANGE the settings in the Advanced or Device Option buttons or unstable operation of the programmed device may occur This new version of loa...

Page 35: ...ve additional restrictions The simplest method of powering them is to connect to an operating Console or VSD If this is done the operator must be more careful since incorrect use could permanently destroy the processor on the device 1 Always have the FISP application loaded on the PC and running PRIOR to powering up the FISP 2 Connect the FISP to the VSD or Console with the power OFF then apply po...

Page 36: ...visit www Nautilus com 2008 Nautilus Inc All rights reserved Nautilus the Nautilus logo Remote Operation Control Be Strong are either registered trademarks or trademarks of Nautilus Inc Nautilus Inc World Headquarters 16400 SE Nautilus Drive Vancouver Washington USA 98683 1 800 628 8458 www Nautilus com Printed in Taiwan ...

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