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Be Strong.

E9

16 and 

EV9

16 

Service Manual 

PN 40478A Rev A (11/2005)

Summary of Contents for BE STRONG E916

Page 1: ...Be Strong E916 and EV916 Service Manual PN 40478A Rev A 11 2005 ...

Page 2: ...ilus Commercial Series Elliptical by other than authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty If you are a consumer and require technical support to resolve a problem with your Nautilus Commercial Series Elliptical please call Nautilus Customer Service at 800 864 1270 USA or 41 460 77 88 outside USA Important Please Read ...

Page 3: ...or Wiring Diagram 19 E916 Console Heart Rate Wiring Diagram 20 E916 Main Power Wiring Diagram 21 Assembly Illustrations Service Parts List EV916 25 Cable Connections EV916 31 Assembly Drawings Overview EV916 33 Cam Covers Pods and Front Knuckle Covers 33 Swing Arm Foot Link Assembly Junction 34 Front Mast Assembly Main Frame Junction 34 Drive Train Cover Assembly 35 Drive Train Assembly w Main Pow...

Page 4: ...rame Junction 56 Drive Train Cover Assembly 56 Crank Cover and Drive Train Assembly 57 Crank Arm Assembly 57 Eccentric Crank Arm Assembly detail 58 Rear Drive Assembly 59 Alternator Assembly 60 Connecting Arm Assembly 60 Foot Link Assembly Right 61 Foot Link Assembly Left 61 Swing Arm Cover and Cupholder 62 Swing Arm Assembly 62 Dynamic Handles and Polar Sensor 63 Dynamic Upper Body Handles and Gr...

Page 5: ...ect 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 aero...

Page 6: ...r hour watts METS resistance level rpm distance and workout profile Heart Rate Monitoring Integrated heat rate monitoring system with polar compatible wireless and contact HR Workout Programs Twelve Quick Start Manual Fat Burner Calorie Burner Intervals HR Zone Trainer multi stage Fit Test Custom Intervals HR Intervals Random Play Resistance Range Twenty 20 watts level 1 20 rpm to 300 watts level 2...

Page 7: ...mber of Functions Ten Heart rate elapsed time calories burned calories burned per hour watts METS resistance level rpm distance and workout profile Heart Rate Monitoring Integrated heat rate monitoring system with polar compatible wireless and contact HR Workout Programs Twelve Quick Start Manual Fat Burner Calorie Burner Intervals HR Zone Trainer multi stage Fit Test Custom Intervals HR Intervals ...

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Page 9: ...rical Series Elliptical Service Manual Console Codes 1 Contents Overview 11 Defaults 11 Customize 11 Machine Status 12 Diagnostics 13 Maintenance Logs 13 Reset Maintenance Hours 14 Error Log 14 Machine Configuration 15 ...

Page 10: ...10 ...

Page 11: ...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 50 400 lbs or 25 180 kg Refer to the following table to scan through and customize the settings Table 2 1 Defaults Step ...

Page 12: ...tion 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...

Page 13: ...nd 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 accrue...

Page 14: ...tively 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 d...

Page 15: ...t 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 ...

Page 16: ...achine 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 y...

Page 17: ...cal Series Elliptical Service Manual Wiring Schematics 2 Contents 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 ...

Page 18: ...18 Console Heart Rate Wiring Diagram EV916 Elliptical Top Level Wiring Diagram ...

Page 19: ...al Series Elliptical Service Manual Main Power Wiring Diagram EV916 Elliptical Power Electronics and Alternator Wiring Diagram Notes Place field diode assembly 21204 between field and ground terminals on the alternator 22661 ...

Page 20: ...20 E916 Elliptical Console Heart Rate Wiring Diagram Console Heart Rate Wiring Diagram 41531 ...

Page 21: ...us Commerical Series Elliptical Service Manual E916 Elliptical Main Power Wiring Diagram Main Power Wiring Diagram Notes Place field diode assembly 21204 between field and ground terminals on the alternator 22661 ...

Page 22: ...22 ...

Page 23: ...rs Pods and Front Knuckle Covers 33 Swing Arm Foot Link Assembly Junction 34 Front Mast Assembly Main Frame Junction 34 Drive Train Cover Assembly 35 Drive Train Assembly w Main Power Assembly 35 Crank Cover and Crank Assembly 36 Rear Drive Assembly 37 Alternator Assembly 38 Foot Link Assembly Left 38 Foot Link Assembly Right 39 Dependency Cover Cupholder Assembly 39 Swing Arm Assembly 40 ...

Page 24: ...ont Mast Assembly Main Frame Junction 56 Drive Train Cover Assembly 56 Crank Cover and Drive Train Assembly 57 Crank Arm Assembly 57 Eccentric Crank Arm Assembly detail 58 Rear Drive Assembly 59 Alternator Assembly 60 Connecting Arm Assembly 60 Foot Linkage Assembly Right 61 Foot Linkage Assembly Left 61 Swing Arm Cover and Cupholder 62 Swing Arm Assembly 62 Dynamic Handles and Polar Sensor 63 Dyn...

Page 25: ...Y CODE PART NO LEVEL DESCRIPTION 1 2 3 4 SM25067 1 25067 ASSY BC 1 POWER SUPPLY NA 14029 PINS CPC NA 21179 CONNECTOR CPC 11 4 PLUG REVRSE NA 21184 CONNECTOR BACKSHELL NA 21757 DECAL WARNING BATTERY CHARGER NA 25066 POWER SUPPLY BC 1 1A WALL PACK SM27857 2 27857 COMMERCIAL PRODUCT WARRANTY NA 2 40334 MANUAL OWNERS CD EV916 E916 NA 2 40335 MANUAL OWNERS EV916 E916 NA 2 40388 MANUAL ASSY E916 EV916 S...

Page 26: ...M22326 1 22326 PIN CLEVIS SM22516 1 22516 CLAMP CABLE 75 DIA SM22517 1 22517 DISK SPEED SENSOR 4400 CL SM22878 1 22878 SCREW SET SOCKET 250 28 X 38 SM22883 1 22883 SCREW SET SOCKET 3 8 16 X 38 SM22937 1 22937 SCREW 375 16 X 3 50 HX HD CAP SM23322 1 23322 BEARING BALL 17MM X 40MM SM23729 1 23729 WASHER 3 8 SPLIT LOCK SM24640 1 24640 SCREW 375 16 X 1 75 HX HD CAP SM25978 1 25978 WHEEL 3 DIA SM27654 ...

Page 27: ...M24049 1 24049 SNAP RING EXTERNAL 1 50 DIA SM27557 1 27557 RETAINING RING 5100 98 SM27654 1 27654 LEVELING PAD 500 13UNC 2A X 1 88 BASE SM40302 3 40302 WELDMENT CONSOLE MOUNT SM40312 3 40312 WELDMENT SWING ARM LEFT SM40313 3 40313 WELDMENT SWING ARM RIGHT SM40315 3 40315 WELDMENT RIGHT MOVING HANDLEBAR SM40316 3 40316 WELDMENT LEFT MOVING HANDLEBAR SM40317 3 40317 LINK DEPENDENCY CAST SM40321 3 40...

Page 28: ...269 GROMMET 2870 7 8 ID SM40318 40318 ASSEMBLY FOOT LINK RIGHT SM22027 1 22027 WASHER 250 SPLIT LOCK SM22028 1 22028 SCREW 250 20X 63 HEX HD CAP SM22032 1 22032 NUT 5 16 18 NC NYLON INSRT HEX SM22047 1 22047 WASHER FLAT 1 4 ID X 5 8 OD NA 3 40309 WELDMENT MAIN FOOTLINK RIGHT SM40424 2 40424 HOUSING FOOT PAD RIGHT SM40434 2 40434 FOOT PAD RIGHT SM40443 1 40443 SCREW 10 32 X 1 00 LG OVAL HD PH SS SM...

Page 29: ...M PAN HD PH SM41269 1 41269 GROMMET 2870 7 8 ID SM40358 1 40358 SHAFT SWING ARM BOTTOM 5300 SM40364 1 40364 ROLLER CAM SM40381 1 40381 COVER CRANK STEEL SM40416 2 40416 COVER RIGHT REAR FRONT SM40417 2 40417 COVER RIGHT REAR BACK SM40418 2 40418 COVER LEFT REAR FRONT SM40419 2 40419 COVER LEFT REAR BACK SM40420 2 40420 COVER CAM OUTSIDE RIGHT SM40421 2 40421 COVER CAM OUTSIDE LEFT SM40422 2 40422 ...

Page 30: ...TOR AND BRACKET STRIDEMASTER SM22022 1 22022 NUT 1 4 20 NC FINISH HEX SM22027 1 22027 WASHER 250 SPLIT LOCK SM22047 1 22047 WASHER FLAT 1 4 ID X 5 8 OD SM25611 1 25611 ASSEMBLY RESISTOR 3800 SM13580 1 13580 WASHER 8 SAE FLAT SM22109 1 22109 WASHER 8 INTERNAL TOOTH LOCK SM22110 1 22110 NUT 8 32 HEX MACH SM22134 1 22134 SCREW 8 32 X 38 PHIL PAN HD SM23783 1 23783 ASSY CABLE RESISTOR SM24989 1 24989 ...

Page 31: ...1 CHR BREAKOUT SM40710 1 40710 CABLE ASSY CONSOLE TO INLINE SM40801 1 40801 ASSY CONSOLE C51 LCD Cable Connections EV916 Cable Connections EV916 Two of the main cable connections for the EV916 elliptical are shown below Wiring diagrams for the EV916 console handles and main power are provided in Section 2 Front Mast to Main Frame Connection CONNECT CABLE PN 40471 FROM FRONT MAST TO CABLE PN 40844 ...

Page 32: ...IGURE 2 NOTE If connectors are not inserted into the Swing Arm tube they will be damaged during use Figure 1 Figure 2 REINSTALL THE SWING ARM RUBBER GROMMET PN 41269 AND INSERT ANY REMAINING SLACK CABLE PN 40470 INTO EITHER TUBE MAKE SURE THE SWING ARM GROMMET PN 41269 IS FULLY INSTALLED AND THAT ONLY THE SHEATHED CABLE PN 40470 IS EXPOSED SEE FIGURE 3 Figure 3 Footlink Cable Swing Arm Cable 3 4 i...

Page 33: ...e specific notes represented by Refer to these notes when replacing parts because they mention critical torque specs and other important servicing information Refer to the Parts List in the preceding pages to locate information on the part numbers that are called out in the assembly drawings 1 Cam Covers Pods and Front Knuckle Covers ...

Page 34: ...34 Swing Arm Foot Link Assembly Junction Front Mast Assembly Main Frame Junction Assembly Drawings EV916 ...

Page 35: ...35 Nautilus Commerical Series Elliptical Service Manual Drive Train Cover Assembly Drive Train Assembly w Main Power Assembly Assembly Drawings EV916 ...

Page 36: ...36 Crank Cover and Crank Assembly Assembly Drawings EV916 ...

Page 37: ...37 Nautilus Commerical Series Elliptical Service Manual Rear Drive Assembly Assembly Drawings EV916 22883 22883 ...

Page 38: ...38 Alternator Assembly Assembly Drawings EV916 Foot Link Assembly Left 020 040 AIR GAP BETWEEN SENSOR PN 21445 AND DISK PN 22517 ...

Page 39: ...39 Nautilus Commerical Series Elliptical Service Manual Assembly Drawings EV916 Dependency Cover Cupholder Assembly Foot Link Assembly Right ...

Page 40: ...40 Assembly Drawings EV916 Swing Arm Assembly ...

Page 41: ...41 Nautilus Commerical Series Elliptical Service Manual Assembly Drawings EV916 Dependency Link Assembly NOTES ...

Page 42: ...42 Assembly Drawings EV916 Dynamic Upper Body Handle Assembly Fixed T Bar Handle Assembly ASSEMBLY SHOWN FROM RIGHT SIDE OF FRONT MAST LOOKING TOWARD REAR DRIVE ...

Page 43: ...43 Nautilus Commerical Series Elliptical Service Manual Assembly Drawings EV916 Console Mount POSITION CONSOLE SO THAT CABLES CAN BE CONNECTED USING THE PROPER CONNECTORS ...

Page 44: ... 4 SM25067 2 25067 ASSY BC 1 POWER SUPPLY NA 14029 PINS CPC NA 21179 CONNECTOR CPC 11 4 PLUG REVRSE NA 21184 CONNECTOR BACKSHELL NA 21757 DECAL WARNING BATTERY CHARGER NA 25066 POWER SUPPLY BC 1 1A WALL PACK SM27857 2 27857 COMMERCIAL PRODUCT WARRANTY NA 2 40334 MANUAL OWNERS CD EV916 E916 NA 2 40335 MANUAL OWNERS EV916 E916 NA 2 40388 MANUAL ASSY E916 EV916 SM12212 2 12212 KEY 250 SQUARE X 750 LO...

Page 45: ...X 75 PAN HD W LOCK SM40751 1 40751 RING RETAINING EXTERNAL 15MM SM40783 1 40783 ASSEMBLY CRANK ARM RIGHT V2 SM12212 12212 KEY 250 SQUARE X 750 LONG SM22036 22036 NUT 250 20 NYLON INSERT SM22047 22047 WASHER FLAT 1 4 ID X 5 8 OD SM27557 27557 RETAINING RING 5100 98 SM40562 40562 SCREW 5 16 18 X 1 50 SHC W NYL SM40594 40594 BEARING BALL 25 X 47 X 12 SM40647 40647 WELDMENT PIVOT MISALIGNMENT NA 40595...

Page 46: ...7 WELDMENT BEARING HSING CONN AR NA 40888 TUBE BEARING HOUSING CONN ARM NA 40889 EXTENSION BEARING HSING CONN A NA 40915 WELDMNT BEARNG HSING CONN AR S NA 40889 EXTENSION BEARING HSING CONN A NA 40916 TUBE BEARNG HSING CONN ARM SHO NA 1 40890 PLUG F 1 50 DIA TUBING 14 20GA SM40908 1 40908 WASHER THRUST 562X1 00X 062 SM40951 40951 ASSEMBLY REAR DRIVE E916 NA 1 12760 KEY 250 SQ X 3 00 LONG NA 1 1358...

Page 47: ... WASHER 3 8 SPLIT LOCK SM24640 1 24640 SCREW 375 16 X 1 75 HX HD CAP SM25978 1 25978 WHEEL 3 DIA SM40501 3 40501 WELDMENT REAR FRAME STRIDEMAST SM40530 1 40530 PULLEY DRIVE MACHINED SM40528 05 40528 HUB PULLEY DRIVE SM40598 3 40598 WELDMENT ALTERNATOR TENSIONER NA 40599 TAB ALTERNATOR TENSIONER NA 40600 SHAFT THREADED ALTERNATOR TENS SM40601 40601 ASSEMBLY LOWER CONTROL BOARD SM13572 1 13572 ASSY ...

Page 48: ...TERMEDIATE PULLEY SM40609 1 40609 SPACER INTERMEDIATE SHAFT LEFT SM40610 1 40610 SPACER INTERMEDIATE SHAFT RIGH SM40611 1 40611 SHAFT CRANK SM40654 1 40654 SCREW 10 32X 75 PANHD W LK WAS SM40678 1 40678 CABLE ASSY BATTERY ELLIPTICAL SM40734 1 40734 BEARING 1 PILLOW BLOCK NO COL SM40844 1 40844 CABLE ASSY MAIN LOWER EV916 SM40909 1 40909 BELT POLY V 61 J 10 RIBS SM40910 1 40910 BELT POLY V 38 J 6 R...

Page 49: ...P SM22047 1 22047 WASHER FLAT 1 4 ID X 5 8 OD SM24049 1 24049 SNAP RING EXTERNAL 1 50 DIA SM24279 1 24279 TYRAP 14x11 0 SM24432 1 24432 WASHER 10 SAE FLAT ZINC PLATD SM25165 1 25165 RECEIVER PLUG IN POLAR SM40464 2 40464 DECAL CONSOLE BACK SM40551 2 40551 COVER ERGOBAR FRONT SM40552 2 40552 COVER ERGOBAR BACK SM40567 2 40567 COVER SWING ARM TOP SM40568 2 40568 COVER SWING ARM TOP WITH INSER SM4057...

Page 50: ...2 40643 HOUSING CHR DYNAMIC FRONT NA 2 40644 HOUSING CHR DYNAMIC REAR NA 1 40680 ASSY CABLE ELLIPTICAL SWINGARM SM40692 1 40692 PCB ASSEMBLY ELLIPT SWINGARM SM40761 2 40761 LABEL SWING ARM WIRE LH SM40776 2 40776 ADHESIVE TRANSFER TAPE 25 MIL SM40896 3 40896 WELDMENT UPPER BODY RIGHT V2 NA 40571 PLATE UPPER BODY HANDLE TOP NA 40653 TUBE CHR UPPER BODY HANDLE NA 40906 TUBE UPPER BODY RIGHT V2 SM409...

Page 51: ...G CONN ARM FRONT R V2 NA 40883 SHAFT CONNECTING ARM FRONT V3 NA 40914 ASSY BRACKT FOOT SUPRT W PEM R NA 40912 BRACKT FOOT SUPPORT 1 TAB R V2 NA 41145 NUT SELF CLINCHING 10 32 SM40960 40960 ASSY FOOT LINK W BEARING RIGHT NA 1 40591 BEARING IGUS JFI 141618 11 NA 3 40898 WELDMENT FOOT LINK RIGHT V2 NA 40444 BRACKET MOUNTING LEG LINK NA 40584 PLATE SUPPORT FOOT PIVOT SIDE NA 40585 HOUSING BEARING FOOT...

Page 52: ...INCHING 10 32 SM40961 40961 ASSY FOOT LINK W BEARING LEFT NA 1 40591 BEARING IGUS JFI 141618 11 NA 3 40897 WELDMENT FOOT LINK LEFT V2 NA 40444 BRACKET MOUNTING LEG LINK NA 40584 PLATE SUPPORT FOOT PIVOT SIDE NA 40585 HOUSING BEARING FOOT PIVOT NA 40586 PLATE SUPPORT FOOT PIVOT FRONT NA 40587 PLATE SUPPORT FOOT PIVOT REAR NA 40588 BRACKET FOOT LINK MISALIGNMENT NA 40589 GUSSET FOOT LINK MISALIGNMEN...

Page 53: ...agrams for the E916 console handles and main power are provided in Section 2 Front Mast to Main Frame Connection CONNECT CABLE 40710 FROM FRONT MAST TO CABLE 40844 FROM MAIN FRAME CENTER TUBE BEFORE SECURING FLANGES TOGETHER THE COLOR CODED CABLES SNAP TOGETHER WITH THE M F CONNECTORS FOR THE CORRESPONDING CABLE COLORS NOTE TAKE CARE NOT TO PINCH CABLES WHEN ASSEMBLING CABLES ...

Page 54: ...ion on the part numbers that are called out in the assembly drawings Some drawings include specific notes represented by Refer to these notes when replacing parts because they mention critical torque specs and other important information 1 Cam Covers Pods and Front Knuckle Covers Assembly Drawings E916 ...

Page 55: ...55 Nautilus Commerical Series Elliptical Service Manual Assembly Drawings E916 Swing Arm Foot Link Assembly Junction ...

Page 56: ...56 Front Mast Assembly Main Frame Junction Drive Train Cover Assembly Assembly Drawings E916 ...

Page 57: ...57 Nautilus Commerical Series Elliptical Service Manual Assembly Drawings E916 Crank Cover and Drive Train Assembly Crank Arm Assembly ...

Page 58: ...58 Assembly Drawings E916 Eccentric Crank Arm Assembly detail 40786 40930 ...

Page 59: ...59 Nautilus Commerical Series Elliptical Service Manual Assembly Drawings E916 Rear Drive Assembly ...

Page 60: ...60 Assembly Drawings E916 Connecting Arm Assembly Alternator Assembly 020 040 AIR GAP BETWEEN SENSOR PN 21445 AND DISK PN 22517 ...

Page 61: ...61 Nautilus Commerical Series Elliptical Service Manual Foot Link Assembly Left Foot Link Assembly Right Assembly Drawings E916 ...

Page 62: ...62 Swing Arm Cover and Cup Holder Swing Arm Assembly Assembly Drawings E916 ...

Page 63: ...63 Nautilus Commerical Series Elliptical Service Manual Dynamic Handles and Polar Sensor POLAR SENSOR PLACEMENT UNDER SWING ARM BRACKET TOP VIEW Assembly Drawings E916 ...

Page 64: ...64 Fixed T Bar Handle Assembly Dynamic Upper Body Handles and Grips Assembly Drawings E916 ...

Page 65: ...65 Nautilus Commerical Series Elliptical Service Manual Console Mount Assembly Drawings E916 POSITION CONSOLE SO THAT CABLES CAN BE CONNECTED USING THE PROPER CONNECTORS 41531 ...

Page 66: ...66 ...

Page 67: ...67 Nautilus Commerical Series Elliptical Service Manual Appendixes Contents Appendix A Required Tools 68 Appendix B International Power Plug Configurations 68 ...

Page 68: ...wrench Hex cap screws on crank arms 9 16 wrench Adjusting belt tension 9 16 Allen wrench Removing and installing screws on crank cover 7 16 Allen wrench Adjusting belt tension 2 Philips screwdriver Removing and installing screws on pod and drivetrain covers Snap Ring Pliers Connecting arm and eccentric crank arm Tape Measure Adjusting belt tension Diagonal cutters General Multimeter Electrical tro...

Page 69: ...ble 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 Inc s liability hereunder is expressly limited to the replacement of goods not complying with this warranty or at Nautilus Inc s election to the return of the purchase price of the exercise pro...

Page 70: ... NAUTILUS INNOVATION CENTER Nautilus Inc 1886 Prairie Way Louisville Colorado USA 80027 Phone 800 864 1270 Fax 800 898 9410 CORPORATE HEADQUARTERS Nautilus Inc World Headquarters 16400 S E Nautilus Drive Vancouver Washington USA 98683 Phone 800 NAUTILUS INTERNATIONAL CUSTOMER SERVICE SWITZERLAND OFFICE Nautilus International S A Rue Jean Prouve 6 1762 Givisiez Switzerland Tel 41 26 460 77 77 Fax 4...

Page 71: ...71 Nautilus Commerical Series Elliptical Service Manual ...

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