Nautilus E618 Service Manual Download

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To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the

wall outlet and wait 5 minutes before cleaning, maintaining or repairing this machine. Place the power cord in a secure

location.

1. Using a #2 Phillips screwdriver, remove the 4 screws from each set

(right and left) of the Handlebar Shrouds. After removing the hardware,

pinch the Handlebar Shrouds to unsnap them from each other. Place

them safely aside.

2. Using a 6mm hex wrench and a 13mm wrench, remove the indicated

bolts from the Lower Handlebar Arms and Pedals. Set the hardware

safely aside for reassembly.

Be aware that the Handlebar Arms will be loose and may

pivot when the hardware is removed. This step may require

two people.

3. Disconnect the indicated Cable (with arrow) from the Upper Handlebar

that goes into the Console Mast.

4. Using a 6mm hex wrench and a 13mm wrench, remove the indicated

hardware (by oval) from the Arm Pivot Rod. Remove the hardware and

the Upper and Lower Handlebar Arms. Set them safely aside for reas-

sembly.

Handlebar Shrouds

Summary of Contents for E618

Page 1: ...lace the Lift Motor 81 15 Replace the Lift Motor Wire in the Console Mast 89 16 Replace the Motor Control Board MCB 94 17 Replace the Pedals and Legs 104 18 Replace the Power Switch Assembly 100 19 Replace the Rail Assembly 109 20 Replace the Servo Motor 113 21 Replace the Shrouds 120 22 Replace the Speed Sensor 125 23 Replace the Static Handlebar 130 24 Replace the Upper and Lower Handlebar Arms ...

Page 2: ... Do not try to change the design or functionality of the machine being serviced as this can adversely affect user safety Do not put the machine back in service until all shrouds instructions warning labels and correct functionality have been verified and tested for correct performance Connect this machine to a properly grounded outlet only see Grounding Instructions Keep the power cord away from h...

Page 3: ...any interference received including interference that may cause undesired operation Note This machine and power supply have been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiat...

Page 4: ...lug illustrated below A temporary adapter that looks like the adapter illustrated may be used to connect this plug to a 2 pole receptacle as shown if a properly grounded outlet is not available The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician The green colored rigid ear lug or the like extending from the adapter must be connecte...

Page 5: ... soft cloth to clean the Console Do not clean with a petroleum based solvent automotive cleaner or any product that contains ammonia Do not clean the Console in direct sunlight or at high temperatures Be sure to keep the Console free of moisture Weekly Check for smooth roller operation Wipe the machine to remove dust dirt or grime Clean the rails and surface of the rollers with a damp cloth Apply ...

Page 6: ...an affect the computer operation Leveling the Machine The machine needs to be leveled if your workout area is uneven or if the Rail Assembly is slightly off the floor To adjust 1 Place the machine in your workout area 2 Safely stand on the back of the Rail Assembly for approximately 20 seconds 3 Step off the machine 4 Loosen the locking nuts and adjust the levelers until they all contact the floor...

Page 7: ...ete list of supported devices review the software app on the App Store or Google Play 2 Follow the instructions on the Software App to sync your device to your exercise machine 3 To sync your workout data with MyFitnessPal or Under Armour Connected Fitness click on the desired program and login with your information Note The Nautilus Trainer Fitness App will automatically sync your workouts after ...

Page 8: ... can help make better conduct These are available on the web or at medical or some larger fitness stores Static Handlebar If tests reveal no other issues Static Handlebar should be replaced Unit operates but Telemetric HR not displayed Chest Strap optional Strap should be POLAR compatible and uncoded Make sure strap is directly against skin and contact area is wet Chest Strap Batteries If strap ha...

Page 9: ...ged Lower and Upper I O Cables requires shroud removal All wires in the cables should be intact If any are cut or crimped replace cable Incline Adjuster Assembly requires shroud removal Be sure Incline Adjuster Assembly is attached to Incline Motor drive screw If the above steps do not resolve the problem contact Cus tomer Service if inside US Canada or your local distributor if outside US Canada ...

Page 10: ...lebar assemblies to isolate sound Replace part making sound Check for loose hardware Tightly secure all hardware on the Stabilizers and the base of the Console Mast Knocking sound during machine operation Check hardware at junction between Lower Handlebar Arm and Pedal Make sure that the alignment tab on the Pivot Sleeve goes into the slot in the hole Be sure the Pivot Sleeve extends through the o...

Page 11: ... setting To change push OK to start the Units option Push the Increase Decrease buttons to change between MILES Imperial English units and KM metric units Note If the units change when there is data in User Statistics the statistics convert to the new units 7 Push OK to set 8 The Console display shows the Sound Settings prompt with the current setting Push the Increase Decrease buttons to change b...

Page 12: ...y key to exit f RUN BUTTON TEST The Console display shows the function of each button as buttons are pressed If the display shows an incorrect function the overlay on the Console may be incorrect for that model If the display does not show a function the firmware version may be incorrect No beeps are sounded during this test To exit the test push and hold one of the long key sequences i e long Pau...

Page 13: ...13 N Q QQ SS RR T FF A B C I E G H J R S K L M X U V W DD F O P TT R S AA BB CC Y Z D EE VV UU II JJ HH LL GG KK PP OO NN U MM Maintenance Parts ...

Page 14: ...er MM Servo Motor H Handlebar Arm Lower Right X Rail Assembly NN Brake Assembly I Handlebar Arm Upper Right Y Crank Assembly Left OO Incline Motor Assembly J Pedal Arm Right Z Leg Left PP Power Switch K Crank Assembly Right AA Pedal Arm Left QQ AC Power Cord L Leg Right BB Handlebar Arm Lower Left RR Media Cable M Roller CC Handlebar Arm Upper Left SS Silicone Lubricant Bottle N Shroud Right DD Tr...

Page 15: ...CB Console Contact Heart Rate CHR sensor HR cable 4Pin Lift motor wire 5Pin Lift motor cable 3Pin Lift motor potentiometer cable 3Pin Servo control cable 9VDC 2Pin I O Data cable 12Pin Red Red Black Black White CCW CW N L Power inlet cable RPM sensor magnetic reed switch Incline Up Down Resistance Up Down ...

Page 16: ...6 Motor Control Board MCB Power Inlet line Power Inlet neutral Lift Motor Wire to Console Lift Motor position potentiometer Servo Control Lift motor common neutral Lift Motor CW line Lift Motor CCW line ...

Page 17: ...ce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wall outlet and wait 5 minutes before cleaning maintaining or repairing this machine Place the power cord in a secure location When disposing of old parts obey the applicable local and provincial requirements For instructions to replace the following parts please refer to the Assembly Manua...

Page 18: ...omponents of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly a...

Page 19: ...ring this machine Place the power cord in a secure location 4 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside 5 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the har...

Page 20: ...er and Lower Handlebar Arms Set them safely aside for reassembly 8 Using a 6mm hex wrench loosen and remove the indicated hardware from the Left Crank Arm and Leg and set it safely aside for reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 9 Using a small standard screwdriver gently pry the cap...

Page 21: ...Puller clockwise The Crank Arm will slide off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 13 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 14 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate sc...

Page 22: ...ottom screws first and then the top screw Slowly remove the Right Shroud 16 Insert 2 5 x 10 cardboard between the Flywheel and the Brake Magnet and tape the cardboard to the Brake Magnet Note Be sure the cardboard covers all of the Brake Magnet Motorized Lift Cover Flywheel Brake Magnet Flywheel Brake Magnet Servo Motor ...

Page 23: ...ce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wall outlet and wait 5 minutes before cleaning maintaining or repairing this machine Place the power cord in a secure location 21 Installation is the reverse procedure Put the Left Shroud in position first to align the screws for the Right Shroud Install the top screws first Be sure the tab...

Page 24: ...nd children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts ...

Page 25: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 26: ...reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 9 Using a small standard screwdriver gently pry the cap off of the Left Crank Arm 10 Using a 14mm socket and ratchet remove the Lock Nut from the Left Crank Arm Leg Crank Arm ...

Page 27: ...de off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 13 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 14 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Le...

Page 28: ...embly Idler Assembly 16 To adjust the Tensioner Nuts on the Tensioner Bracket use a 10mm open end wrench to hold the Tensioner Bolt steady and turn the nuts with a second 10mm open end wrench 17 When the tension is correct tighten the nuts against the Tensioner Bracket to hold the bolt and the Tensioner Assembly in position Note This step may require two people 18 Carefully turn the Right Crank Ar...

Page 29: ...attach the Shrouds to the Frame Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds Installation does not require the use of the crank puller Be sure the Crank Arms are con nected at 180 from each other 20 Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correc...

Page 30: ...ers Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own ...

Page 31: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 32: ...reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Using a small standard screwdriver gently pry the cap off of the Left Crank Arm 7 Using a 14mm socket and ratchet remove the Lock Nut from the Left Crank Arm Leg Crank Arm ...

Page 33: ...e off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 10 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 11 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Lef...

Page 34: ... Belt 16 Install the new Tensioner Assembly routing the Drive Belt correctly Secure the hardware Note Be sure to adjust the replacement Tensioner Bolt and Tension er Nuts to the previous length Note Your machine may not match the image For reference only 17 To test the Drive Belt tension Push the Drive Belt downward at the midpoint M between the pulleys and measure the distance The Drive Belt shou...

Page 35: ... hazards when you turn the Right Crank Arm Adjust the belt tension again if necessary 21 Installation is the reverse procedure Put the Left Shroud in position first to align the screws for the Right Shroud Install the top screws first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping scr...

Page 36: ...ers Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own ...

Page 37: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 38: ...reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Using a small standard screwdriver gently pry the cap off of the Left Crank Arm 7 Using a 14mm socket and ratchet remove the Lock Nut from the Left Crank Arm Leg Crank Arm ...

Page 39: ...to slide off the Crank Arm 10 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 11 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Left Shr...

Page 40: ...attaches the Brake Assembly to the Main Frame Bracket NOTICE Hold the Brake Assembly so that it does not fall Do not crimp the cables 16 Remove the Brake Assembly and then the cardboard Discard the old Brake Assembly 17 Installation is the reverse procedure Tape the cardboard to the new Brake Magnet Be sure the cardboard will completely cover the new Brake Magnet before installation NOTICE Do not ...

Page 41: ...t Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the Frame Installation does not require the use of the crank puller Be sure the Crank Arms are connected at 180 from each other 20 Inspect your machine to ensure that all hardware is tight and components are...

Page 42: ...ll times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus replacement p...

Page 43: ...eaning maintaining or repairing the machine Place the power cord in a secure location 1 To remove the Console Junction Cover pinch the sides to release the side snaps and then pivot it forward and off of the machine 2 Using a 6mm hex wrench remove the indicated hardware from the Console Mast Console Junction Cover Console Junction Cover Static Handlebar Console Console Mast ...

Page 44: ...eople 4 Using a 2 Phillips screwdriver remove the four indicated screws from the Console and remove the Static Handlebar Note Be sure to observe how the cables route through the Static Handle bar from the Console before removing it to assist with re assembly Do not crimp the cables 5 Installation is the reverse procedure NOTICE Do not crimp the cables 6 Inspect your machine to ensure that all hard...

Page 45: ...segment is the currently active value month day year 9 Push OK to set 10 Time Push the Increase Decrease buttons to adjust the currently active value flashing Push the Left Right buttons to change which segment is the currently active value hour minute AM or PM 11 Push OK to set 12 Units of Measurement Push the Increase Decrease buttons to adjust between MILES Imperial English or KM metric 13 Push...

Page 46: ... away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessa...

Page 47: ...aintaining or repairing this machine Place the power cord in a secure location 1 To remove the Console Junction Cover pinch the sides to release the side snaps and then pivot it forward and off of the machine 2 Using a 6mm hex wrench remove the indicated hardware from the Console Mast Console Junction Cover Console Junction Cover Static Handlebar Console Console Mast ...

Page 48: ...his step may require two people 4 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside 5 Using a 6mm hex wrench and a 13mm wrench remove the indicated hardware from the Lower Handlebar Arms and Pedals Be aware that the Handlebar Arm will...

Page 49: ...ast continue to Step 10 10 Remove the Arm Pivot Rod from the Console Mast and set it safely aside for reassembly Note Be aware that the Arm Pivot Rod is coated with lubrication Place it on a rag or piece of cardboard to contain the lubrication 11 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Console Mast 12 U...

Page 50: ... allow the cables to fall down into the Console Mast 15 Inspect your machine to ensure that all hardware is tight and compo nents are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual ...

Page 51: ...om the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use o...

Page 52: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 53: ...y On each side of the machine remove the Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Using a small standard screwdriver gently pry the cap off of the Crank Arm 7 Using a 14mm socket and ratchet remove the Lock Nut from the Crank Arm Leg Crank Arm ...

Page 54: ...slide off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 10 Installation is the reverse procedure Note Installation does not require the use of the crank puller Be sure the Crank Arms are connected at 180 from each other 11 Dispose of the old parts 12 Inspect your machine to ensure that all hardware is tight and compon...

Page 55: ...nders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement...

Page 56: ...aintaining or repairing this machine Place the power cord in a secure location 1 To remove the Console Junction Cover pinch the sides to release the side snaps and then pivot it forward and off of the machine 2 Using a 6mm hex wrench remove the indicated hardware from the Console Mast Console Junction Cover Console Junction Cover Static Handlebar Console Console Mast ...

Page 57: ...his step may require two people 4 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside 5 Using a 6mm hex wrench and a 13mm wrench remove the indicated hardware from the Lower Handlebar Arms and Pedals Be aware that the Handlebar Arm will...

Page 58: ...e hardware indicated from the Console Mast Slightly pull the Console Mast up and disconnect the cables Set the hardware aside for reassembly NOTICE Do not crimp the cables Do not allow the cables to fall down into the Main Unit or into the Console Mast This step may require two people 11 Remove the Console Mast from the Upper Shroud 12 Tie a length of string to the end of the Input Output I O Cabl...

Page 59: ...nnect the other cable from the Mast and the Main Frame NOTICE Do not crimp the cables This step may require two people 16 Reassembly is the reverse procedure NOTICE Do not crimp the cables Untie the string from the Lift Motor Wire Do not allow the cables to fall down into the Console Mast Be sure the tabs in the Top Shroud snap into the Main Assembly 17 Installation is the reverse procedure NOTICE...

Page 60: ...nician or bystanders Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward s...

Page 61: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 62: ...reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Using a small standard screwdriver gently pry the cap off of the Left Crank Arm 7 Using a 14mm socket and ratchet remove the Lock Nut from the Left Crank Arm Leg Crank Arm ...

Page 63: ...e off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 10 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 11 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Lef...

Page 64: ...lt can be released from the Tensioner Bracket 15 Using a 6mm hex wrench and a 13mm wrench loosen the Tensioner Assembly Hardware A that attaches the Tensioner Assembly to the Frame Bracket Note Use the hex wrench to hold the bolt in place on the outside and turn the nut from the inside 16 Turn the Drive Pulley clockwise while forcing the Drive Belt to the outside to remove it The belt will come of...

Page 65: ...ive Belt in position on the Flywheel Pulley Put the Drive Belt in position around the Tensioner Assembly Be sure that the upper portion of the Drive Belt is under the Tensioner Bearings on the Tensioner Assembly The Flywheel is heavy This step may require two people 21 Center the Flywheel Axle in the Frame Brackets and hand tighten the hardware on each end of the Flywheel Axle 22 Put the Drive Bel...

Page 66: ...embly Idler Assembly 25 To adjust the Tensioner Nuts on the Tensioner Bracket use a 10mm open end wrench to hold the Tensioner Bolt steady and turn the nuts with a second 10mm open end wrench 26 When the tension is correct tighten the nuts against the Tensioner Bracket to hold the bolt and the Tensioner Assembly in position Note This step may require two people 27 Carefully turn the Right Crank Ar...

Page 67: ... level 30 Installation is the reverse procedure Put the Left Shroud in position first to align the screws for the Right Shroud Install the top screws first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the Frame Installation does not require the use of th...

Page 68: ...ing serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nauti...

Page 69: ...n is the reverse procedure 4 Dispose of the old part 5 Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual To reduce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wal...

Page 70: ... bystanders Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on y...

Page 71: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 72: ...ch side of the machine remove the Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Bend the edges of the Top Shroud to disengage the inside tabs from the Main Assembly 7 Using a small standard screwdriver gently pry the cap off of the Crank Arm Leg Crank Arm ...

Page 73: ...ed that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 11 Using a 2 Phillips screwdriver remove the 7 indicated screws from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Left Shroud NOTICE Be sure not to crimp any cables 12 Bend the edges of the Top Shroud to disengage the inside tabs from the Main A...

Page 74: ... Collar Nut and the Lift Motor base and record the number 17 Using the 18mm socket and wrench and 18mm open end wrench loosen and remove the hex head bolts that attach the Incline Adjuster Assembly to the Lift Motor shaft Set the bolts aside for reassembly 18 Carefully remove the old Incline Adjuster Assembly and discard Note Do not rotate the Lift Motor Collar Nut on the Shaft while the Incline A...

Page 75: ...ews first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the Frame Installation does not require the use of the crank puller Be sure the Crank Arms are connected at 180 from each other 20 Dispose of the old parts 21 Inspect your machine to ensure that all ...

Page 76: ...nders Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your ow...

Page 77: ...aintaining or repairing this machine Place the power cord in a secure location 1 To remove the Console Junction Cover pinch the sides to release the side snaps and then pivot it forward and off of the machine 2 Using a 6mm hex wrench remove the indicated hardware from the Console Mast Console Junction Cover Console Junction Cover Static Handlebar Console Console Mast ...

Page 78: ...his step may require two people 4 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside 5 Using a 6mm hex wrench and a 13mm wrench remove the indicated hardware from the Lower Handlebar Arms and Pedals Be aware that the Handlebar Arm will...

Page 79: ...t Rod The hardware on both ends of the Arm Pivot Rod will need to be held to remove it 8 Remove the Handlebar Arms 9 Using a 2 Phillips screwdriver remove the 5 screws 3 indicated on left side two on right side from the Water Bottle Holder 10 Remove the indicated grommet by arrow from the Console mast that secures the Remote Incline Cable and remove it from the Cable 11 Tie a length of string to t...

Page 80: ...new Remote Incline Cable 15 Reassembly is the reverse procedure NOTICE Do not crimp the cables Untie the string from the Lift Motor Wire Do not allow the cables to fall down into the Console Mast Be sure the tabs in the Top Shroud snap into the Main Assembly 16 Inspect your machine to ensure that all hardware is tight and compo nents are properly assembled Do not use until the machine has been ful...

Page 81: ... the service technician or bystanders Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do h...

Page 82: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 83: ...ch side of the machine remove the Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Bend the edges of the Top Shroud to disengage the inside tabs from the Main Assembly 7 Using a small standard screwdriver gently pry the cap off of the Crank Arm Leg Crank Arm ...

Page 84: ...ed that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 11 Using a 2 Phillips screwdriver remove the 7 indicated screws from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Left Shroud NOTICE Be sure not to crimp any cables 12 Bend the edges of the Top Shroud to disengage the inside tabs from the Main A...

Page 85: ...ol Board MCB Assembly on your machine Power Inlet Cable Power switch to MCB Lift Motor Cable Lower Lift Motor to MCB Lift Motor Cable Upper MCB to Console Servo Motor Cable MCB to Servo Motor Speed Sensor Cable Speed Sensor to Servo Motor Input Output I O Cable Servo Motor to Console Note Be sure to note where all cables are routed for re assembly 17 Remove the zipties that hold the cables 18 Usin...

Page 86: ...19 Using a 2 Phillips screwdriver remove the top screw to free the Lift Motor ground wire Hand tighten the top screw to hold the MCB Assembly in position on the Frame until reassembly 20 Disconnect the Lift Motor cable from the Motor Control Board after noting the connector locations Note Be sure to note where all cables attach for re assembly Lift motor ground wire MCB Assembly ...

Page 87: ...ble to the proper locations on the MCB Secure the cables with zipties Use the top screw to attach the green Lift Motor ground wire to the Frame Be sure not to crimp any cables 26 Turn the power on Machine is on Current is active There is risk of electrical shock 27 From the Power Up Mode screen push and hold down the PAUSE STOP button and Right arrow button for about 3 seconds to go into the Conso...

Page 88: ...confirm corrrect operation Push the 0 lift preset button to confirm correct operation Disconnect all power and allow to sit for 5 minutes A1 A2 35mm Spacer 36 Reassembly is the reverse procedure Secure the cables with zipties NOTICE Do not crimp the cables Put the Left Shroud in position first to align the screws for the Right Shroud Install the top screws first NOTICE This step may require two pe...

Page 89: ...nd children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts ...

Page 90: ...aintaining or repairing this machine Place the power cord in a secure location 1 To remove the Console Junction Cover pinch the sides to release the side snaps and then pivot it forward and off of the machine 2 Using a 6mm hex wrench remove the indicated hardware from the Console Mast Console Junction Cover Console Junction Cover Static Handlebar Console Console Mast ...

Page 91: ...his step may require two people 4 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside 5 Using a 6mm hex wrench and a 13mm wrench remove the indicated hardware from the Lower Handlebar Arms and Pedals Be aware that the Handlebar Arm will...

Page 92: ...e the hardware indicated from the Console Mast Slightly pull the Console Mast up and disconnect the cables Set the hardware aside for reassembly NOTICE Do not crimp the cables Do not allow the cables to fall down into the Main Unit or into the Console Mast This step may require two people 11 Remove the Console Mast from the Upper Shroud 12 Tie a length of string to the end of the Lift Motor Wire a...

Page 93: ...e to the Lift Motor Wire from the Main Frame Reconnect the other cable from the Mast and the Main Frame NOTICE Do not crimp the cables This step may require two people 16 Reassembly is the reverse procedure NOTICE Do not crimp the cables Untie the string from the Lift Motor Wire Do not allow the cables to fall down into the Console Mast Be sure the tabs in the Top Shroud snap into the Main Assembl...

Page 94: ...rs Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own I...

Page 95: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 96: ...reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Using a small standard screwdriver gently pry the cap off of the Left Crank Arm 7 Using a 14mm socket and ratchet remove the Lock Nut from the Left Crank Arm Leg Crank Arm ...

Page 97: ...e off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 10 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 11 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Lef...

Page 98: ...CB cover Carefully remove the MCB cover NOTICE Do not crimp the cables 15 Disconnect the cables from the Motor Control Board after noting their locations see next page for detailed image Note Be sure to note where all cables attach for re assembly 16 Using a 2 Phillips screwdriver remove the 2 indicated screws that attach the MCB Assembly to the Frame 17 Remove the old MCB Assembly and install the...

Page 99: ... crank puller Be sure the Crank Arms are connected at 180 from each other 19 Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct perfor mance in accordance with the Owner s Manual Note After replacing the MCB Assembly the resistance levels of the machine may be different The ...

Page 100: ...e Contact Heart Rate CHR sensor HR cable 4Pin Lift motor wire 5Pin Lift motor cable 3Pin Lift motor potentiometer cable 3Pin Servo control cable 9VDC 2Pin I O Data cable 12Pin Red Red Black Black White CCW CW N L Power inlet cable RPM sensor magnetic reed switch Incline Up Down Resistance Up Down ...

Page 101: ...t being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine N...

Page 102: ...of the Left Pedal and Leg To remove the Right Pedal and Leg adjust the procedure accordingly 1 Using a 6mm hex wrench and 13mm wrench remove the indicated hardware from the Pedal 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated hardware from the Lower Handlebar Arm and Pedal Be aware that the Handlebar Arm will be loose and may pivot when the hardware is removed Note To assist with ...

Page 103: ... replace with the new one 6 Installation is the reverse procedure 7 Discard the old parts 8 Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner s Manual Leg Crank Arm ...

Page 104: ...bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replac...

Page 105: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 106: ...y On each side of the machine remove the Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 9 Using a small standard screwdriver gently pry the cap off of the Crank Arm 10 Using a 14mm socket and ratchet remove the Lock Nut from the Crank Arm Leg Crank Arm ...

Page 107: ...start to slide off the Crank Arm 13 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 14 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Le...

Page 108: ...wire to the bracket and Frame Be sure not to crimp any cables Put the Left Shroud in position first to align the screws for the Right Shroud Install the top screws first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the Frame Installation does not require...

Page 109: ...ay from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary ...

Page 110: ...l Assembly If you have access to the hardware that attaches the Incline Adjuster to the Rail Assembly continue to Step 10 If additional space is required for removal and installation continue to Step 3 3 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Plac...

Page 111: ...Disconnect the Cable from the Upper Handlebar that goes into the Console Mast 6 Using a 6mm hex wrench and a 13mm wrench remove the hardware from the Lower Handlebar Arms and the Arm Pivot Rod Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed 7 Remove the Handlebar Arm Assemblies and set them safely aside 8 Using a 6mm hex wrench remove the indicated hardwar...

Page 112: ...or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own NOTICE This step may require two people 13 Installation is the reverse procedure Note Remove the plastic scratch guard strips from the Rails If neces sary apply silicone lubricant to a cloth and wipe the Rails to eliminate roller noise 14 Dis...

Page 113: ...ause injury to the service technician or bystanders Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do n...

Page 114: ...is machine Place the power cord in a secure location 3 Using a 2 Phillips screwdriver remove the 4 screws from each set right and left of the Handlebar Shrouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside 4 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware s...

Page 115: ...e the Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 8 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Console Mast 9 Using a 6mm hex wrench remove the hardware indicated from the Console Mast Slightly pull the Mast up and disconnec...

Page 116: ...ised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 14 Using a 2 Phillips screwdriver remove the 7 indicated screws from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Left Shroud NOTICE Be sure not to crimp any cables 15 Bend the edges of the Top Shroud to disengage the inside tabs from the Main...

Page 117: ...d Sensor Cable and Servo Motor Cable from the wiring harness 21 Tie the length of string to the end of the Lower Input Output I O Cable at the top of the Mast mount Remove the zipties that attach the Lower Input Output I O Cable to the Frame Pull the cable and string down through the hole on the side of the Frame so that the string extends through the Frame NOTICE Hold the Lower Lift Motor Wire so...

Page 118: ...Console Cable on the new Servo Motor Carefully pull the cable through the hole to the top of the Console Mast mount Untie the string and discard it NOTICE Do not crimp the cables 28 Reinstall the Console Mast with the Upper Shroud Turn the power on Machine is on Current is active There is risk of electrical shock 29 Use the console to set the resistance to the highest level Unplug the machine Disc...

Page 119: ...ews first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the Frame Installation does not require the use of the crank puller Be sure the Crank Arms are connected at 180 from each other 32 Dispose of the old parts 33 Inspect your machine to ensure that all ...

Page 120: ...n away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necess...

Page 121: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 122: ...d the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Top Shroud up the Mast If you are not replacing the Upper Shroud go to Step 9 7 Remove the hardware indicated from the Mast Gently pull the Mast out and disconnect the cables Set the hardware Mast and Top Shroud safely aside NOTICE Do not crimp the cables This step may require two peopl...

Page 123: ...uller clockwise The Crank Arm will slide off as it is tightened Note Be advised that it may take a lot of force to get the Crank Puller to start to slide off the Crank Arm 12 Bend the edges of the Top Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 13 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screw...

Page 124: ...Motorized Lift Cover from the Incline Adjuster Assembly 17 Installation is the reverse procedure Put the Left Shroud in position first to align the screws for the Right Shroud Install the top screws first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the ...

Page 125: ...product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only gen...

Page 126: ...ach other Place them safely aside 2 Using a 6mm hex wrench and a 13mm wrench remove the indicated bolts from the Lower Handlebar Arms and Pedals Set the hardware safely aside for reassembly Be aware that the Handlebar Arms will be loose and may pivot when the hardware is removed This step may require two people 3 Disconnect the indicated Cable with arrow from the Upper Handlebar that goes into the...

Page 127: ...r reassembly Remove the left Leg and Pedal together from the Rail Assembly and set them safely aside for reassembly NOTICE This step may require two people 6 Using a small standard screwdriver gently pry the cap off of the Left Crank Arm 7 Using a 14mm socket and ratchet remove the Lock Nut from the Left Crank Arm Leg Crank Arm ...

Page 128: ... to slide off the Crank Arm 10 Bend the edges of the Upper Shroud to disengage the inside tabs from the Main Assembly and slide the Shroud Cap and Upper Shroud up the Mast 11 Using a 2 Phillips screwdriver remove the 7 indicated screws ar rows indicate screws under the Upper Shroud from the Left Shroud and remove them Remove the bottom screws first and then the top screws Slowly remove the Left Sh...

Page 129: ...Right Shroud Install the top screws first Be sure the tabs in the Motorized Lift Cover snap into the Side Shrouds NOTICE This step may require two people Be sure not to crimp any cables Note Self tapping screws attach the Shrouds to the Frame Installation does not require the use of the crank puller Be sure the Crank Arms are connected at 180 from each other 18 Dispose of the old parts Speed Senso...

Page 130: ... serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine Nautilus...

Page 131: ...leaning maintaining or repairing the machine Place the power cord in a secure location 1 To remove the Console Junction Cover pinch the sides to release the side snaps and then pivot it forward and off of the machine 2 Using a 6mm hex wrench remove the indicated hardware from the Console Mast Console Junction Cover Console Junction Cover Static Handlebar Console Console Mast ...

Page 132: ...eople 4 Using a 2 Phillips screwdriver remove the four indicated screws from the Console and remove the Static Handlebar Note Be sure to observe how the cables route through the Static Handle bar from the Console before removing it to assist with re assembly Do not crimp the cables 5 Installation is the reverse procedure NOTICE Do not crimp the cables 6 Inspect your machine to ensure that all hard...

Page 133: ...ildren away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkward Enlist the service of a second person when you do maintenance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are n...

Page 134: ...ouds After removing the hardware pinch the Handlebar Shrouds to unsnap them from each other Place them safely aside Note This procedure shows the removal and replacement of the Left Upper and Lower Handlebar Arm To remove the Right Handlebar adjust the procedure accordingly 2 Disconnect the Cable from the Upper Handlebar that goes into the Console Mast 3 Using a 6mm hex wrench remove the 4 screws ...

Page 135: ... Arm Pivot Rod The hardware on both ends of the Arm Pivot Rod will need to be held to remove it 7 Remove the old Lower Handlebar Arm and replace with the new one 8 Installation is the reverse procedure Make sure the Upper Handlebar Arms are secure before you exercise 9 Discard the old parts 10 Inspect your machine to ensure that all hardware is tight and compo nents are properly assembled Do not u...

Page 136: ...owing warnings Read and understand the Service Manual before working on the machine Failure to obey the instructions and safety warnings could cause injury to the service technician or bystanders Disconnect all power to the machine before you service it Keep bystanders and children away from the product being serviced at all times Make sure that the repair is done in an appropriate work space away...

Page 137: ...tabilizer D Set the Endcap and screw safely aside 4 Using the 6mm hex key and 13mm wrench loosen and remove the hardware C1 from the old Transport Wheel assembly C Remove the old Transport Wheel from the front stabilizer bracket D1 Set the Transport Wheel and hardware safely aside 5 Installation is the reverse procedure NOTICE Before fully attaching the Endcap be sure that the Transport Wheel can ...

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Nautilus E618, Service Manual

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