Nautilus R618 Service Manual Download Page 13 | Manualshive

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13

REPLACEMENT PROCEDURE SKILL LEVEL

Level I :

Low - very little mechanical knowledge or exposure.

Level II :

Intermediate - some experience with mechanical procedures

Level III :

Advanced - knowledgeable about mechanical procedures

!

Disconnect all power to the machine before you service it.
When disposing of old parts, obey the applicable local and provincial requirements.

For instructions to replace the following parts, please refer to the Assembly Manual for your bike:
• AC Adapter

• Seat

• Seat Post

• Front Stabilizer

• Rear Stabilizer

• Water Bottle Holder

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Summary of Contents for R618

Page 1: ...Data Cable in the Mast 42 12 Brake Assembly 45 13 Servo Motor 47 14 Drive Belt and Flywheel Assembly 51 15 Belt Tensioner Assembly Idler Assembly 54 16 RPM Sensor Speed Sensor 56 17 Power Inlet 58 Table of Contents Nautilus Inc www NautilusInc com 5415 Centerpoint Parkway Groveport OH 43125 U S A Customer Service North America 800 605 3369 csnls nautilus com outside U S www nautilusinternational c...

Page 2: ...ce the labels If purchased in US Canada contact Customer Service for replacement labels If purchased outside US Canada contact your local distributor for them 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 ...

Page 3: ...hildren and pets away Read and follow all warnings on this machine Refer to the Owner s Manual for additional warnings and safety information The heart rate displayed is an approximation and should be used for reference only Not intended for use by anyone under 14 years of age The maximum user weight for this machine is 325 lbs 147 kg This machine is for home use only Consult a physician prior to ...

Page 4: ...rence to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving a...

Page 5: ...ipe your machine and Console free of moisture Note Avoid excessive moisture on the Console NOTICE If necessary only use a mild dish soap with a 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 Clea...

Page 6: ... Download the free Software App named Nautilus Trainer The software app is available on the App Store and Google Play Note For a complete 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 ...

Page 7: ...ctions orientation Be sure cable is connected securely and oriented properly Small latch on connector should line up and snap into place Check console display for damage Check for visual sign that console display is cracked or other wise damaged Replace Console if damaged Console Display If Console only has partial display and all connections are fine replace the Console If the above steps do not ...

Page 8: ...sole Check for visual sign that Console is damaged Replace Con sole if damaged Check data cable integrity All wires in cable should be intact If any are visibly crimped or cut replace cable Check data cable connections orientation Be sure cable is connected securely and oriented properly Reseat all connections Small latch on connector should line up and snap into place Check Servo Motor requires s...

Page 9: ...on threads and reinstall the pedals Seat post movement Check locking pin Be sure adjustment pin is locked into one of the seat post adjustment holes Check adjustment knob Be sure knob is securely tightened Console continuously cycles through program screens Console is in demonstra tion mode Hold down the PAUSE END button and Left button together for 3 seconds Workout results will not sync with Blu...

Page 10: ...ay shows the TOTAL RUN HOURS for the machine To go to the next Console Setup Mode prompt push the OK button To enter the Manufacturing Menu MFG Menu For the later version of the console hold down the PAUSE END button and Increase button together for 3 sec onds while in the Power Up Mode For the earlier version of the console hold down the PAUSE END button and Left button together for 3 seconds whi...

Page 11: ...All segments on 2 All segments off 3 Set individual segments one at a time until all segments are illuminated Press any key to exit i RESET CONSOLE Resets the data from user inputs The Console setup user records and workout records will be reset to defaults This option does not reset MFG NVM non volatile memory 11 The Console display shows the Software Version prompt 12 For the next prompt push th...

Page 12: ...s O Seat Post w Slider AA Servo Motor D Crank Arms P Adjustment Knob BB Drive Belt E Left Shroud Q AC Adapter CC Drive Pulley F Power Inlet R Water Bottle Holder DD Handlebar Mount Cover G Right Shroud S Rear Stabilizer EE T handle H Top Shroud T Levelers FF Console Pivot Shroud I Mast Gasket U Front Stabilizer GG Remote Resistance Control J Data Cable V Transport Wheels HH Resistance Cable K Hand...

Page 13: ...I Advanced knowledgeable about mechanical procedures Disconnect all power to the machine before you service it When disposing of old parts obey the applicable local and provincial requirements For instructions to replace the following parts please refer to the Assembly Manual for your bike AC Adapter Seat Seat Post Front Stabilizer Rear Stabilizer Water Bottle Holder ...

Page 14: ...n 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 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...

Page 15: ... nut on one side steady and loosen the nut on the opposite side with a 15 mm socket and wrench 4 Move the Flywheel in the Main Frame bracket as necessary to adjust the tension Hold it in position and tighten the hardware Note This step may require two people To tighten the Flywheel hardware use a 15 mm open end wrench to hold the nut on one side steady and tighten the nut on the opposite side with...

Page 16: ...o crimp any cables 7 Final Inspection 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 ...

Page 17: ...ual 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 from foot traffic and exposure to bystanders Some...

Page 18: ...he Mast Lean the Top Shroud against the Seat Post mount to keep it clear of the pulley assembly Note It may be necessary to remove the Water Bottle Holder 4 Insert 2 5 x 10 cardboard between the Brake Magnet A and the Flywheel B and tape the cardboard to the Brake Magnet Note Be sure the cardboard covers all of the Brake Magnet 5 Turn the power on again Machine is on Current is active There is ris...

Page 19: ...to check the resistance adjustment Machine is on Current is active There is risk of electrical shock Note Before fully attaching the Shrouds remove the cardboard from between the Brake Magnet A and the Flywheel B Power up the machine to verify that the Magnet Arm can move freely and that the Brake Magnet and Flywheel do not touch 9 Final Inspection Inspect your machine to ensure that all hardware ...

Page 20: ...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 from foot traffic and exposure to bystanders Some components of the equipment can be heavy or ...

Page 21: ...ial Setup During the first power up the Console should be set up with the date time your preferred measurement units and machine type 1 Date 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 month day year 2 Push OK to set 3 Time Push the Increase Decrease buttons to adjust the currentl...

Page 22: ...he 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 from foot traffic and exposure to bystanders Some components of the equipment can be heavy or awkwar...

Page 23: ...d tighten to prevent cross threading Then tighten fully with pedal wrench Note The Left Pedal is reverse threaded Be sure to attach Pedals on the correct side of the Bike Orientation is based from a seated position on the bike The Left Pedal has an L the Right Pedal an R 3 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled Do not use un...

Page 24: ...nual 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 from foot traffic and exposure to bystanders Som...

Page 25: ...reassembly Note The Left Pedal is reverse threaded Orientation is based from a seated position on the bike The Left Pedal has an L the Right Pedal an R 2 Using a flathead screwdriver remove the threaded Cap A from the Crank Arm B to expose the Hex Head Bolt C 3 Using a wrench and socket remove the Hex Head Bolt C R L A B C B ...

Page 26: ...er portion CP2 of the Crank Puller should show Note Be sure the end of the Bolt CP1 of the Crank Puller is flush with the Nut CP2 as shown before use 5 Using a wrench turn the inner portion CP3 of the Crank Puller clockwise The Crank Arm B will slide off as it is tightened CP1 CP2 CP3 B CP2 CP3 Crank arm shown is on a 170 bike ...

Page 27: ...hten fully with pedal wrench Note The Left Pedal is reverse threaded Be sure to attach Pedals on the correct side of the Bike Orientation is based from a seated position on the bike The Left Pedal has an L the Right Pedal an R 7 Final Inspection 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 ...

Page 28: ...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 29: ...abilizer 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 t...

Page 30: ...e 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 from foot traffic and exposure to bystanders Some components of the equip...

Page 31: ...nk Puller is in the correct position only 1 2 threads on the outer portion CP2 of the Crank Puller should show Note Be sure the end of the Bolt CP1 of the Crank Puller is flush with the Nut CP2 as shown before use 5 Using a wrench turn the inner portion CP3 of the Crank Puller clockwise The Crank Arm C will slide off as it is tightened Go to Step 8 6 Twist the Crank Cover P toward the front of the...

Page 32: ...onnect the cables Set the hard ware Mast and Mast Gasket safely aside NOTICE Do not crimp the cables This step may require two people Note Do not let the cable fall down inside the Frame 9 Bend the edges of the Top Shroud to disengage the inside tabs from the Main Assembly and remove the Top Shroud X2 Cable connectors ...

Page 33: ...Left Shroud Remove the bottom screws first and then the top screws Slowly remove the Left Shroud Note Find the Power Inlet E in the Left Shroud Disconnect the Power Inlet cable E1 from the wiring harness F NOTICE Be sure not to crimp any cables F E1 E E1 E Power Inlet cable connection ...

Page 34: ...screws for the Right Shroud Install the top screws first NOTICE Be sure not to crimp any cables Be sure the tabs in the Top Shroud snap into the Main Assembly Be sure the Crank Arms are connected at 180 from each other 13 Final Inspection 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 inspect...

Page 35: ... 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 from foot traffic and exposure to bystanders Some components of the...

Page 36: ... for reassembly Note Do not let the cables fall down inside the Mast This step may require two people 4 Remove the Handlebar Bracket Cover and set it safely aside for reassmbly 5 Tie the length of string to the end of the Heart Rate Cable and Resistance Cable at the top of the Mast Grasp the section of HR Cable and Resistance Cable under the Handlebar Bracket and carefully pull the cables and stri...

Page 37: ... ends of the HR cable and Resistance Cable Carefully pull the cables through the slot under the Handlebar Bracket to the top of the mast Fully tighten the T handle to keep the Handlebar in position Push the cover into position on the Handlebar Bracket NOTICE Do not crimp the cables Do not let the cables fall down in the Mast 10 Connect the cables to the back of the Console and attach the Console t...

Page 38: ...e 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 from foot traffic and exposure to bystanders Some components of the equip...

Page 39: ... sistance Cable at the top of the Mast Set the Console and screws safely aside for reassembly Note Do not let the cables fall down inside the Mast This step may require two people 4 Remove the Handlebar Bracket Cover and set it safely aside for reassmbly 5 Grasp the section of HR Cable and Resistance Cable under the Handlebar Bracket and carefully pull the cables down through the Mast and out of t...

Page 40: ...ut and disconnect the cables Set the hard ware Mast Gasket and Top Shroud safely aside for reas sembly Discard the old Mast NOTICE Do not crimp the cables This step may require two people Note Do not let the cables fall down inside the Frame 10 Install the replacement Console Mast and the Mast Gasket on Main Assembly NOTICE Make sure the Console Cable connector does not fall into the Console Mast ...

Page 41: ...n the T handle to keep the Handlebar in position Push the cover into position on the Handlebar Bracket NOTICE Do not crimp the cables Do not let the cables fall down in the Mast 13 Connect the cables to the back of the Console and attach the Console to the Mast NOTICE Do not crimp the cables 14 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly a...

Page 42: ...re 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 from foot traffic and exposure to bystanders Some compone...

Page 43: ... at the top of the Mast Set the Console and screws safely aside for reassembly Note Do not let the cables fall down inside the Mast This step may require two people 4 Remove the Mast Gasket Set it safely aside for reassembly 5 Remove the hardware indicated from the Mast Gently pull the Mast out and disconnect the cables Set the hard ware safely aside for reassembly NOTICE Do not crimp the cables T...

Page 44: ...ng from the Data Cable and connect the cable to the Data Cable from the Main Frame NOTICE Do not crimp the cables This step may require two people 9 Put the Mast back in position in the Main Frame and reinstall the Hardware Note Do not let the cables fall down inside the Mast NOTICE Be sure not to crimp any cables This step may require two people 10 Reinstall the Mast Gasket 11 Connect the cables ...

Page 45: ...ual 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 from foot traffic and exposure to bystanders Some...

Page 46: ...l completely cover the new Brake Magnet before installation NOTICE Do not crimp the cables 7 Before fully attaching the Shrouds remove the cardboard from between the Brake Magnet A and the Flywheel B Power up the machine to verify that the Magnet Arm can move freely and that the Brake Magnet and Flywheel do not touch at the maximum resistance level Machine is on Current is active There is risk of ...

Page 47: ...rvice 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 from foot traffic and exposure to bystan...

Page 48: ...ush QuickStart and verify that the console shows that the default resistance level is 4 Set the resistance to the highest level Disconnect all power and allow to sit for 5 minutes 2 Carefully remove the Shrouds Refer to the Replace the Shrouds procedure in this manual 3 Measure and mark the position of the Servo Motor bracket C on the Main Frame 4 Insert 2 5 x 10 cardboard between the Brake Magnet...

Page 49: ...rom the Main Frame Pull back and release the Magnet Arm K enough to disengage it from the Motor Pulley Shaft L 9 Loosen and remove the two hex head bolts M from the Servo Motor C NOTICE Hold the Servo Motor so that it does not fall 10 Remove the Servo Motor C Discard the old Servo Motor 11 Installation is the reverse procedure Adjust the new Servo Motor to same position recorded in Step 3 NOTICE D...

Page 50: ...using the needlenose pliers Note Before fully attaching the Shrouds remove the cardboard from between the Brake Magnet A and the Flywheel B Power up the machine to verify that the Magnet Arm can move freely and that the Brake Magnet and Flywheel do not touch at the maximum resistance level If necessary refer to the Set the Brake Tension procedure 16 Final Inspection Inspect your machine to ensure ...

Page 51: ...llowing 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 aw...

Page 52: ...nt procedure Note Your machine may not match the image For reference only 1 Carefully remove the Shrouds Refer to the Replace the Shrouds procedure in this manual 2 Slowly turn the Drive Pulley A backward and carefully ease the Drive Belt B off the Drive Pulley to the outside Be sure to keep fingers clear of all pinch hazards as you turn the Drive Pulley Disconnect all power to the machine before ...

Page 53: ...n each end of the Flywheel axle 9 Put the Drive Belt B onto the Drive Pulley A Make sure the Drive Belt is aligned on the Flywheel pulley C1 Belt Tensioner E and Drive Pulley 10 Before you fully tighten the Flywheel hardware reattach the Belt Tensioner spring E1 with the pliers Make sure that the belt tension is correct Refer to the Belt Tension Adjustment section in this manual Note This step may...

Page 54: ...ent obey the following 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 appropriat...

Page 55: ...m the Main Frame and the Drive Belt C Discard the old Belt Tensioner assembly 6 Install the new Belt Tensioner assembly Adjust the Belt Tensioner position to the angle of the previous position recorded in Step 2 NOTICE Do not overtighten the hardware E The Belt Tensioner must be able to pivot If the hardware is too tight this can cause wear on the bearings 7 Put the Drive Belt C onto the Drive Pul...

Page 56: ...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 from foot traffic and exposure to ...

Page 57: ...r and cable and discard it NOTICE Do not crimp any cables 4 Installation is the reverse procedure NOTICE Do not crimp any cables Be sure the routing for the new RPM Sensor cable B and other wiring is correct to prevent interference from moving parts Note Before fully attaching the Shrouds verify that the RPM Sensor A and Speed Sensor Magnet D on the Drive Pulley do not touch 5 Final Inspection Ins...

Page 58: ...nual 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 from foot traffic and exposure to bystanders Som...

Page 59: ...may not match the image For reference only 1 Carefully remove the Left Shroud Refer to the Replace the Shrouds procedure in this manual 2 Carefully disconnect the Power Inlet cable A in the Shroud from the wiring harness B on the motor Disconnect all power to the machine before you service it A B B A Recumbent bike Upright bike ...

Page 60: ...let assembly 5 Installation is the reverse procedure NOTICE Do not crimp any cables Be sure the Power Inlet plug is seated evenly in the hole 6 Final Inspection 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 C A C A ...

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