Nautilus E626 Service Manual Download

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Nautilus

U624/U626 (Model Year 2014)

Upright Bikes Service Manual

8008323.040115.A

Service Manual

Important Safety Instructions

Safety Warning Labels and Serial Number

Reading the Product Specification Label

Specifications

Maintenance 4

Leveling the Machne

Moving the Machine

Troubleshooting 6

Console Service Mode

Maintenance Parts Exploded View

Replacement Procedure Skill Level

Mechanical Procedures

Belt Tension Adjustment

Set the Brake Tension (Calibration)

Part Replacement

Console

Pedals

Crank Arms – U626

Transport Wheels, Front Endcaps and Footpads

Shrouds

Handlebar Assembly

Console Mast

Data Cable in the Mast

Brake Assembly

Servo Motor

Drive Belt and Flywheel Assembly

Belt Tensioner Assembly (Idler Assembly)

Drive Pulley Assembly (Crank Assembly) – U624

RPM Sensor (Speed Sensor)

Power Inlet

Table of Contents

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respective owners.

ORIGINAL DOCUMENT - ENGLISH VERSION ONLY

Summary of Contents for E626

Page 1: ...Arms U626 23 Transport Wheels Front Endcaps and Footpads 27 Shrouds 29 Handlebar Assembly 34 Console Mast 37 Data Cable in the Mast 41 Brake Assembly 44 Servo Motor 46 Drive Belt and Flywheel Assembly 50 Belt Tensioner Assembly Idler Assembly 53 Drive Pulley Assembly Crank Assembly U624 55 RPM Sensor Speed Sensor 58 Power Inlet 60 Table of Contents Nautilus Inc www NautilusInc com Customer Service...

Page 2: ...ds from your local distributor 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 This product contains magnets Magnetic fields can interfere with the normal use of c...

Page 3: ...sage Class H Consumer use only Maximum User Weight 136kg 300lb Equipment Type Fitness Made in China 8004288_A Manufacture Date Code 58mm 30mm Patent www nautilusinc com IP Nautilus Inc YYWW 18225 NE Riverside Parkway Portland Or 97230 www nautilusinternational com Phone 1 800 NAUTILUS Serial number Product specification 104cm 41 8 55cm 21 6 146cm 57 6 Maximum User Weight 136 kg 300 lb Total Surfac...

Page 4: ...inutes 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 Daily Before each use examine the exercise machine for loose broken damaged or worn parts Do not use if found in this condition Repair or replace all parts at the first sign of wear or damage After each workout use ...

Page 5: ...the bike downward Push the bike to the desired location NOTICE Be careful when you move the bike Abrupt motions can affect the computer operation Leveling Your Bike Levelers are found on each side of the Rear Stabilizer Turn the stabilizer foot to adjust Make sure the bike is level and stable before you exercise ...

Page 6: ... conduct These are available on the web or at medical or some larger fitness stores Handlebar If tests reveal no other issues Handlebars should be replaced Unit operates but Telemetric HR not displayed U626 only Chest Strap optional Strap should be POLAR compatible and uncoded Make sure strap is directly against skin and contact area is wet Check User Profile Select the Edit User Profile option fo...

Page 7: ...peed sensor should be aligned with magnet and connected to data cable Realign sensor if necessary Replace if there is any damage to the sensor or the connecting wire Unit rocks does not sit level Check leveler adjustment Adjust levelers until bike is level Check surface under unit Adjustment may not be able to compensate for extremely un even surfaces Move bike to level area Pedals loose unit diff...

Page 8: ... setting Push the Increase Decrease buttons to change between ON and OFF 11 Push OK to set 12 The Console display 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 hold down the PAUSE END button and Down button together for 3 seconds The Console display shows the Firmware Version string Push the Up Down...

Page 9: ...et 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 13 The Console display shows the Software Version prompt 14 For the next prompt push the OK button 15 The Console will displa...

Page 10: ...sors X Brake Assembly C Pedals N Seat Y RPM Sensor D Crank Arms O Seat Post w Slider Z Speed Sensor Magnet E Left Shroud P Adjustment Knob AA Servo Motor F Power Inlet Q AC Adapter BB Drive Belt G Right Shroud R Water Bottle Holder CC Drive Pulley H Top Shroud S Rear Stabilizer DD Handlebar Mount Cover I Mast Gasket T Levelers EE T handle J Data Cable U Front Stabilizer FF Cover Crank Disc K Handl...

Page 11: ...Y RPM Sensor D Crank Arms O Seat Post w Slider Z Speed Sensor Magnet E Left Shroud P Adjustment Knob AA Servo Motor F Power Inlet Q AC Adapter BB Drive Belt G Right Shroud R Water Bottle Holder CC Drive Pulley H Top Shroud S Rear Stabilizer DD Handlebar Mount Cover I Mast Gasket T Levelers EE T handle J Data Cable U Front Stabilizer FF Cover Crank Disc K Handlebars V Transport Wheels ...

Page 12: ... 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 When disposing of old parts obey the applicable local and provincial requirements For instructions to replace the following parts please refer to the Assembly ...

Page 13: ...ers 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 p...

Page 14: ...h 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 a 15 mm socket and wrench 5 Carefully turn the crank arms and check the movement of the driv...

Page 15: ...lly with pedal wrench 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 16 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 ...

Page 16: ...e steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine replacement parts and hardware supplied by Nautilus Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional placards applied to the pr...

Page 17: ...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 18: ...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 19: ...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 not try to do...

Page 20: ...Manual Initial 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 t...

Page 21: ... 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warra...

Page 22: ...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 23: ...n 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional placar...

Page 24: ...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 Crank arm shown is on a Schwinn 170 bike ...

Page 25: ...reads 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 B will slide off as it is tightened CP1 CP2 CP3 B CP2 CP3 ...

Page 26: ...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 27: ...e 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and...

Page 28: ...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 Trans port Wheel can ...

Page 29: ...ance steps involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional placards applied to th...

Page 30: ...ld 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 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 befor...

Page 31: ...Carefully remove the Crank Covers and set them safely aside 8 Slide the Mast Gasket up the Mast 9 Remove the hardware indicated from the Mast Gently pull the Mast out and disconnect the cables Set the hardware 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 10 Bend the edges of the Top Shroud to ...

Page 32: ...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 33: ...in Assembly U624 bike To reinstall the Pedals carefully align the threads and hand tighten to prevent cross threading Then tighten fully with pedal wrench 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 U626 bike Be sure the Crank Arms are connected at 180 from each other 14 Final Inspection Inspect your m...

Page 34: ...nd 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instruc...

Page 35: ... safely aside for reassembly 4 Tie the length of string to the end of the Heart Rate Cable at the top of the Mast Grasp the section of HR Cable under the Handlebar Bracket and carefully pull the cable and string down through the Mast and out of the hole so that the string extends through the Mast and Handlebar Bracket Note Do not let the Data Cable fall down inside the Mast To reduce the risk of e...

Page 36: ...he end of the HR cable Carefully pull the cable 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 9 Connect the cables to the back of the Console and attach the Console to the Mast NOTICE Do n...

Page 37: ...son 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional...

Page 38: ...y require two people 3 Remove the Handlebar Bracket Cover and set it safely aside for reassembly 4 Grasp the section of HR Cable under the Handlebar Bracket and carefully pull the cable down through the Mast and out of the hole in the Handlebar Bracket Note Do not let the Data Cable fall down inside the Mast To reduce the risk of electrical shock or unsupervised usage of the equipment always unplu...

Page 39: ...out and disconnect the cables Set the hardware Mast Gasket and Top Shroud safely aside for reassembly 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 9 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 Al...

Page 40: ...ndle 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 12 Connect the cables to the back of the Console and attach the Console to the Mast NOTICE Do not crimp the cables 13 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled D...

Page 41: ... 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 replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers a...

Page 42: ...ket Set it safely aside for reassembly 4 Remove the hardware indicated from the Mast Gently pull the Mast out and disconnect the cables Set the hardware safely aside for reassembly NOTICE Do not crimp the cables This step may require two people Note Do not let the cable fall down inside the Frame To reduce the risk of electrical shock or unsupervised usage of the equipment always unplug the power ...

Page 43: ...e 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 8 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 9 Reinstall the Mast Gasket 10 Connect the cables to the back...

Page 44: ...s involving these components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional placards applied to the product...

Page 45: ...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 electrical shock If necessary refer to the Set the Brake Tension procedure 8 Final Inspection...

Page 46: ...se components Do not try to do heavy or awkward steps on your own If replacement parts are necessary use only genuine replacement parts and hardware supplied by Nautilus Failure to use genuine replace ment parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional placards applied to the product stay present a...

Page 47: ...he 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 A and the Flywheel B and tape the cardboard to the Brake Magnet Note Be sure the cardboard c...

Page 48: ...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 49: ...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 50: ...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 use...

Page 51: ...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 To reduce the risk of electrical shock or unsupervised usage of the equipment always unplug the power cord from the wall outlet and wait...

Page 52: ...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 53: ...hildren 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 ...

Page 54: ...ew 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 Pulley B Make sure the Drive Belt is aligned on the Flywheel pulley F Belt Tensioner A and Drive...

Page 55: ...hildren 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 ...

Page 56: ...ng C1 from the hook D on the frame 4 Loosen and remove the Locknut E Bumper F and Bracket G from the Pulley Shaft Assembly H 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 NOTICE It is necessary to remove...

Page 57: ...n the Flywheel pulley N Belt Tensioner C and Drive Pulley Be sure that the upper portion of the Drive Belt B is under the bearings on the Belt Tensioner C 8 Using the needlenose pliers reattach the Belt Tensioner spring C1 Make sure that the belt tension is correct Refer to the Belt Tension Adjustment section in this manual Note This step may require two people 9 Final Inspection Inspect your mach...

Page 58: ...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 59: ...edure 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 Inspect your machine to ensure that all hardware is tight and components are properly assembled...

Page 60: ...s 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 par...

Page 61: ...eplace 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 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 A B B A Recum...

Page 62: ...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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Nautilus E626, Service Manual

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