Nautilus R916, U916 Service Manual

Model U916

Be Strong.

™

Commercial Series Bike

PN 001-6884 Rev B (03/27/2007)

Model R916

Service Manual

Model: U916 & R916

Important—Please Read

This manual is intended for authorized Nautilus or Nautilus certied service personnel and not for the consumer.
There are no user serviceable parts. Servicing of the Nautilus® Commercial Series Bike by other than authorized
Nautilus or Nautilus certied service personnel may result in voiding of the warranty.

If you are a consumer and require technical support to resolve a problem with your Nautilus® Commercial
Series Bike, please call Nautilus® Customer Service at 800-628-8458 (North America) or [phone]
(outside North America).

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Table of Contents

Product Specifications ................................5

Important Safety Information ...............6

Safety Warning Labels ...........................................7

Maintenance .......................................................9

Maintenance Records .......................................... 11

Resetting the Maintenance Hour Timer ...............11

Routine Maintenance

Checking the Battery Charge................................ 11

Recharging the Battery Back-up .......................... 12

Battery Disposal ...................................................12

........................................... 11

Console Codes ................................................13

Overview................................................................15

Defaults .................................................................15

Cable Connections - U916

Cable Connections - R916 .....................................56

.....................................53

Appendixes ........................................................59

Required Tools .......................................................60

Using a Multimeter ...............................................61

International Power Plug Configurations ..............64

Warranty Information

Contact Numbers .........................................................67

...................................................65

Customize ..............................................................15

Machine Status .....................................................16

Diagnostics ............................................................17

Maintenance Logs .................................................18

Machine Configuration ..........................................20

Electrical Troubleshooting ......................21

U916/R916 Main Wiring Diagram .......................23

U916 Console Heart Rate Wiring Diagram ...........24

R916 Console Heart Rate Wiring Diagram ...........25

General Bike Electronics Troubleshooting ............26

Mechanical Troubleshooting ................35

Removing/Replacing Parts -

U916 and R916 Common Parts..............................37

Removing/Replacing Parts -

U916 Parts .............................................................48

Removing/Replacing Parts -

R916 Parts .............................................................51

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Contents

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PRODUCT SPECIFICATIONS

U916 Upright Bike R916 Recumbent Bike

Length 45 in. (114.3 cm) 67 in (170.18 cm)

Width 24 in. (60.96 cm) 24 in. (60.96 cm)

Height 57 in. (144.78 cm) 46 in. (116.84 cm)

Workout Area 50” W x 81” L (127 cm x 205.74 cm) 50” W x 103” L (127 cm x 261.62 cm)

Unit Weight 150 lb. (68 kg) 180 lbs (82 kg)

Physical

Shipping Package Weight 178 lb. (81 kg) 231 lbs (105 kg)

Max User Weight Supported 400 lb. (182 kg) 400 lb. (182 kg)

Belt(s) Two: Poly-V (6V) self-tensioning belt and timing belt

Power

Cordless; or 108-132VAC 60 Hz, or 220-240VAC 50 Hz, 20 watts maximum
(operation with charger connected)

Battery Type 6VDC sealed lead-acid

Battery Charge Time 8 hours to full charge, starting with discharged battery

Electrical

Display C51 blue/white LCD with backlight. Tactile membrane keypanel

Number of Functions

Heart Rate Monitoring

Eleven: Heart rate, elapsed time, calories burned, calories burned per hour,
watts, METS, resistance level, rpm, speed, distance, and workout profile

Integrated heat rate monitoring system with polar-compatible wireless and
contact HR

Eleven: Quick Start, Manual, Fat Burner, Calorie Burner, Intervals, HR Zone

Workout Programs

Trainer, multi-stage Fit Test. Calorie Goal, HR Intervals, Random Play, Custom
Intervals

Functionality

Resistance Range Twenty: 20 watts (level 1, 20 rpm) to 500 watts (level 20, 80 rpm)

Language Options English, German, French, Spanish, Italian, Dutch, Portuguese

C-Safe Compatible Level 2 compatible. Owner/manager will be able to customize console.

Operating Temperature 50–90 oF (10–32 oC)

Storage Temperature -25–50 oC

Operating Humidity (non­condensing)

Environmental

Storage Humidty (non­condensing)

3–95% relative humidity

3–95% relative humidity

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SAFETY REQUIREMENTS

7 ! 2 . ) . '

7 ! 2 . ) . '

IMPORTANT SAFETY INFORMATION: SAVE THESE INSTRUCTIONS

The following definition applies to the word “Warning” found throughout this guide:

- Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.

This symbol appearing ThroughouT This manual means

pay aTTenTion! be alerT! your safeTy is involved!

1. Read, understand and carefully follow all warnings,
instructions and procedures in this manual. Failure to do
so can produce a serious electrical shock hazard or other
serious injury.

2. The external power supply should always be unplugged from the
AC wall outlet before removing or installing parts. Never make
adjustments or repairs while an exercise program is in progress.

3. Close supervision is necessary whenever the machine is being
used or serviced whenever children, invalids, or disabled persons
are in the vicinity.

4. Keep hands away from all moving parts. Keep feet on the pedals
while exercising or testing the machine.

5. Do not operate the machine with the side covers removed, or
outdoors.

6. Use this machine only for its intended use as described in this
Manual. Do not use parts, attachments, or accessories other than
those provided by Nautilus, Inc.

7. Do not use the ex ternal power supply if it has a damaged cord or
plug, it is not working properly, if it has been dropped or damaged,
or dropped in water. Contact our Technical Service Department to
arrange for the return of damaged parts.

8. To avoid potential safety and electrical problems, replace with
manufacturer’s specified par ts only.

9. Connect the external power supply to a properly grounded AC wall
outlet.

10. Keep all cords away from heated surfaces.

14. Keep the area underneath and around the machine clear.

15. Do not operate where aerosol (spray) products are being used.

16. Always wear insulated gloves when handling batteries.

17. Do not crush, incinerate, or dismantle the battery.

THE ELECTROLY TE CONTAINS SUL FURIC ACID, WHICH CAN

CAUSE SERIOUS DAMAGE TO EYES AND SKIN. SHOULD

THIS OCCUR, FLUSH PROFUSELY WITH WATER

AND SEEK MEDICAL ATTENTION.

18. The safety level provided by the design of this equipment can
only be maintained when the equipment is regularly examined for
damage and wear. Inoperable components should be replaced
immediately or the equipment be put out of use until it is repaired.

19. Failure to follow the guidelines may compromise the effectiveness
of the exercise experience, expose you (and possibly others) to
injury, and reduce the longevit y of the machine. Follow all training
instructions listed in the manual and/or on the machine.

Failure to follow the conditions set forth below shall limit, to the extent
allowed by law, Nautilus, Inc. responsibility for the safety, reliability,
and performance of this equipment.

• The operator manual must be read in full by each owner and trainer

before the product is first used. Each user must be instructed in the
proper use of the bike and its accessories.

• The equipment must be used in accordance with the instructions

for use.

11. To disconnect the external power supply, remove the plug from the
AC wall outlet.

12. Do not let liquid enter the console. If liquid does enter the console,
the console must be inspected and tested for safety by an approved
technician before it can be used again.

13. Never drop or insert any object into any opening on the machine.

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• Only Nautilus-trained or Nautilus-authorized personnel should
carry out assembly operations, extensions, readjustments,
modifications, or repairs.

• For further information or instruction on use, maintenance or
specifications, please contact your Authorized Nautilus Fitness
Dealer or Service Technician.

SAFETY WARNING LABELS

The following safety warnings are located on the Nautilus® Commercial Series Bike. Please read all safety precautions and
warning information prior to using your product. Be sure to replace any warning label if damaged, illegible, or missing. If
you need replacement labels, please call a Nautilus Representative at [phone] (North America) or [phone]
(International office).

Label 2

Label 1

Label 1

Label 2

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SAFETY WARNING LABELS

The following safety warnings are located on the unit. Please review and understand the safety warning labels and their
locations on the unit prior to use.

If you do not have, or cannot find, or need to replace a warning label please call 1-800-628-8458 (North America) or
[phone] (International office) to obtain a new label.

Label 1: See Figure 1 for general warning label.

Location: The warning label in Figure 1 is located on the

side of the console mast.

Label 2: See Figure 2 for general exercise warning label.

Figure 2

Location: Affixed to the console face below the keypanel.

Figure 1

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1

Maintenance

Contents

Maintenance Records .................................................................................11

Resetting the Maintenance Hour Timer ..................................................... 11

Routine Maintenance.................................................................................. 11

Checking the Battery Charge ...................................................................... 11

Recharging the Battery Back-up ................................................................. 12

Battery Disposal .......................................................................................... 12

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10

Maintenance

Maintenance Records

For ease of maintenance the U916 and R916 console will keep track of hours, number of workouts, time between last
servicing, etc. You can quickly access any of the custom menus by pressing [LEVEL: UP], [4], [ENTER]. The console will
then display “MACHINE STATUS.” Use the [Level: UP] and [Level: DOWN] keys to scroll through the options. For details,
refer to the Machine Status Console Codes.

Resetting the Maintenance Hour Timer

After each maintenance period reset the counter. Press [LEVEL: UP], [7], [ENTER]. Then use the Level keys to scroll
through the options. When “MAINT HOURS” is displayed, press [ENTER]. Press the [0] key, then press [ENTER]. Press
[CLEAR] to return to the opening screen.

Routine Maintenance

Upon receiving your machine, use a soft, clean towel to wipe off the dust, which may have accumulated during shipping.
Your new machine will require minor assembly. Refer to the “Installation Instructions” section for details.

Cleaning

1. DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANERS ON THE CONSOLE. Clean the console daily
with a water-dampened cloth and wipe dry after cleaning.

2. Clean the exterior of the machine daily using soap and water or a diluted, non-mineral based household cleaner such
as Fantastic®.

Inspection

1. Frame:

Inspect the frame for any rust, bubbling, or paint chips during the weekly cleaning. The salt in perspiration
can damage the unpainted surfaces. Repair the damaged area with a touch-up paint kit purchased from Nautilus (call
Customer Service for order information).

Checking the Battery Charge

1. Using your multimeter, touch the red lead to the positive terminal of the battery and the black lead to the negative
terminal.

2. If the voltage level is less than 6.1 VDC, charge the battery.

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Maintenance

Recharging the Battery Back-Up

The Commercial Series U916 and R916 bikes are both self-powered (cordless) with a rechargeable battery back-up.
Typically, the bike can be operated without plugging in the battery charger. If, however, the console flickers during
operation or the console display does not light up while using the machine, then use the battery charger to recharge the
battery back-up.

The battery charger is supplied with the unit and plugs into a standard 115 volt, 15 amp outlet, or a 220 volt, 15 amp outlet.
(All major voltage plugs are available.) The plug-in for the battery charger is located
in the front of the machine at the base.

NOTE: If installing the optional LCD Monitor, refer to the NV915 installation manual at
this time.

Plug the wall pack battery charger into the connector and charge the battery for
approximately 24 hours and then recheck it. It is okay to use the machine while the
battery charger is connected.

When the bike is not connected to an external power source, the console will power
on as the user starts to pedal machine, and will stay lit for up to 60 seconds in pause
mode. The console will power off after 60 seconds of stopping exercise.

If the bike is connected to an external power source, the console will power on automatically and stay on until power is
disconnected.

Battery charger plug-in

Battery Disposal

When ordering new batteries, you will need to properly dispose of (recycle) your old lead-acid batteries. Most federal
and state regulations require lead-acid batteries to be recycled. Do not throw away old batteries. Lead is a toxic heavy
metal, hazardous to living organisms. Disposal instructions and a list of recycling centers are tabulated in the Appendix.
If you have questions, contact the Customer Service Department at 800-628-8458 (North America) or [phone]
(International office).

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2

Console Codes

Contents

Overview ..................................................................................................... 15

Defaults ....................................................................................................... 15

Customize .................................................................................................... 15

Machine Status ........................................................................................... 16

Diagnostics.................................................................................................. 17

Maintenance Logs....................................................................................... 18

Reset Maintenance Hours ...................................................................... 19

Error Log.................................................................................................. 19

Machine Configuration................................................................................ 20

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14

Customization

Overview

To enter a Service Mode, the unit must be in IDLE DISPLAY state or an ERROR. The service screens cannot be entered during
a workout, paused or in a WARNING state. (If the unit is in a Warning state, you must press [CLEAR] before entering the
Service Modes.) To access the console codes, press the Level Up button (

▲), the group number code, and [ENTER]. Then use

the arrow buttons to scroll through the menu options for each group. The procedures are outlined in the tables below.

There are six groups of Service Mode console codes: Defaults (codes starting with 2), Customize (codes starting with 3),
Machine Status (codes starting with 4), Diagnostics (codes starting with 6), Maintenance Logs (codes starting with 7), and
Change Machine (codes starting with 8). Each group of codes is defined below.

Defaults

You can customize several workout parameters on the R916/U916 Bike with default values to conform to your individual
requirements, including:

• % target heartrate (10-90%)

• age (10-99)

• workout time (5-99 min)

• workout level (1-20)

• weight (50-400 lbs. or 25-180 kg)

Refer to the following table to scan through and customize the settings:

Table 2–1. Defaults

Step No. Press Keys Display (What you will see)

1

2 ▼ or ▲

3

4 ▼ or ▲ (or numeric keypad)

5

6

▲, 2, ENTER

ENTER

ENTER

CLEAR

DEFAULTS

CHR PERCENT, AGE, TIME, LEVEL, WEIGHT

Selected choice

Default value changes

DEFAULTS

SELECT WORKOUT

Customize

You can customize several console settings on the R916/U916 Bike with default values to conform to your individual
requirements, including:

• resetting all configurable settings to factory defaults (see below)

• adjusting lower screen contrast (0-15)

• adjusting upper screen contrast (0-15)

• console language

• choosing type of heartrate inputs (description below)

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Machine Status

• change units (USA units or metric units)

• cooldown time (1-10 min)

• maximum time limit (10-99 min or OFF)

Refer to the following table to scan through and customize the settings:

Table 2–2. Customize

Step No. Press Keys Display (What you will see)

1 ▲, 3, ENTER CUSTOMIZE

2 ▼ or ▲ SET DEFAULTS, CONTRAST ADJ LOWER,

CONTRAST ADJ UPPER, LANGUAGE,
SELECT STATS*, HR INPUTS, CHANGE
UNITS, COOL DOWN, MAX TIME LIMIT

3 ENTER Selected choice

4 ▼ or ▲ (or numeeric keypad) Default value changes

5 ENTER CUSTOMIZE

6 CLEAR SELECT WORKOUT

*The SELECT STATS menu display option is not active for the R916 and U916.

Set Defaults – resets the machine to the factory defaults for all configurable values. Please note that selecting this option
will require the machine to be reconfigured (see Change Machine section).

NOTE: All error and history counter data (Maint Hours, Distance, Workouts, Run Hours, Error Log, and QA ID Number) will

be lost if Set Defaults is selected.

HR Inputs – enables the various heart rate inputs that can be used. Heart rate configurations include: Locked Inputs (both
heart rate monitors are read until it detects a valid signal to lock on, at which point the other HR inputs are ignored), HAND
HR PRGM OFF, Both HR OFF, Hand Only, Telemetry Only, and Either Input (if one input is lost, then the other input may
become active).

Change Units - changes all displayed data (service information and user data) to the selected units. Units are: Miles or
Kilometers, MilesPerHour or KilometersPerHour, Pounds (LB) or Kilograms (KG), MinutesPerMile or MinutesPerKM.

Machine Status

Use the machine status codes to view maintenance information such as:

• maintenance hours

• machine type (U/R916)

• console software version

• distance traveled

• number of workouts

• machine run-time hours

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Refer to the following table to scan through and customize the settings:

Table 2–3. Machine Status

Step No. Press Keys Display (What you will see)

1 ▲, 4, ENTER MACHINE STATUS

Diagnostics

2 ▼ or ▲

3 CLEAR SELECT WORKOUT

MAINT HOURS, U/R916 [or other], CONS,
DISTANCE, WORKOUTS, RUN HOURS

Maint Hours – displays the number of hours (incremented every hour) the machine has been running. The start value is set
under the Maintenance Logs service screen. (The start value can be set to any value—e.g. if the service tech had entered
100 in the Maintenance Logs service screen and there was 1 hour of running time on the machine, the value under this
Maint Hours screen would read 101).

Machine Type – should display U/R916. “NTM Config REQD” appears on the console if the software has been updated on
the machine or the machine froze up and the power had to be cycled. The message also appears when the console assembly
has been replaced and no configuration established. Configuring the machine will eliminate this message (see the table
“Machine Configuration”).

Distance – displays the total distance in miles (or kilometers) of machine operation. This value is auto-incremented every
1/100th or 1/10th unit, depending on how many miles/km have accrued.

Workouts – displays the total number of workouts performed on the machine. This value is auto-incremented only if the
user enters a workout and either completes the workout or presses the [STOP] key twice.

Run Hours – displays the total number of hours on the machine.

NOTE: The R&D options (codes starting with 5) are not used for servicing machines. Do not change these settings. If an

R&D setting is inadvertently changed, it will reset when the machine is powered off and then back on.

Diagnostics

Use diagnostic codes to test various components of the machine such as the:

tachometer

•

• alternator

• I/O

• sensor (for EV9.16 only)

• serial ports

• keypad

• display

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Maintenance Logs

Refer to the following table to scan through the diagnostic tests and view diagnostic information:

Table 2–4. Diagnostics

Step No. Press Keys Display (What you will see)

1 ▲, 6, ENTER DIAGNOSTICS

2 ▼ or ▲ TACH TEST, ALT TEST, I/O TEST,

A SENSOR B, SERIAL PORTS, KEY TEST,
DISPLAY TEST

3 ENTER Selected choice

4 CLEAR DIAGNOSTICS

5 CLEAR SELECT WORKOUT

Tach Test – performs a tachometer test. On the left hand side of the display the target rate of 2000 rpm is displayed. On
the right hand side of the display the actual rpm is displayed. If the actual rpm is above the target rate, then the alternator
field turns on (the level increases). If the actual rpm is below the target rate, then the alternator field shuts off (the level
decreases).

Alt Test – performs an alternator test. By pressing the level up key, the alternator field will turn on and the steps will
become harder to rotate. By pressing the level down key, the alternator field will turn off and the steps will become easier to
rotate.

I/O Test – The AUX and B+ values represent the current and voltage delivered from the alternator respectively. AUX is
scaled by 1000 and B+ is scaled by 300. These values will increase with the speed of the alternator (note that both values
will reach 0 if the alternator is left at rest). The “---” string is displayed at all times since the bikes do not require a magnetic
key.

A Sensor B – is used only on the ellipticals. The A Sensor B diagnostic screen ensures the optical detector is functional.
The A value is displayed on the left hand side of the upper display (B is not used on the EV9.16). Under normal conditions,
the A value should toggle between the “0” and “1”.

Serial Ports - tests the serial ports (UARTS) for proper functionality. The tech can choose from either the CSAFE-1
Loopback or TM Loopback tests. Both of these tests result in PASS or FAIL. Please note that a null modem must be used to
perform these tests.

Key Test - tests all of the user interface keys. Once a key is pressed, its value will show up on the display screen. After all
keys have been pressed and are functional, a PASS message appears on the display.

Display Test - will test all segments on both the top and bottom displays.

Maintenance Logs

The MAINTENANCE LOGS settings allow you to view the quality assurance data, the machine’s error log, and reset the time
between service and maintenance calls.

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Refer to the following table to scan through the Maintenance Logs tests and view diagnostic information:

Table 2–5. Maintenance Logs

Step No. Press Keys Display (What you will see)

Maintenance Logs

1

2 ▼ or ▲ QA ID NUMBER*, MAINT HOURS, ERROR

3 ENTER Selected choice

4 CLEAR after viewing (or reset) MAINTENANCE LOGS

5 CLEAR SELECT WORKOUT

* The QA ID NUMBER option is not used for servicing machines in the field.

▲, 7, ENTER

MAINTENANCE LOGS

LOG

The following tables provide the steps for resetting the time between service or maintenance calls, and for viewing the error
log:

Table 2–6. Reset Maintenance Hours

Step No. Press Keys Display (What you will see)

1 ▲, 7, ENTER MAINTENANCE LOGS

2 ▼, ▼ MAINT HOURS

3 ENTER MAINT HOURS ####

4 CLEAR to exit after viewing, or

0, ENTER to reset

MAINTENANCE LOGS

5 CLEAR SELECT WORKOUT

Maint Hours – lets the service technician enter a value representing the maintenance hours.

Table 2–7. Error Log

Step No. Press Keys Display (What you will see)

1 ▲, 7, ENTER MAINTENANCE LOGS

2 ▼, ▼, ▼ ERROR LOG

3 ENTER NO ERROR or the highest priority error

4 ▼ or ▲ Scrolls through the error log list

5 CLEAR SELECT WORKOUT

Error Log – displays fatal errors accrued on the system. The log holds up to 8 error entries. Errors are handled in two ways:

n First, as a non-fatal Warning, which will display the error response text but continue system operation until you

press the [CLEAR] key. Warnings are not logged in the Error Log.

n The second way is a fatal Error, which will stop the exercise and return the system to an idle intensity state. The

console will display the error response and a number showing how many errors were logged during the specific
event. (Some errors trigger multiple responses). To view the non-displayed errors, access the Error Log. The unit will
not let you restart the program unless power has been turned off and then back on.

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Machine Status

Once you access the Error Log, you can cycle the display through 8 entries by using the up/down keys. Each entry displays
the error label, its position in the log (1-8), and the time (hours) the error occurred. Note that the most recent error might
not be in log position 1—as the number of errors exceeds 8, the newest error will overwrite the oldest. In addition, if a new
error is identical to the log’s previous entry, the system checks the time. If the time is the same (within minutes), the error is
not logged, to help prevent redundant errors.

The only way to reset the Error Log is to reconfigure the machine.

Machine Configuration

Use Machine Configuration to change the machine type. The choices are:

• Stepper

• StepMill

• U/R916

• Elliptical

In general, only the U/R916 machine type is used for the U916 or R916.

Refer to the following table to scan through and customize the settings:

Table 2–8. Machine Configuration

Step No. Press Keys Display (What you will see)

1

2

3

4

5

▲, 8, ENTER

ENTER

▼ or ▲

ENTER

CLEAR

CHANGE MACHINE

U/R916

NTM CONFIG RQD, STEPPER CL, STEPMILL,
ELLIPTICAL, U/R916

Selects your choice

SELECT WORKOUT

NTM Config RQD – resets the machine to a “blank” configuration. The configuration must be set to Elliptical (or other
machine type) for the workout functions to operate.

Stepper CL – configures the machine as a cordless Stepper. Please note that there is a sense line to let the software
know if the system is a Stepper PT (corded); if the system is indeed a Stepper PT, then Stepper PT will appear in the screen
instead of Stepper CL.

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3

Electrical Troubleshooting

Contents

U916 and R916 Main Power Wiring Diagram ........................................ 23

U916 Console Heart Rate Wiring Diagram ............................................ 24

R916 Console Heart Rate Wiring Diagram ............................................ 25

General Bike Electronics Troubleshooting .............................................. 26

Contact Heart Rate Testing ....................................................................28

Battery Charge Testing ........................................................................... 29

Alternator Testing ................................................................................... 30

Start-Up Circuit Testing .......................................................................... 31

Load Resistor Testing .............................................................................32

Shut-Down Testing ................................................................................. 33

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