Nautilus U624 Service Manual

Model year 2014 upright bikes

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Assembly and owner's manual (36 pages)

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Summary of Contents for Nautilus U624

Page 1: Table Of Contents
Power Inlet Nautilus, Inc., www.NautilusInc.com - Customer Service: technics@nautilus.com | 18225 NE Riverside Parkway, Portland, OR 97230 USA | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Polar...
Page 2: Important Safety Instructions
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or other- wise protected by common law. Polar and Bluetooth are registered trademarks of their respective owners.
Page 3: Safety Warning Labels And Serial Number
Manufacture Date Code: YYWW YYWW 20957 20957 compliant compliant Brand: NAUTILUS Model: U626 Brand: NAUTILUS Model: U624 Electrical Rating: 9V DC, 1.5A Electrical Rating: 9V DC, 1.5A Nautilus, Inc. Accuracy Class: C Nautilus, Inc. ® Accuracy Class: C Usage Class: H /Consumer use only.
Page 4: Maintenance
Maintenance Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is necessary to do the necessary tasks. Equipment must be regularly examined for damage and repairs. The owner is responsible to make sure that regular maintenance is done.
Page 5 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. Moving the Bike To move the upright bike, carefully tilt the Handlebars toward you while pushing the front of the bike downward. Push the bike to the desired location.
Page 6: Troubleshooting
Troubleshooting Condition/Problem Things to Check Solution No display/partial display/ Check electrical (wall) Make sure unit is plugged into a functioning wall outlet. unit will not turn on outlet Check connection on Connection should be secure and undamaged. Replace console adapter or connection at unit if either are damaged. Check data cable integrity All wires in cable should be intact.
Page 7 Condition/Problem Things to Check Solution Console shuts off (enters Check electrical (wall) Make sure unit is plugged into a functioning wall outlet. sleep mode) while in use outlet Check connection on Connection should be secure and undamaged. Replace console adapter or connection at unit if either are damaged. Check data cable integrity All wires in the cable should be intact.
Page 8: Console Service Mode
Console Service Mode – x624 / x626 series (MY14) Consoles The Console Setup Mode lets you input the date and time, set the units of measurement to either English or Metric, change the machine type, control the sound settings ( on/ off), or see maintenance statistics (Total Run Hours – for service technician use only).
Page 9 All LEDs Off 1 second Sequence Segments 1 at a time – on 1 second, off 1 second Press any key to exit test h. RUN LCD TEST – Drives 3x5 and 1x5 LCD displays with the following patterns: All segments on All segments off Set individual segments one at a time until all segments are illuminated.
Page 10: Maintenance Parts Exploded View
Maintenance Parts Exploded View Your machine may differ. Use only as a guide. U624 Console HR Cable Flywheel Console Mast CHR Sensors Brake Assembly Pedals Seat RPM Sensor Crank Arms Seat Post w/ Slider Speed Sensor Magnet Left Shroud Adjustment Knob...
Page 11 U626 Console HR Cable Flywheel Console Mast CHR Sensors Brake Assembly Pedals Seat RPM Sensor Crank Arms Seat Post w/ Slider Speed Sensor Magnet Left Shroud Adjustment Knob Servo Motor Power Inlet AC Adapter Drive Belt Right Shroud Water Bottle Holder Drive Pulley Top Shroud Rear Stabilizer...
Page 12: Replacement Procedure Skill Level
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 WA R N I N G To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power D A N G E R cord from the wall outlet and wait 5 minutes before cleaning, maintaining or repairing this machine.
Page 13 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 14 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. 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.
Page 15 Reassembly is the reverse procedure. NOTICE: Be sure not to crimp any cables. U624/R624 bikes—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.
Page 16 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 17: Console
NOTICE: It is necessary to remove the shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. Note: Your machine may not match the image. For reference only. Disconnect and reconnect the AC Adapter from the wall outlet to turn the power off and on.
Page 18 To adjust the Brake tension, loosen the 2 hex head bolts (C) and move the Servo Motor assembly (D) until the closest point on the Brake Magnet (A) is within 3.0 mm (1/8”) of the Flywheel (B). Tighten the bolts. Note: If the cardboard is not 3mm (1/8”) thick, you can use the pages of a paperback book to measure the gap.
Page 19 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 20 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location. Note: Your machine may not match the image.
Page 21 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 22: Pedals
Note: Your machine may not match the image. For reference only. Loosen and remove the old Pedals. Discard the old Pedals. 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”.
Page 23 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 24 Note: Your machine may not match the image. For reference only. Loosen and remove the old Pedals. Set them safely aside for 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”.
Page 25 Thread the Crank Puller into the Crank Arm (B). When the Crank 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.
Page 26 Installation is the reverse procedure. Installation does not require the use of the crank puller. Be sure the Crank Arms are connected at 180° from each other. 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.
Page 27: Transport Wheels, Front Endcaps And Footpads
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 28 Note: Your machine may not match the image. For reference only. Place a static object (like a book or box) under the front stabilizer (C). The static object should not be compressible. Using a short #2 Phillips screwdriver, loosen and remove the screws (A1) from the Footpad (A), and set them safely aside.
Page 29 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 30 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. Note: Your machine may not match the image.
Page 31 Loosen and remove the Pedals. Set them safely aside for 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”. Twist the Crank Cover (P) toward the front of the machine to disengage the inner tabs.
Page 32 11. Using a #2 Phillips Screwdriver, remove the 6 screws (indicated) that secure the 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).
Page 33 NOTICE: Be sure not to crimp any cables. Be sure the tabs in the Top Shroud snap into the Main Assembly. U624 bike—To reinstall the Pedals, carefully align the threads and hand tighten to prevent cross-threading. Then tighten fully with pedal wrench.
Page 34 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 35 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. Note: Your machine may not match the image.
Page 36 Remove the T-handle and washers that attach the Handlebar to the Mast. Set them safely aside for reassembly. NOTICE: Hold the Handlebar so that it does not fall. Untie the string from the HR Cable. Remove the old Handlebar and discard it.
Page 37 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 38 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. Note: Your machine may not match the image.
Page 39: Shrouds
Remove the T-handle and washers that attach the Handlebar to the Mast. Set them safely aside for reassembly. NOTICE: Hold the Handlebar so that it does not fall. Remove the Handlebar and set it safely aside for reassembly. Remove the Mast Gasket. Remove the hardware (indicated) from the Mast.
Page 40 10. Put the Handlebar in the bracket, adjust the Handlebar to the desired angle, and install the T-handle through the holes and washers. NOTICE: Do not crimp the cables. 11. Use the pull cable in the Handlebar Bracket to route the HR cable through the slot under the Handlebar Bracket to the top of the mast.
Page 41 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 42 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. Note: Your machine may not match the image.
Page 43 Tie the length of string to the end (A) of the Data Cable at the base of the Mast. Hold the other end of the Data Cable (B) and carefully pull it out of the Mast so that the string extends through the length of the Mast. Untie the string from the old Data Cable and discard the old cable.
Page 44: Brake Assembly
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 45 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It may be necessary to adjust the Brake tension at the end of this procedure. Refer to the “Set the Brake Tension” procedure. 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.
Page 46: Servo Motor
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 47 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It may be necessary to adjust the Brake tension at the end of this procedure. Refer to the “Set the Brake Tension” procedure. 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.
Page 48 Observe the cable routing. Disconnect the Speed Sensor Cable (D) and Power Inlet Cable (E) from the wiring harness (F). Tie the length of string to the end of the lower Console Cable (G) at the top of the Mast mount. Pull the cable and string down through the hole (H) at the base of the Mast so that the string extends through the mast.
Page 49 13. Reinstall the Mast, Console, Mast Gasket and Top Shroud. (Refer to the “Replace the Shrouds” procedure.) Turn the power on. Machine is on. Current is active. There is risk of electrical shock. 14. Use the console to set the resistance to the highest level. Unplug the machine.
Page 50: Drive Belt And Flywheel Assembly
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 51 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It is necessary to adjust the Drive Belt tension at the end of this procedure. Refer to the “Belt Tension Adjustment” procedure 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.
Page 52 Using needlenose pliers, carefully release the spring (E1) on the Belt Tensioner (E). To remove the hardware from the Flywheel (C), use the 15 mm open end wrench to hold the nut (F) on one side steady and remove the nut on the opposite side with the 15 mm socket and wrench.
Page 53: Belt Tensioner Assembly (Idler Assembly)
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or other- wise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 54 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It is necessary to adjust the Drive Belt tension at the end of this procedure. Refer to the “Belt Tension Adjustment” procedure 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.
Page 55 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or other- wise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 56 NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. It is necessary to adjust the Drive Belt tension at the end of this procedure. Refer to the “Belt Tension Adjustment” procedure 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.
Page 57 Carefully pull the Pulley Shaft Assembly (H) until it works out of the Frame and releases the Washer (J), Bumper (K), Bearings (L) and Bearing Brackets (M). Installation is the reverse procedure. NOTICE: Do not overtighten the crank hardware as this can damage the bearings.
Page 58 Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 59: Rpm Sensor (Speed Sensor)
NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. 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.
Page 60: Power Inlet
Nautilus, Inc., , www.NautilusInc.com - Customer Service: technics@nautilus.com | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY Important Safety Instructions - Before servicing or using this equipment, obey the following warnings: This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 61: Power Inlet
NOTICE: It is necessary to remove the Shrouds for this procedure. Refer to the “Replace the Shrouds” procedure. 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.
Page 62: Power Inlet
Loosen and remove the thin Nut from the Power Inlet (C) on the outside of the Shroud. Pull the Power Inlet plug (C) out of the hole toward the inside of the Shroud. Discard the old Power Inlet assembly. Installation is the reverse procedure. NOTICE: Do not crimp any cables.

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Nautilus U624 Service Manual

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