Be Strong.
Attention! This manual is intended for authorized Nautilus or Nautilus certified service personnel and not for the consumer. There are no user serviceable parts. Servicing of the Nautilus Commercial Series Treadmill by other than authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty. For detailed instructions and information on assembly and use for the Nautilus® Commerical series TREADCLIMBER®, model tC916, refer to the assembly and owner’s manuals. 7! 2 . ) .
Table of contents Important Safety Precautions............. 4 PRODUCT SPECIFICATIONS ........................... 6 Mechanical Service 1.0 Removing The Console ............................................. 7 2.0 A ccessing The Console For Programming ................ 8 3.0 Removing Rear Step ................................................. 9 4.0 VSD Assembly Grounding ....................................... 10 5.0 Removing Uprights ................................................. 12 6.
Important safety precautions - save these instructions IMPORTANT SAFETY INSTRUCTIONS The following definition applies to the word “Warning” found throughout this manual: WARNING - Used to call attention to POTENTIAL hazards that could result in personal injury or loss of life. WHEN USING ELECTRICAL EQUIPMENT ALWAYS FOLLOW THESE BASIC PRECAUTIONS: 7! 2 . ) . ' To reduce the risk of burns, electric shock or injury to persons read and follow all safety warnings and instructions in this manual.
Important safety precautions 7. To avoid potential safety and electrical problems, replace with manufacturer’s specified parts only. 8. This equipment is classified Class I, Type B, ordinary equipment. Not protected against fluid ingress. Rated for continuous operation. Do not operate this equipment in the presence of flammable anesthetic mixtures. 9. Do not let liquid enter the controller.
PRODUCT SPECIFICATIONS NOTE: A ll instructions in the manual are given with the orientation of standing on the TreadClimber® exercise machine facing the console. The console is the front, while the rear step is the back. User Weight Capacity: 400 lbs (182 kg) Speed Range: 0.5 to 6 mph (default set to 4.0 mph) [.8 to 9.5 km/h (default set to 6.
Mechanical service 1.0 - REMOVING THE CONSOLE Tools Needed: • Phillips head screw driver • 5/32 Allen bit Figure 1-1 7! 2 . ) . ' To avoid electrical shock or damage to the unit you must power off the unit and make sure all power has been drained from the unit and capacitors by ensuring there are no lighted leds on the console. $!.'%2 Figure 1-2 1-1: Turn off the unit and unplug from the wall outlet. !4 4 % . 4 ) / .
Mechanical service 2.0 - ACCESSING THE CONSOLE FOR PROGRAMMING Tools Needed: • Phillips head screw driver 2-1: Turn off the unit. 2-2: Remove six (6) screws (P/N - SM41271) from back side of console to remove cover and gain access for programming (see Figure 2-1 and Figure 2-2). 3 screws per side 2-3: Attach FISP connector for software programming to this connection (see Figure 2-3). 2-4: Turn on the unit. Figure 2-1 2-5: The LED on the FISP will blink momentarily, then stay on solid.
Mechanical service 3.0 - REMOVING REAR STEP Tools Needed: • Phillips head screw driver • 5/32 Allen bit 7! 2 . ) . ' Two Middle Screws To avoid electrical shock or damage to the unit you must power off the unit and make sure all power has been drained from the unit and capacitors by ensuring there are no lighted leds on the console. Figure 3-1 $!.'%2 3-1: Unplug the unit from the power source and ensure that all power has been drained from the unit.
Mechanical service 4.0 - VSD ASSEMBLY GROUNDING Parts Affected: • Front Trim Cover - P/N: SM17652 • Right Pan Cover - P/N: SM17653 • Right Side Cover - P/N: SM17655 • VSD Assembly, TC916 - P/N: SM17688 • Flat Washer, 1/4 ID x 5/8 OD - P/N: SM22047 • Screw, .250-20 x .75, HX Wash HD P/N: SM27594 Figure 1: Tools Needed: • 1/8 Allen Bit • 3/8 inch Socket or Open End Wrench 7! 2 . ) .
Mechanical service 4-6: Remove the two (2) VSD Bracket Screws (P/N - SM27594), then remove the VSD Assmebly (see Figure 4). Figure 3: 4-7: Position the new VSD Assembly in place and attach with the two (2) bracket screws. 4-8: Reconnect the previously marked cables to the VSD Assembly. 4-9: Reattach all covers and verify that all machine functions are working properly.
Mechanical service 5.0 - REMOVING UPRIGHTS Tools Needed: • 1/8 Allen bit • 5/32 Allen bit • 3/4 inch Socket • Phillips head screw driver 7! 2 . ) . ' Detaching and moving the upright portion of this product requires two people! You must have a minimum of two people to properly support the heavy upright structure so the console does not fall and cause damage to the unit. Figure 5-1 $!.'%2 7! 2 . ) .
Mechanical service B) From the Encoder Assembly PC board (Not shown). NOTE: The Encoder is under the Treadles and you will have to reach into the machine to disconnect. C) From the Hydraulic Cylinder. See Figure 5-5. 5-5: Remove the Right Lower Cover (P/N - SM17657) and Left Lower Cover (P/N - SM17658). See Figure 5-6 and 5-7. Figure 5-4 5-6: Remove four (4) upright weldment bolts (see Figure 5-8). Cylinder control cables located here. Figure 5-5 Figure 5-6: Lower plastic parts.
Mechanical service 6.0 - REMOVING BASE PLASTIC Tools Needed: • Phillips head screw driver • 1/8 Allen bit Figure 6-1 7! 2 . ) . ' To avoid electrical shock or damage to the unit you must power off the unit and make sure all power has been drained from the unit and capacitors by ensuring there are no lighted leds on the console. $!.'%2 Figure 6-2 6-1: Remove three (3) front plastic screws (see Figure 6-1).
Mechanical service 7.0 - BELT TENSION AND ALIGNMENT Parts Affected: • Left Treadle Assembly - P/N 17623 • Right Treadle Assembly - P/N 17617 • Treadle Belt - P/N - SM17860 Alignment adjustment Tools Needed: • 5/16 Allen bit Belt alignment and tensioning adjustments (see Figure 1). NOTE: S ee Figure 1 for belt and tensioning adjustment screws. The adjustments are the same on the right and left side of the machine.
Mechanical service 8.0 - BELT AND DECK REPLACEMENT Tools Needed: 7/16 & 3/4 Wrench or Socket 3/8 Allen Socket 1/8, 5/32 & 5/16 Allen Wrench Phillips screwdriver wood blocks 4-6 inch (10-15 cm) thick 8-1: Remove rear cover and rear step (see Figure 1 and Figure 2). 8-2: Remove side pivot covers, side frame covers, front cover, bottom frame covers and treadle covers (see Figure 1). 8-3: Loosen four 1/2” - 13 bolts holding uprights to frame using 3/4 socket or wrench.
Mechanical service BELT AND DECK REPLACEMENT continued: Figure 2: Rear cover and rear step removed. Figure 5: Brace treadles with wooden blocks. Figure 3: Removing end casting with Allen wrench. Figure 6: Remove treadle bolts & pivot bolts; 4 bolts per side. Figure 4: Remove deck. Figure 7: Lift treadle to create clearance.
Mechanical service 9.0 - TREADLE ADJUSTMENT TROUBLESHOOTING Parts Affected: • Treadle Assembly • Hydraulic Cylinder Tools Needed: • Phillips Screwdriver • Hex Key • Socket Wrench • Flat Screwdriver Figure A-1 Troubleshooting Treadle Steps: a: etermining if there is a D problem with the hydraulic cylinder (either air in the system or contaminants in the oil and valves), or in the connecting hardware: Figure A-2 NOTE: Two people are required to complete this step.
Mechanical service 9A-3: C heck the cylinder by feeling the shaft of the cylinder and pulling up and down on the left treadle. If the cylinder shaft moves in and out of the cylinder body by more than an 1/8th inch (3.2 mm), then the cylinder will need to be replaced.
Mechanical service B: I f the problem is not in the hydraulic cylinder or the connecting hardware, then perform the following electronic and software checks: 9B-1: Turn the unit on. Move the treadles up and down until they come to a locked position. 9B-2: If the treadles do not come to a locked position within 2 to 4 steps, then position the treadles level. Turn the power off. Wait 10 seconds, then turn the power on. Move the treadles up and down until they come to a locked position.
Mechanical service mechanism. This can be checked by verifying the number of encoder counts in the diagnostic software. See section D of this bulletin to check the encoder counts. e) If the treadles are parallel or within 1 inch of parallel when the encoder PCB light comes one, reset the treadle center in the software mode. Go to Section E of this bulletin to reset the treadle center in the software mode.
Mechanical service D: To check the encoder range of movement and to make sure the large encoder wheel is not slipping during movement, follow these steps: 9D-1: F rom the Intro screen, press [Speed UP] [6] [ENTER]. The display will read “DIAGNOSTIC”. Press the [Speed UP] or [Speed DOWN] keys to scroll through the options until “TREADCLIMBER” is displayed. Press [ENTER]. Figure D-1 9D-2: T he top line of the display will read: “ENCODER - XX” (see Figure D-1). Press the [9] key.
Mechanical service E: To reset the treadle center in software to match the treadle center on the encoder, follow these steps: 9E-1: From the Intro screen, press [Speed UP] [6] [ENTER]. The display will read “DIAGNOSTIC”. Press the [Speed UP] or [Speed DOWN] keys to scroll through the options until “TREADLE CENTER” is displayed. Press [ENTER]. Figure E-1 9E-2: The top line of the display will read: “VIRTUAL CENTER - XX” (see Figure E-1). With the treadles held parallel, press the [STOP] key.
Mechanical service 10.0 - REPLACEMENT OF PIVOT COVERS Parts Affected: • Right Pivot Cover - P/N 17660 • Left Pivot Cover - P/N 17661 Tools Needed: • 3/16 Allen Wrench • 5/32 Allen • 1/8 Allen • Phillips Screwdriver • 3/4 inch Socket • 3/4 inch Wrench or Open Ended Wrench • Wedge support or flat head screwdriver to use as a wedge See Figure 1 for Steps 10-1 thru 10-4. 10-1: Remove Rear Step (P/N -17733) and Step Plate (P/N - 17591). 10-2: Remove Rear Plastic Cover (P/N - 17659).
Mechanical service )--%$)!4% !#4)/. 2%15)2%$ $!.'%2 #!54)/. 10-5: Loosen 4 inside bolts (2 on each side) that attach the upright (P/N - 17626) to base frame (see Figure 2). Figure 2 Slide Uprights Back DO NOT REMOVE BOLTS COMPLETELY. TO DO SO WILL CAUSE THE UPRIGHT SUPPORTS TO FALL RESULTING IN DAMAGE TO THE UNIT AND POSSIBLE INJURY TO BYSTANDERS. THE BOLTS MUST NOT BE BACKED BEYOND A MAXIMUM DISTANCE OF 1/2 INCH. SEE FIGURE 2. !4 4 % . 4 ) / . toMAXIMUM 3/4” MAX (1.
Mechanical service 11.
Mechanical service 11-9: With a 3/8 inch Allen wrench and 3/4 inch wrench placed on the Nut (P/N - SM22893) under the frame, loosen Bolt (P/N - SM17677) from the Cylinder Mount Weldment (P/N - SM17586) and bracket attachment welded to the base frame. Figure 2: Removing the bolt connecting the Hydraulic Cylinder to the Dependency Linkage. 11-10: Remove the bolt holding the cylinder to the dependency link using a 3/4 inch open-end wrench and 3/4 inch socket (see Figure 2).
Mechanical service 12.0 - VIBRATION TROUBLESHOOTING Parts Affected: • Rear Step - P/N SM17733 • Step Plate Weldment - P/N SM17591 • Flywheel - P/N SM41059 • Snap Ring - P/N SM17692 • Rear Roller Assembly - P/N SM17501 Figure 1: Flywheel set screws Tools Needed: • Phillips screwdriver • 5/32 Allen bit To Correct Vibration in treadles: 12-1: Remove the rear step and step plate weldment exposing the rear roller.
Mechanical service Check the Front Roller Snap Ring: 12-6: Verify that the snap ring on the front rollers is in place properly (see Figure 2). NOTE: This can be seen more easily with the treadle guards removed. Check the Rear Roller Pulley: 12-7: Check the rear roller pulley, if the pulley wobbles it was pressed on incorrectly and the entire roller needs to be replaced.
CARDIO CONSOLE CODES General Information: • Press the UP Speed/Load key [], the numeric [ # ] key, and then press the [ENTER] key once to enter this mode. Pressing [] or [] forwards or backs up through the selections. Pressing [ENTER] then selects that item. Enter values then press the [ENTER] key again to store the value. • Once in console codes mode, pressing [] [] forwards or backs up through the selection, pressing [ENTER] then selects that item.
CARDIO CONSOLE CODES Workout Default Console Codes Continued… [] [ 5 ] [ ENTER ] “ R AND D” [] [ENTER] “ PROGRAM LOOP” [] [ENTER] “ COM TIMEOUT” [] [ 6 ] [ ENTER ] “ DIAGNOSTIC ” [] [ ENTER ] “DISPLAY TEST” [] [ ENTER ] “KEY TEST” [] [ ENTER ] “SERIAL PORTS” [] [ ENTER ] “A SENSOR B” [] [ ENTER ] “I/O TEST” [] [ ENTER ] “BUS VOLTS” [] [ ENTER ] “TREADLE CENTER” [] [ ENTER ] “TREADCLIMBER” [] [ 7 ] [ ENTER ] “ MAINTENANCE LOGS ” [] [ ENTER ] “ERROR LOG” [] [ ENTER ] “MAIN
CARDIO CONSOLE CODES 32
PARTS LIST Ordering Replacement Parts: In the US, call 800-628-8458. Outside the US, call +44-26-460-77-77. Authorized Nautilus representitives will assist you with your specific service requirements. Items in the parts list highlighted in gray are replaceable. Items with no warranty code or part number are replaceable as part of a higher-level assembly only. Warranty Notes (For units in the USA only): 1 - Part covered under standard 3 year parts warranty for replacement.
PARTS LIST Ref #: Part #: Description: Warranty: 98 SM17808 Screw, 10-32 x .375, SHCS, SS 3 year 63 SM17809 Screw, 10-32 x .625, SHCS SS 3 year 173 SM17815 Screw, Button HD Cap, 10-32 x 5 /8L 3 year 68 sm17860 Belt, Treadclimber 1 year 30 sm17862 Deck, Treadle 1 year 228 sm22047 Washer, Flat 1/4 ID x 5/8 OD 3 year 90 sm22098 Screw, .250-20 x 1.50, Hex Head Cap 3 year 58 sm22276 Screw, #6 S.T. x .625 Hex OR TO 3 year 254 sm25777 Screw, .250-20 x 1.
PARTS LIST Ref #: Assembly #: Part #: Description: Warranty: 58 sm22276 Screw, #6 S.T. x .625 Hex OR TO 3 year 254 sm25777 Screw, .250-20 x 1.00 Button Head 3 year 88 sm27585 Washer, .406 x .812 x .
PARTS LIST Ref #: Assembly #: Part #: Warranty: 153 sm17658 Cover, Left Pivot 1 year 154 sm17659 Cover, Lower Front Step 1 year 107 sm17668 Cover, Top Upright Right 1 year 108 sm17669 Cover, Top Upright Left 1 year Assembly, Console TC916 3 year 155 SM17670 46 SM17676 Screw, 3/8-24 x 2.00, SHC 3 year 177 SM17682 Screw, 3/8-16 x 1.00 Button Head Cap 3 year 172 SM17683 Screw, .500-13 x 3.25, Hex Head Cap 3 year 175 sm17686 Leveler, 0.500 inches-13 x 0.
EXPLODED VIEWS Working with exploded views The reference numbers in the drawings on the following pages correlate to the reference numbers in the parts list on the preceding pages.
EXPLODED VIEWS Base Frame with Dependency Link and Hydraulic System: Dependency Link: 38
EXPLODED VIEWS Treadle Assembly: Console Upright Assembly, Rear Step and Console Assembly: Nautilus® TreadClimber®, Model TC916 Service Manual 39
EXPLODED VIEWS Base Frame Covers: (Right side as you stand on unit facing console.) Base Frame Covers: (Left side as you stand on unit facing console.
EXPLODED VIEWS Treadle Deck and Belt Assembly: (Right side as you stand on unit facing console.) Treadle Deck and Belt Assembly: (Left side as you stand on unit facing console.
EXPLODED VIEWS Treadle Arm Assembly: (Right side as you stand on unit facing console.) Treadle Arm Assembly: (Left side as you stand on unit facing console.
EXPLODED VIEWS Treadle Covers - Top and Bottom: (Right side as you stand on unit facing console.) Treadle Covers - Top and Bottom: (Left side as you stand on unit facing console.
EXPLODED VIEWS ROC Bar Assembly: Console Upright and Cover Assembly: 44
EXPLODED VIEWS Rear Step and Support Platform: Nautilus® TreadClimber®, Model TC916 Service Manual 45
What this means First Action Second Action Third Action Fourth Action P51 Processor PCBA Nonoperational. Processor is non-operational. No power or P51 Processor PCBA has failed. P51 Processor PCBA Nonoperational. DS1 Flashing @ Irregular Rate DS1 Off DS1 On Continuous Power off/on treadmill, see if problem selfclears. Power off/on treadmill, see if problem selfclears. Check for unplugged or damaged cables.
Stored data such as user preferences, total time, and mileage has been corrupted. EEPROM Error Power off/on treadmill, see if problem selfclears. Defaults and configuration data will need to be entered again. Internally generated processor Power off/on treadmill, see if problem selferror. clears. First Action High Voltage Drive Bus is discharged and VSD PCBA is safe to handle. Normal powered up condition. Do not handle VSD PCBA until LEDs go out after about 2 minutes.
The processor on the VSD PCBA cannot communicate with the motor control IC on the VSD PCBA. Unit must be reconfigured as a Press [CLEAR]. TreadClimber. Go to Change Machine Mode (Speed Increase, 8, Enter, Enter), then scroll to “TreadClimber” using the Speed Increase and Speed Decrease keys. DRV RESET GRD LIMIT ERROR Early versions of software displayed this error as “ABS ERROR” or “POWER LOSS ERROR” 1 - The DC bus that powers the walkbelt is too low or high.
Message appears when Pin 10 of the communication cable between the P51 Processor and VSD PCBAs are open. Replace Communication cable which connects J10 on P51 Processor PCBA on VSD PCBA. Walkbelt motor current is too low. Walkbelt motor current is too high or walkbelt motor thermal switch has opened due to a motor overload. OUT CUR ERROR SYS OVRLD ERROR This error is usually caused by excessive drag or friction on the deck. Closely inspect the deck and look for signs of excessive wear.
Unit must be reconfigured as either a Treadmill or TreadClimber or VSD PCBA has wrong jumper configuration. Treadmill or TreadClimber communications error. Means P51 Processor PCBA can’t talk serially to VSD PCBA. TM COM ERROR What this means TC/TM CONFIG RQRD 1. LED 3. Operation Operational on Error PCBAs Codes Cycle power and see if problem self-clears. Press [CLEAR].
Wiring Schematic GREY #40865 PCBA, C52 LCD DISPLAY U7 U9 U8 U11 U10 1 10 17754 P1 DS1 DS2 DS4 1 2 1 P3 10 9 DS3 4 3 1 P17 #41442 REMOTE CHR/WHR DISPLAY (RIBBON CABLE TO DISPLAY BOARD) T.C.
Wiring Schematic 52
1. 2. 3. 4.
17786 27000 CTHR 41180 MAIN MOTOR 27487 41443 41193 RED BLK WHT YEL YEL P9 P8 P7 P6 P5 P1 (C3) 17824 3 (C3) P10 CHOKE 41404 J3 P12 C1 C2 C3 J2 J16 J14 BLU BRN (C2) PCB CONFIGURATION PLATE ASSY 230V AC 17823 ENCODER ASSY 17545 2 17590 NEMA 6-15 P UPRIGHT ASSY TC9 17626 MODEL ASSY, TREADCLIMBER T9 00200-002 J3 J1 (NO CONNECTION) P4 P1 MAGNET 41154 MAGNETIC SWITCH ASSY 40854 KEYPANEL TC9 17716 CONSOLE ASSY TC9 17670 41194 7 TRANSFORMER 27964 12 HYDRAULIC CYLI
17844 TV IN TV 17786 MAIN MOTOR 27487 17845 RED BLK WHT YEL YEL 27000 41193 P9 P8 P7 P6 P5 P1 (C3) 17824 3 (C3) P10 CHOKE 41404 J3 P12 5 41399 C1 C2 C3 BLU BRN (C2) 41194 PCB CONFIGURATION PLATE ASSY 230V AC 17823 ENCODER ASSY 17545 2 UPRIGHT ASSY TC9 17626 4 MODEL ASSY, TREADCLIMBER T9 00200-003 J3 J1 (NO CONNECTION) P4 P1 MAGNET 41154 MAGNETIC SWITCH ASSY 40854 KEYPANEL TC9 17716 CONSOLE ASSY TC9 17837 (17670) J2 J16 J14 7 TRANSFORMER 27964 12 HYDRAULIC C
TV IN 17844 TV 17786 MAIN MOTOR 27487 17845 27000 CTHR 41180 41193 RED BLK WHT YEL YEL P9 P8 P7 P6 P5 P1 (C3) 17824 3 (C3) P10 J3 JUMPER 1 27122 P12 BLU BRN C1 C2 C3 BLU BRN (C2) 41194 PCB CONFIGURATION PLATE ASSY 120V AC 17719 ENCODER ASSY 17545 2 17785 NEMA 5-20 P UPRIGHT ASSY TC9 17626 MODEL ASSY, TREADCLIMBER T9 00200-004 J3 J1 (NO CONNECTION) P4 P1 MAGNETIC SWITCH ASSY 40854 KEYPANEL TC9 17716 MAGNET 41154 CONSOLE ASSY TC9 17835 (17670) J2 J16 J14
17844 TV IN TV 17786 MAIN MOTOR 27487 17845 27000 CTHR 41180 41193 RED BLK WHT YEL YEL P9 P8 P7 P6 P5 P1 (C3) 17824 3 (C3) P10 CHOKE 41404 J3 P12 C1 C2 C3 J2 J16 J14 BLU BRN (C2) PCB CONFIGURATION PLATE ASSY 2300V AC 17823 ENCODER ASSY 17545 2 17590 NEMA 6-15P UPRIGHT ASSY TC9 17626 MODEL ASSY, TREADCLIMBER T9 00200-005 J3 J1 (NO CONNECTION) P4 P1 MAGNET 41154 MAGNETIC SWITCH ASSY 40854 KEYPANEL TC9 17716 CONSOLE ASSY TC9 17835 (17670) 41194 7 TRANSFORMER 2796
Important contact numbers If you need assistance, please have both the serial number of your machine and the date of purchase available when you contact the appropriate Nautilus office listed below. OFFICES IN THE UNITED STATES: E-mail: cstech@nautilus.com • NAUTILUS INNOVATION CENTER Nautilus, Inc. 1886 Prairie Way Louisville, Colorado, USA 80027 Vancouver, Washington, USA 98683 Phone: 800-NAUTILUS (800-628-8458) Email: customerservice@nautilus.
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Model TC9.16 ©2006. Nautilus, Inc. All rights reserved. Nautilus, the Nautilus Logo, ROC, TreadClimber, StairMaster and Changing the Game in Health and Fitness are either registered trademarks of trademarks of Nautilus, Inc. Polar and Fantastic are registered trademarks of their respective companies. Nautilus, Inc. World Headquarters, 16400 SE Nautilus Drive, Vancouver, Washington, USA 98683 1-800-NAUTILUS www.nautilus.
