Service Manual
Contents
1. Jezeg 130044 uonoejes 1YBISM Service Manual Service Procedures Nautilus ONE Tower Shroud Removal Tools Required 9 16 Socket Wrench 9 16 Wrench 5 32 Hex Wrench Remove the Top Cover 1 1 Remove the two mounting screws on the rear of the top cover with a 5 32 Hex wrench Figure 1 1 2 Remove the cover by lifting the rear edge up and forward to clear the front slot Figure 2 Remove the Handlebar 2 1 Remove the 4 3 8 hex head bolts 4 lock washers and 4 lock nuts with a 9 16 socket wrench 2 2 Carefully lift the handlebar and place aside Figure 3 Remove the Rear Shroud 3 1 Remove one screw at the top of the shroud with a 5 32 Hex wrench Lift up and out of the bottom slot Figure 4 Shroud Removal continued on next page Service Manual 5 Figure 1 Figure 3 Figure 4 Service Procedures Nautilus ONE Tower Shroud Removal cont Remove the Outside Shroud Note The large round bezel does not need to be removed from the outside shroud 4 1 Liftthe shroud up until the tabs stop at the top of the P slot Figure 5 NOTICE Do not attempt to remove shroud by prying with any kind of tool 4 2 Pull shroud outward to remove from the P slots Figure 6 Remove the Inside Shroud D 1 Remove the center cap behind the dial Adjust the dial to the lowest setting and lift the dial up and out of the way Unsnap the center cap out of the shroud opening tabs Figure 7 5 2 Li2. Kobis Str 4 51147 Koln Tel 49 02203 2020 0 Fax 49 02203 2020 45 45 ITALY Nautilus Italy S r l Via della Mercanzia 103 40050 Funo di Argelato Bologna Tel 39 051 664 6201 Fax 39 051 664 7461 SWITZERLAND Nautilus Switzerland SA Rue Jean Prouv 6 CH 1762 Givisiez Tel 41 026 460 77 66 Fax 41 026 460 77 60 UNITED KINGDOM Nautilus UK Ltd Nautilus UK 4 Vincent Avenue Crownhill Milton Wrenchnes Bucks MK8 OAB Tel 44 1908 267 345 Fax 44 1908 567 346 CHINA Nautilus Representative Office Nautilus Shanghai 7A No 728 Yan an Rd West 200050 Shanghai China Tel 86 21 523 707 00 Fax 86 21 523 707 09 NAUTILUS One 2007 Nautilus Inc All rights reserved Nautilus the Nautilus Logo Universal the Universal Logo Bowflex StairMaster Pearl Izumi and Nautilus Institute are either registered trademarks ortrademarks of Nautilus Inc Schwinn is a registered trademark All other trademarks are owned by their respective companies Nautilus Inc World Headquarters 16400 SE Nautilus Drive Vancouver WA 98683 1 800 NAUTILUS www nautilus com Nautilus Bowflex Schwinn Fitness Pearl Izumi StairMaster Universal Nautilus Institute
3. S6CP e Nautilus ONE Shoulder Press S6SP e Nautilus ONE Bicep Curl S6BC e Nautilus ONE Tricep Extension S6TE Tools Required e 9 16 Socket and Ratchet e 7 32 Hex Wrench Figure 1 e 1 4 Hex Wrench 1 1 Remove 2 3 8 upholstery bolts with a 9 16 Socket and Ratchet 1 2 Remove the seat pad by pulling it upwards Figure 1 1 3 Remove the release handle shoulder bolt with a 1 4 Hex wrench and a 9 16 Socket and ratchet Figure 2 1 4 Remove the handle Figure 2 Remove using a 1 4 Hex head wrench and 9 16 socket and ratchet 12 Service Manual Service Procedures 1 5 Remove the top 7 32 Hex head screw with a 7 32 Hex Wrench Figure 3 1 6 Remove the bottom 7 32 Hex head screw while supporting the seat bracket with your free hand Figure 4 Figure 4 13 Service Manual Service Procedures Note Itis neccessary to disassemble the seat frame from the weight stack This will allow the service personnel to access the gas spring assembly Please refer to pages 9 and 10 of this service manual for the seat frame tower disassembly and belt timing 1 7 Once the seat frame has been disconnected from the weight tower and with the seat bracket removed Figure 5 tip the seat frame on its back Figures 6 amp 7 The seat frame is heavy Use two people for this step to prevent injury Figure 5 Figure 6 Figure 7 14 Service Manual Service Procedures Note Fi
4. acking plate bolt Figure 7 6 3 Rotate the add on weight lever clockwise and remove the bottom bolt with a 1 2 socket Figure 8 Figure 7 6 4 Remove the add on weight lever and weight selection backing plate by pulling away from the weight tower Figure 9 6 5 Reverse these steps to assemble the knob Figure 9 18 Service Manual Contact Information OFFICES IN THE UNITED STATES E mail customerservice nautilus com TECHNICAL CUSTOMER SERVICE Phone 800 NAUTILUS 800 628 8458 Fax 877 686 6466 E mail cstech nautilus com CORPORATE HEADOUARTERS Nautilus Inc World Headquarters 16400 SE Nautilus Drive Vancouver Washington USA 98683 Phone 800 NAUTILUS 800 628 8458 INTERNATIONAL OFFICES For technical assistance and a list of distributors in your area please call or fax one of the following numbers Please supply the serial number of your machine and the date of purchase when you call Nautilus Use the space in the boxes below to write down this information To find the serial number on your machine refer to the Safety Warning Label information page Dial the number of the office close to you Serial Number Date of Purchase 19 Service Manual INTERNATIONAL CUSTOMER SERVICE Nautilus International S A Rue Jean Prouv 1762 Givisiez Switzerland Tel 41 26 460 77 77 Fax 41 26 460 77 70 E mail technics nautilus com GERMANY and AUSTRIA Nautilus Deutschland GmbH Albin
5. al 2 1 Carefully pry the 3 decal from the knob 2 2 Remove the plastic decal by slowly working the prying tool between the back of the decal and the front surface of the knob Figure 2 Remove the Weight Selection Figure 2 Knob Assembly Retaining Bolt 3 1 Hold the knob assembly and use the 5 32 Hex wrench to turn the button head screw counter clockwise Figure 3 Note The 1 4 x 20 x 1 long screw was installed with removable strength thread lock Apply more removable strength thread lock when replacing the Assembly Retaining Bolt and tighten to 10 Ib ft with a torque wrench 3 2 Pull the weight selection knob assembly away from the weight tower Figure 3 Remove the Bezel 4 1 Unsnap the bezel from the add on weight lever housing and set it aside Figure 5 17 Figure 5 Service Manual Service Procedures Knob Removal cont Remove Number Wheel D 1 Pullthe number wheel assembly away from the weight tower Figure 6 Remove the Add On Weight Lever 6 1 The handle adjustment knob has two index pins that insert into the add on weight cam Use a small flat head screwdriver to help separate the add on weight lever from the black plastic cam Pull the add on weight lever assembly away from he tower approximately 1 5 Note The lever assembly should rotate freely but the weight selection backing plate will stay affixed 6 2 Use a 1 2 socket with 6 socket wrench extension to remove the top weight selection b
6. back in service until the machine shrouds instructions warning labels and have been verified and tested for proper performance e Ifyou any questions regarding the Service Manual or the servicing of our equipment please contact qualified Nautilus personnel immediately 1 Service Manual Exploded Views L M9IA 19MO uB ev G 0SZ SAS LM A quuess y wes pue 3 99 sjuno wN 9u 8u pue auely pno4us ep s no G 0SZ LM 9UIBU3 9299 o ude o woq 1989 w INO sninnew L6F9 000 1e99q uuod w INO SIN Ajquiassy qouy 399198 1uBI AA des e3 ueo Suo pJeo2eld pno4us episu pnoJugs 1e9y Assembly Manual Exploded Views CH Me 192MO 1YBISM G 0GZ SAS LM ped 1004 Jamo 10014 pno4us ep s no ped 1004 Jamo Je9y dey 191497 sue p1e9eld pno4us episu uU X 0 P L M9J9S de 19 0S peor uoyng u8 E X 0 D L MINS de 19 0S peor uonng Service Manual Exploded Views A quuessy U01399 9S 10619M G 0SZ SAS LAA uC L X 8 MIS jueunsn py I uAA quuassy qouy 101399198 1YBISM 18290 0 X QO SGL X QI O L 4eysem onseld JOYSEM 19915 8 uc L X AI 13197 Ll Buiysng SNDI JUBIaM uo ppy N 9 e d Bu 9eg 9924 M 19qUINN uo 99j9S 1uBI AA di o l ud L XAI 1A9YSEM 991S ul Bu usng SNDI I99uM49qQu nN
7. ftthe shroud up until the tabs stop at the top of the P slot 5 3 Pull the shroud outward to remove it from the P slots Figure 8 6 Service Manual Figure 5 Figure 6 Figure 7 Figure 8 Service Procedures Nautilus ONE Tower Shroud Installation Attach the Rear Shroud 1 1 Put Rear Shroud into the Bottom slot and secure with one screw atthe top Attach the Inside Shroud 2 1 Put Inside Shroud into P slots in the Steel Frame and fit the adjustment knob assembly through the center hole of the shroud 2 2 Insert front and back tabs into the P slot openings See Fig 1 2 3 Push down on both front and back to seat tabs at the bottom of the P slots NOTICE Do not attempt to force the shroud downward or tabs may be broken off When the tabs are aligned to the P slots the cover should drop down into the slots with minimal resistance 2 4 Install the center cap behind the dial Adjust the dial to the lowest setting and lift the dial up and out of the way Figure 2 Snap the center cap into the shroud opening tabs Make sure to align the cap to the open ring Attach the Outside Shroud 3 1 Put Outside Shroud into the P slots in the Steel Frame 3 2 Push down on both front and back to seat tabs at the bottom of the P slots When the tabs are aligned to the P slots the cover should drop down into the slots with minimal resistance 3 3 Align and attach the tab slot where the front of both side s
8. gure 8 shows a seat disconnected from the weight tower to gain access to the gas spring seat adjustment assembly 1 8 Remove the 2 plate retaining screws with a 7 32 Hex wrench Figure 9 1 9 Pull the gas spring seat adjustment assembly out of the seat frame tube Figure 10 Figure 8 Plate Retaining 4 Screws ES Figure 9 Figure 10 15 Service Manual Service Procedures 1 10 Finish removing the gas spring seat adjustment assembly Figure 11 1 11 Replace the gas spring if neccessary not pictured 1 12 Insertthe gas spring seat frame assembly into the seat frame tube Figure 12 1 13 Confirm the horse shoe shaped bracket is aligned Figure 13 Note If the plate is installed backwards the gas spring seat frame assembly will not operate properly 1 14 Tighten 2 7 32 Hex screws with a 7 32 Hex wrench Figure 14 1 15 Refer back to pages 9 10 for seat frame tower installation instructions 16 Service Manual alim Figure 11 Figure 12 T ma pi w Horseshoe Shaped Bracket Figure 13 Plate Retaining Screws Figure 14 Service Procedures Weight Selection Knob Removal Tools Required Torque Wrench Remove the Center Cap 1 1 Adjust the dial to the lowest setting 1 2 Liftthe dial assembly up and move it aside Figure 1 1 3 Remove the center cap by carefully prying between the inside shroud and center cap Remove the Nautilus ONE 3 Dec
9. h AdjustableWrench movement arm s are not resting firmly against the rubber 4 03 1055 LOCK NUT 1 2 13 stop s reduce belttension as necessary The movement arm must rest against the rubber stops to ensure proper omar initial weight drive to seat frame assembly and jackshaft Weight Drive timing Belt tensioning procedures are located on Page 11 asi of this service manual Weight Drive 1 1 Remove 3 1 2 13 x 3 bolts from the Tower with 3 4 socket wrench Figure 1 1 2 Remove the Weight Drive Support from the Seat Frame by removing 4 1 2 13 x 1 1 4 bolts and 4 1 2 13 Lock Nuts with 3 4 socket wrench and adjustable wrench Discard 1 bolt and 1 nut Figure 2 Weight Drive Support P q Seat Frame Weight Drive r Y WE Tue PIE S d M aree lt Z d4 i 9 L g e 7 ge Pss Seat Frame Q per Plate 2x 2 Return plates to Nautilus Inc I 709 Powerhouse Rd Independence VA 24348 Figure 2 9 Service Manual Service Procedures Weight Drive Installation Removal cont 1 3 Align the Seat Frame Weight Drive holes to Tower Weight Drive holes and pins Insert 3 1 2 x 1 1 4 bolts into weight drive and 3 1 2 x 3 bolts into seat frame plate Carefully align Seat Frame to the Tower and tighten all bolts Figure 3 Note Confirm that the movement arm is at rest against the rubber st
10. hrouds meet at the top of the front post NOTICE Do not attempt to force the shroud downward or tabs may be broken off Attach the Handlebar Assembly 4 1 Position the handle bars over the plastic shrounds Figure 3 4 2 Attach the handlebar with 4 hex head bolts 4 lock washers and 4 lock nuts Attach the Rear Shroud 5 1 Position the handle bars over the plastic shrounds Figure 4 1 Service Manual A Figure 1 Figure 2 Figure 3 Figure 4 Nautilus ONE Tower Shroud Installation cont Attach the Top Cover 6 1 Lower the top cover onto side shrouds making sure that the tops edges of both side shrouds fit securely into the slots on each side of the top cover Figure 5and 6 Note Push inward on the top edge of the length of both side shrouds to assure the top cover is securely attached If you can push the shroud inward it is not in the slot and needs to be installed again 6 2 Install the two mounting screws on the rear of the top Figure 7 Note Overtightening the shield screws may cause the top shield to crack Service Manual Figure 5 Figure 6 Figure 7 Service Procedures Weight Drive Installation Removal NO PART NO DESCRIPTION OTY 1 56 0161 WEIGHT DRIVE SUPPORT _ a 2 011331 BOLTHH1v2 18X3 Installation Tip Inspectthe seat frame movement arm s before assembly to the weight tower If the Tools Required 3 4 Socket Wrenc
11. o NAUTILUS Nautilus ONE GY Service Manual Nautilus Bowflex Schwinn Fitness Pearl Izumi StairMaster Universal Nautilus Institute a brand of OQ NAUTILUS 001 7147 120507A Table of Contents Safety WamingS 2 ke kl na nA a a a MNA asua k buic be Ek aa n e n n dc LED DUE ua a aa Lane 1 Explod d VIEWS ao d LIED 2 Service Procedures si ay y u uuu kaza E A tees a SE ken diwa ar oar Ma QUIS ana xi A sua janda aka 5 JOWeOF Ohroud Sef OY al sky sin dd did diari 5 Tower Shroua lnstallati ian a 7 Weight Drive Installation Removal 9 Screw Pel Ad jUSsti l t say AA Ve lara aa AAA A 11 Bottom Loading Gas Spring Replacement 12 NOD IREMIOV alll ys lA usns a nu Peng Ke eee au z 18 Contact information did 19 Required Tools 1 9 16 Socket Wrench 2 3 4 Socket Wrench 3 Torque Wrench 4 9 16 Wrench 5 Adjustable Wrench 6 5 32 Hex Wrench 1 5 16 Hex Wrench 8 7 32 Hex Wrench 9 1 4 Hex Wrench Safety Warnings A This icon means a potentially hazardous situation which if not avoided could result in death or serious Injury Obey the following warnings T Read and understand all Warnings on this machine Specific Caution Warning and or Danger decals may be applied to call attention to specific hazards e Carefully read and understand
12. op s If the movement arms are not resting on the rubber stops then reduce seat frame belt tension see page 11 Ensure that the Weight Drive belt cam Is resting against the cam stop If it is not at rest then refer to Troubleshooting Steps on this page to reduce Weight Engine Drive belt tension Make sure that the dial selects and engages the weight plates 1 4 Reverse steps 1 1 through 1 3 for Weight Drive removal Troubleshooting Steps 2 1 6 Turn the weight selection dial to several different resistance settings to confim the dial now engages Tools Required 3 8 wrench the weight plates 2 1 If the dial does not select and engage the 2 1 7 Tighten the two Belt Clamp Retaining bolts with a 3 8 weight plates the Weight engine Drive Belt wrench Confirm that the weight selection dial will may be too tight select and engage the weight plates 2 1 1 Ensure clearance is 1 8 between the weight 2 1 8 Replace the top cover hooks and the weight plate hooks Figure 2 2 2 If the movement arms do not rest fully against the page 11 rubber stop s in the starting position the Weight 2 1 2 Refer to the Remove the Top Cover Engine Drive steps 2 1 1 through 2 2 8 will be the instructions steps 1 1 through 1 2 on page steps to correct 5 of this Service Manual 2 1 3 With the top cover removed loosen do not remove the two Belt Clamp Retaining Bolts with a 3 8 wrench Figure 2 page 11 2 14 Turn the weight selection dial
13. the Service Manual before you work on the machine Failure to follow Instructions and safety warnings could result in injury to service technician or bystanders e Damaged machines or machines under repair must be marked as Out of Service set aside and prohibited from being used by customers or others e Keep bystanders and children away from the product being serviced at all times e Make sure that repair is done in an appropriate work space away from foot traffic and exposure to unauthorized personnel e Adjustments and repairs to Nautilus equipment must only be performed by a professional service technician trained to service Nautilus equipment e Some components of the equipment may be heavy or awkward Use a second person or other resources when performing maintenance steps involving these parts Do not perform steps that require heavy lifting or awkward movement on your own e Use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts may cause a risk to users keep the machine from operating properly or void the warranty e Make sure that all warning stickers and instructional placards on the machine stay attached and are in good condition Request replacement warning stickers or placards if necessary from Nautilus customer service e Do not attempt to modify the design or functionality if the machine This could compromise user safety and may void the warranty e Do not place the machine
14. to the minimum resistance setting and liftthe weight drive engine assembly up several inches by the dial assembly 2 15 Release the knob to allow the work box to drop This should allow the belt to slip in the clamp reducing tension on the Weight Engine Drive Belt 10 Service Manual Service Procedures Seat Frame Belt Cam Adjustment Tools Required 5 16 Hex Wrench Articulating Clamp Mount Sliding Belt 1 1 Use a 5 16 Hex Wrench to tighten or Adjustment Clamp Button Head Belt loosen the Button Head Belt Adjustment Adjustment Bolt Bolt Note Turning the screw clockwise increases tension Turning the screw counter clockwise reduces tension Figure 1 Note Increasing tension on the belt tensioning screw tightens not only the seat frame belt N and proportionately increases tension on the weight engine drive belt Excessive belt tension will cause weight hook to weight plate hook malfunctions Figure 2 5 16 HexWrench Seat Frame Belt Cam Figure 1 3 8 Belt Clamp Maintain proper clearance of 1 8 between the Weight Hooks and weight Plate Hooks er Weight Plate j NA d Hooks Weight Engine a Drive Belt 2 Figure 2 11 Service Manual Service Procedures Bottom Loading Gas Spring Replacement These procedures apply to the following units e Nautilus ONE Mid Row S6MR e Nautilus ONE Lat Pull S6LATP e Nautilus ONE Chest Press
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