Bowflex TreadClimber 1000 3000 & 5000 Service Manual

Service Manual Nautilus ® Bowflex ® Schwinn ® Fitness Universal ® Bowﬂex® TreadClimber® 1000, 3000 & 5000 004-4549.110510.B ® ®

Table of Contents Important Safety Instructions.......................................... 3 Safety Warning Labels and Serial Number .................. 4 Emergency Stop Procedure ............................................ 5 Product Specifications..................................................... 6 Important Service Information ........................................ 7 Bowflex ® TreadClimber ® Versions .................................. 7 Moving and Storage.......................................................... 8 Maintenance ..................................................................... 9 Walking Belt and Deck Lubrication ............................... 10 Mechanical Service Procedures ................................... 12 Walking Belt Adjustment ................................................. 12 Correct a Hesitating or Slipping Belt ............................. 13 Walking Belt Electrostatic Reduction ............................... 14 Restore Clearance between Treadle and Upright ........... 15 Secure the Treadle Alignment ........................................ 15 Balance Treadle Resistance ........................................... 16 Restore Treadle Locking (Treadmill Mode) ................... 17 Electrical Service Procedures........................................ 18 Calibration .......................................................................... 18 Troubleshooting ................................................................. 20 Console Error Codes ......................................................... 20 Hot or Burning Odor ......................................................... 21 Troubleshooting Procedures............................................ 22 TreadClimber ® FAQs ......................................................... 32 Motor Control Board (MCB) ............................................ 33 TC3000 / TC5000 MCB .................................................. 33 LED Diagnostics ........................................................... 33 TC 1000 MCB ................................................................. 34 Speed Sensor Wire Connections ................................... 35 Electrical Layout (TC3000 / TC5000) ............................... 36 AC Inlet Wiring ................................................................... 37 Replacing Parts ................................................................. 38 Removing the Treadle Assembly ..................................... 38 Installing the Treadle Assembly ...................................... 42 Hydraulic Cylinders .......................................................... 45 Motor Drive Belt ................................................................ 46 Drive Pulley ........................................................................ 47 Walking Belt ....................................................................... 49 Motor .................................................................................. 55 Motor Control Board (MCB) ............................................ 57 AC Inlet ............................................................................... 58 Step Sensor (Version 1 only) ........................................... 59 Speed Sensor .................................................................... 60 IGUS Assembly .................................................................. 61 Friction Block ..................................................................... 63 Lower I/O Cable to MCB .................................................. 67 Console Top Cover ............................................................. 68 Console Bottom Cover ..................................................... 69 Console/Handlebar Assembly ......................................... 70 I/O Cable in the Right Upright ......................................... 71 Right Upright ....................................................................... 73 Left Upright ......................................................................... 75 Left Drive Bracket .............................................................. 77 Front Roller Assembly ....................................................... 81 Rear Roller Assembly ....................................................... 84 Deck .................................................................................... 88 Warranty Parts ................................................................... 89 Exploded Views .................................................................. 89

Important Safety Instructions This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Obey the following warnings: Read and understand the Service Manual before working on the machine. Failure to obey the instructions and safety warnings could cause injury to the service technician or bystanders. Disconnect all power and allow to sit for 5 min. before you service this machine. • Keep children away from the product being serviced at all times. • Make sure that the repair is done in an appropriate work space away from foot traffic and exposure to bystanders. • Some components of the equipment can be heavy or awkward. Enlist the service of a second person when you do maintenance steps involving these components. Do not try to do heavy or awkward steps on your own. • Use only genuine Nautilus supplied or approved replacement parts and hardware. Failure to use genuine replacement parts can adversely affect the safety and functionality of the equipment creating a risk to users. • Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing maintenance or replacing components. If necessary request replacement warning stickers or placards from Nautilus customer service. • Do not try to change the design or functionality of the machine being serviced as this can adversely affect user safety. • Do not use the machine until all shrouds, instructions, warning labels and correct functionality have been verified and tested for correct performance. DANGER Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | Asia Paciﬁc & Latin America +01-360-859-5180, technics-APLA@nautilus.com | ©2010. Nautilus, Inc. All rights reserved. Nautilus, Inc. (www.NautilusInc.com) trademarks include NAUTILUS®, BOWFLEX®, SCHWINN® and UNIVERSAL® and respective logos. Other trademarks are the property of their respective owners. Service Manual 3

Safety Warning Labels and Serial Number Make sure that you have the serial number when you contact Customer Service. Newer models have the serial number on the bottom of the console. Note: On older models, the console, base, and/or treadle assembly can each have their own serial number label. Look on the bottom of the console, on the base next to the treadle locking lever, or on the treadle assembly below the rear roller. Important Safety Instructions Serial number All models Older models Older models Safety labels 1 2 3 1 WARNING 1. Remove control key when not in use and store out of reach of children. 2. If you feel any unusual chest pain or tightness in your chest, shortness of breath, or dizziness, feel faint or have any discomfort while you exercise, STOP! CAUTION 1. To avoid injury, stand on the foot platforms before starting TreadClimber. 2. Read and understand the Owner’s Manual and operation instructions prior to use. If you do not have an Owner’s Manual, call 800-792-6784 to obtain one. 3. Keep children and pets away. 4. Max user wt. 300 lbs. / 136 kg 2 DANGER HAZARDOUS VOLTAGE. Contact will cause electric shock or burn. Turn off and Lock out power before servicing. 3 WARNING Moving parts can crush and cut. Lock out power before servicing. Service Manual 4

Important Safety Instructions Emergency Stop Procedures The TreadClimber ® machine is equipped with a Safety Key that can prevent serious injury, as well as prevent children from playing with and/or being injured on the machine. If the Safety Key is not fully inserted into the safety keyhole, the TreadClimber ® machine will NOT power up. To prevent unsupervised operation of the machine, always remove the Safety Key and disconnect the power cord from the wall outlet or AC input. Always attach the Safety Key clip to your clothing during your workout. When you use the machine, only remove the Safety Key in an emergency. When the key is removed while the machine is in operation, it will stop quickly, which could cause the loss of balance and possible injury. Be sure to remove the Safety Key for safe storage when not in operation. Safety Key with Clip Service Manual 5

Product Specifications Physical Dimensions Length 46 in. (117 cm) Width 28.5 in. (72.5 cm) Height 55.25 in. (140.5 cm) Assembled Weight 185 lbs. (84 kg) Shipping Weight 220 lbs. (100 kg) System Capacities Maximum Weight Capacity 300 lbs (136 kg) Speed TC1000 0.5 to 3.8 mph (0.8 to 6.1 kmh ) TC3000 and TC5000 0.7 to 4.0 mph (1.1 to 6.4 kmh) Treadmill Incline 0% grade Workout Resistance Levels 1 to 12 Warranty Length See the Warranty sheet for full information per machine type. Component Specifications Belt 7.75 in. x 38.5 in. (19.5 cm x 98 cm) Motor 0.5 hp continuous duty Frame Powder-coated steel Operational Voltage 95 to 130 VAC 50 - 60 Hz Operational Current 12A Max Regulatory Approvals Marks c-ETL-US The standard for Safety for Motor-Operated Massage and Exercise Machines UL 1647, 3rd Ed. and Motor-Operated Appliances CAN/CSA-C22.2 No. 68-92 TC1000 TC3000 TC5000 Note: the decals may vary by model and manufacture date. Service Manual 6

Important Service Information Bowflex ® TreadClimber ® Versions Bowflex ® TreadClimber ® models TC1000, TC3000, and TC5000 were mechanically redesigned for release in early 2008. The mechanical changes include removal of the teeter mechanism, different hydraulic cylinders, and different treadle locking mechanisms. Although both versions are still very similar in design and function, there are differences in troubleshooting steps and replacement procedures. It is always important to identify the unit as a Version #1 (2004-2007) or Version #2 (after 2007). VERSION #1 uses a dependency linkage, or “teeter”, to cause treadle movement to be interdependent and uses standard hydraulic cylinders. VERSION #2 does not use a dependency linkage and uses spring return hydraulic cylinders. Find out what version Bowflex ® TreadClimber ® you have before you replace any parts or do mechanical troubleshooting. Use the instructions below to determine the TreadClimber version: How to Identify Version #1 and Version #2 Do the following test to check to determine the machine version: 1. Go to the front of the machine where the red treadle-lock lever is located and unlock the Bowflex ® TreadClimber ® treadles (lever in down position). 2. Use your foot to push down one of the treadles as far down as it will go. Remove your foot. • If the depressed treadle remains in the down position and the opposite treadle rises, the machine is the Version #1 design. • If the depressed treadle rises to the resting position and the opposite treadle does not move, the machine is the Version #2 design. Service Manual 7

The TreadClimber ® machine weighs 185 lbs. (84 kg) when fully assembled, and should never be moved or lifted without taking some precautionary care. There are two lift handles on the back of the base and two wheels on the front of the base (one on each side). The TreadClimber ® machine requires 90 pounds (41 kg.) of force to lift the base to the 30 degree angle necessary to roll it on the front wheels. We recommend that you do not ever attempt to lift or move the TreadClimber ® machine without help. When lifted correctly, your TreadClimber ® machine can be rolled on the wheels for storage and/or cleaning. Failure to follow precautions could result in physical injury to you, or damage to the machine, or both. Do not use the uprights, arms, or console to lift or move the TreadClimber ® machine. Doing so can cause physical injury to you, and can damage or destroy the TreadClimber ® machine. TreadClimber ® Base – Front Wheels TreadClimber ® Base Rear Lift Handles Moving and Storage Service Manual 8

Maintenance Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is necessary to do the necessary tasks. The safety and integrity designed into a machine can only be maintained when the equipment is regularly examined for damage and repaired. It is the sole responsibility of the owner to ensure that regular maintenance is performed. The owner is responsible to make sure that regular maintenance is done. Worn or damaged components must be repaired or replaced immediately. Only manufacturer supplied components should be used to maintain/ repair the equipment. This product, its packaging, and components contain chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. This Notice is provided in accordance with California’s Proposition 65. If you would like additional information, please refer to our website at www.nautilus.com/prop65. Always unplug your TreadClimber ® machine from the outlet and let sit for 5 minutes before cleaning or servicing the unit. Helpful Hints All references to the right or left side, and to the front or back are made as if you were on the TreadClimber ® machine ready to exercise. Initial Service Use a soft, clean towel to wipe off dust. Accessories For the best performance, we recommend that the TreadClimber ® machine be placed on a rubber mat. The rubber mat will help keep dust and debris away from the TreadClimber ® machine’s motor and belts, reduce noise and increase stability. The Bowflex ® TreadClimber ® Machine Mat is professional quality and is designed specifically to fit under the Bowflex ® TreadClimber ® fitness machine. The mat protects floors from scratches and perspiration and it gives workout areas a clean, finished look. For more information on this accessory and other Bowflex ® products available from Nautilus, Inc. visit: www.NautilusInc.com or www.TreadClimber.com. Cleaning General cleaning of the TreadClimber ® machine will prolong the life of the machine and improve performance. Keep the unit clean by dusting regularly. Be sure to dust the exposed part of the deck on either side of the Walking Belts and the side rails. Clean the top of the belt with a clean cloth lightly dampened with warm water and a small amount of mild soap. Wipe carefully and thoroughly with a dry cloth. Be careful to keep liquid away from inside the base frame and beneath the belts. NOTICE: Do not clean with a petroleum based solvent or an automotive cleaner. Be sure to keep the Console free of moisture. Do not use the machine until the Walking Belts are dry. Service Manual 9

Maintenance Walking Belt and Deck Lubrication The TreadClimber ® machine is equipped with a pre-lubricated, low maintenance deck and belt system. Belt friction may affect the function and life of the TreadClimber ® machine. For the best results from the TreadClimber ® machine, lubricate the treadles periodically with a silicone lubricant, using the following instructions: 1. Unplug the TreadClimber ® machine completely from the wall outlet, and remove the power cord from the incoming power plug. Always unplug the power cord from the wall outlet and wait 5 minutes after unplugging the machine before removing or installing parts to avoid the risk of electrocution, shock or mechanical injury. 2. While the TreadClimber ® machine’s treadle surfaces are still warm (not hot), apply a very thin layer of silicone lubricant directly onto the treadle beneath each belt. Gently lift each side of the belt and apply a few drops of the lubricant. Always use a silicone-based lubricant. Never use a degreaser like WD-40 ® on the Bowﬂex ® TreadClimber ® exercise machine as this could seriously impact performance. 3. Plug the power cord back into the machine base and then into the wall outlet. 4. Stand to one side of your TreadClimber ® machine. 5. Turn on your TreadClimber ® , and start the belts at the slowest speed. Let the belts run for approximately 15 seconds. 6. Turn off your TreadClimber ® machine. 7. Take care to wipe up any excess lubricant from the treadles and surrounding ﬂoor. We also recommend a periodic inspection of the treadle surfaces under the belts. If the decks appear worn, contact Nautilus ® Customer Service. To reduce the possibility of slipping, be sure the treadle area is free from grease or oil. Wipe off any excess oil from the machine surfaces. Use the following timetable as a guide to lubricate the decks: • Light user (fewer than 3 hours/week): every 6 months • Medium user (3-5 hours/week): every 3 months • Heavy user (more than 5 hours/week): every month We recommend that you use the following: • Lube-N-Walk ® Treadmill Lubrication Kit, available from Nautilus, Inc. • 100% pure silicone spray, available at most hardware and auto parts stores DANGER Service Manual 10

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Bowflex TreadClimber 1000 3000 & 5000 Service Manual

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