Service Manual TC5300 • TC6000 P/N: 001-6890 Rev B (06/2007)
7! 2 . ) . ' $!.'%2 !4 4 % . 4 ) / . For detailed instructions and information on assembly and use for THE Bowflex® treadclimber®, model tc5300 and tc6000, fitness machine refer to the assembly and owner’s manual. )--%$)!4% !#4)/. 2%15)2%$ #!54)/.
Table of contents Product Features --------------------------------------------------------- 1 Product Specifications -------------------------------------------------- 2 Important Safety Precautions ------------------------------------------- 3 Mechanical Service Guide 1.0 Replacement of AC Inlet -------------------------------------- 7 2.0 Replacement of Console with Handlebars ------------------ 8 3.0 Replacement of Upper Console ------------------------------ 10 4.
Product features TC5300 Console Display TC5300 TC6000 Console Display Transport Handles, Incoming Power Plug, and Main Power Switch TC6000 Rear Step and Rear Moving Wheels Bowflex® TreadClimber ® Service Manual
Product specifications Throughout this manual, all references to the left or right side, and to the front or back, are made as if you were on the TreadClimber® fitness machine, ready to exercise. For example, the power cord is plugged into the incoming power plug at the front of the base.
Important safety precautions Save These Instructions 7! 2 . ) . ' The following definitions apply to the word “Warning” found throughout this manual: 7! 2 . ) . ' Used to call attention to POTENTIAL hazards that could result in personal injury or loss of life. Failure to follow these precautions can cause damage to the Bowflex® TreadClimber® fitness machine, serious injury to users and bystanders, and can also compromise the effectiveness of your exercise program. $!.
Important safety precautions 12. Never adjust the Hydraulic Cylinder Workout Settings while belts are in motion. Step completely off of the TreadClimber® fitness machine, stop the belts, and turn the power off prior to adjusting. 13. Maximum user weight for the Bowflex® TreadClimber® fitness machine is 300 pounds (136 kgs). For your safety, do not use or allow others to use the Bowflex® TreadClimber® fitness machine if they weigh in excess of 300 pounds (136 kgs). 14.
Important safety precautions Safety Warning Labels BEFORE USING YOUR PRODUCT: The following safety warnings are located in site specific areas on the Bowflex® TreadClimber® fitness machine. All locations are given as if you were standing on the fitness machine ready to exercise. 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.
Important safety precautions Emergency Stop Procedures Your TreadClimber ® fitness machine is equipped with a SAFETY KEY that can protect you from serious injury and inhibit children from playing with and/or being injured on the TreadClimber ® fitness machine. If the Safety Key is not fully inserted into the safety keyhole, located below the console display, the TreadClimber ® fitness machine will NOT power up. Always ATTACH the safety key clip to your clothing during your workout.
Mechanical Service guide 1.0 - REPLACEMENT OF AC INLET Tools Needed: • Phillips Screwdriver Figure 1: NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF. ALWAYS UNPLUG THE POWER CORD FROM THE OUTLET AND WAIT 5-MINUTES BEFORE PERFORMING REPAIRS OR MAINTENANCE.
Mechanical Service guide 2.0 - REPLACEMENT OF CONSOLE WITH HANDLEBARS Tools Needed: • Phillips Screwdriver • 1/2 inch wrench • 3/16 inch Allen wrench Figure 1: NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide Figure 4: 7! 2 . ) . ' Use caution when connecting the wiring harness to ensure that the wires do not become pinched or come into contact with any moving part. The TreadClimber® $!.'%2 fitness machine will not work and an electric shock hazard may be present if the wires become pinched. 2-7 O nce the cable connection is made, slide the brackets on the handlebar into the tops of the upright tubes. Figure 5: !4 4 % . 4 ) / .
Mechanical Service guide 3.0 - REPLACEMENT OF UPPER CONSOLE Figure 1: Tools Needed: • Small Screwdriver • Phillips Screwdriver NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide 4.0 - ROC Cable Replacement Instructions (TC6000 Only) Figure 2: 4-1 Remove the console back. (Fig. 1) 4-2 Disconnect the remote HR wire from the lower left side of the printed circuit board (viewed from front). Red, black, white wires. (Fig. 2) 4-3 Remove the console bottom. 4-4 Locate the connector on upper right, and unplug it from the console Printed Circuit Board. Cut the zip ties and let the wire hang free. (viewed from front) .
Mechanical Service guide 5.0 - REPLACEMENT OF INTERNAL WIRE IN RIGHT UPRIGHT Figure 1: Tools Needed: • Phillips Screwdriver • 3/16 inch Allen wrench 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF. ALWAYS UNPLUG THE POWER CORD FROM THE OUTLET AND WAIT 5-MINUTES BEFORE PERFORMING REPAIRS OR MAINTENANCE. $!.'%2 Figure 2: Upright cover removed.
Mechanical Service guide 5-7 R emove wire from right upright by pulling from the bottom. Figure 4: 5-8 T hread new wire through right upright. Making sure the cable exits through the lower slotted hole in the upright. 5-9 R e-attach cable connector at base of right upright. 5-10 A ttach cable connector from console to the cable connector from the right upright. 5-11 W ith the help of another person, lift the console back onto both uprights, ensuring that junction covers are in place.
Mechanical Service guide 14 Figure 7: Figure 8: Figure 9: Figure 10:
Mechanical Service guide 6.0 - REPLACEMENT OF SPEED SENSOR Figure 1: Tools Needed: • Phillips Screwdriver NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 6-1 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF. ALWAYS UNPLUG THE POWER CORD FROM THE OUTLET AND WAIT 5-MINUTES BEFORE PERFORMING REPAIRS OR MAINTENANCE.
Mechanical Service guide 6-7 D isconnect speed sensor plug from left treadle pivot bracket. Figure 4: 6-8 I nsert new speed sensor, connecting white cable connectors, and making sure not to push sensor plug too far through connector hole in left treadle pivot bracket. NOTE: T he speed sensor and grommet (red) should be 1/8 inch or less from the magnet on the pulley, but shouldn’t come into contact with pulley or magnet (see Figure 7). 6-9 Replace Rear Step.
Mechanical Service guide 7.0 - REPLACEMENT OF STEP SENSOR Figure 1: Tools Needed: • Phillips Screwdriver NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF. ALWAYS UNPLUG THE POWER CORD FROM THE OUTLET AND WAIT 5-MINUTES BEFORE PERFORMING REPAIRS OR MAINTENANCE. $!.
Mechanical Service guide 8.0 - REPLACEMENT OF MOTOR BELT Figure 1: Tools Needed: • Phillips Screwdriver • Flathead Screwdriver NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide 8-8 Ease new motor belt onto drive pulley and flywheel. Figure 4: 8-9 O nce belt is tightly attached, re-tension the belt by tightening tension bolt with a 1/2 inch wrench, replace left cast cover, hardware plug, rear step, rear plastic cover, and rear step plastic cover. 8-10 Recalibrate machine according to Appendix 3.
Mechanical Service guide 9.0 - REPLACEMENT OF HYDRAULIC CYLINDERS Tools Needed: • 1/2 inch Wrench Figure 1: NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. Hydraulic cylinders MUST be replaced in pairs. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide 10.0 - REPLACEMENT OF BELTS Tools Needed: • Phillips Screwdriver • Flathead Screwdriver • Allen Wrench • 1/2 inch Wrench • (2) 9/16 inch Wrench Figure 1: 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF. ALWAYS UNPLUG THE POWER CORD FROM THE OUTLET AND WAIT 5-MINUTES BEFORE PERFORMING REPAIRS OR MAINTENANCE. $!.
Mechanical Service guide 10-6 Ease poly-v belt off of the rear roller pulley. Tensioning screw may need to be loosened (see Section 9.0 Replacing Motor Belt). See Figure 6. Figure 4: 10-7 R emove the 4 front roller adjustment screws using a 3/16 Allen Key (see Figure 7). Remove the 2 front rollers by loosening the 2 inside front roller brackets using a 3/16 Allen Wrench and 1/2 inch wrench (see Figures 8, 9, 10). 10-8 R emove the rear roller with a 1/2 inch wrench (1 screw).
Mechanical Service guide 10-17 Re-attach hydraulic cylinders to treadle frame. Figure 7: 10-18 Tension belts with Allen key (see Appendix 2). 10-19 R eplace and tension motor belt (see Section 9.0 Replacing Motor Belt). 10-20 Replace cast covers and hardware plugs. 10-21 Replace rear step. 10-22 Replace 4 rear plastic covers. 10-23 Recalibrate machine according to Appendix 3.
Mechanical Service guide Figure 12: Figure 13: Cross Member Bolts 24 Figure 14: Figure 15: Damage caused to treadle by rear step if not covered.
Mechanical Service guide 11.0 - REPLACEMENT OF VIRTUAL PIVOT ASSEMBLY Figure 1: Tools Needed: • Phillips and Flathead Screwdriver • 1/2 inch Wrench • 3/16 Allen Wrench • (2) 9/16 inch Wrench NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide 11-8 S tanding on the left side of the machine detach the treadle/teeter cross tube by removing 2 bolts with two 9/16 inch wrenches (see Figure 7). Figure 4: 11-9 P lace a rag on the rear step frame to protect treadle plastic from damage. Rotate left treadle back (pivoting about treadle pivot bracket) until it rests on the rear step frame (see Figure 8 & 9). 11-10 Repeat Steps 11-7 to 11-9 for the right treadle.
Mechanical Service guide Figure 7: Figure 8: Cross Member Bolts Figure 9: Figure 10: Figure 11: Figure 12: Bowflex® TreadClimber ® Service Manual 27
Mechanical Service guide 12.0 - LOCKING MECHANISM ADJUSTMENT Tools Needed: • Phillips Screwdriver • 1/2 inch wrench • 3/16 Allen Wrench Figure 1: Right & Left Top Base Plastic Covers NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide Figure 4: Minor Adjustment & Lockout Level 12-7 R eplace right and left top base plastic (3 screws each). Lockout Lever 12-8 Replace front base plastic (4 screws). 12-9 P lug power cord back into the front of the unit and recalibrate (see Appendix 3 for Calibration Procedure).
Mechanical Service guide 13.0 - REPLACEMENT OF LOCK-OUT LEVER Tools Needed: • Phillips Screwdriver • 7/16 inch wrench Figure 1: Right & Left Top Base Plastic Covers NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
Mechanical Service guide 13-7 R eplace cable and fine adjustment assembly on the new lockout lever. Install the new lockout lever on the base frame locking lever bracket with the 7/16 inch bolt and retaining spring. NOTE: M ake sure the spring is on the left side of the lockout lever between the lockout retaining bracket (base frame) and the lockout lever. See Figure 2, 4 and 5.
Electrical and Mechanical troubleshooting guide Condition/Problem Unit will not power up/turn on/start 32 Things to Check Solution Outlet. Make sure outlet is functioning correctly. Verify this by plugging another object (ex: lamp) into the outlet. If outlet is connected to a light switch, check to make sure it is on. If outlet is not functioning find a working outlet. Power cord not plugged in.
Electrical and Mechanical troubleshooting guide Condition/Problem Speed displayed is not accurate. Heart rate not displayed while using chest strap. Walking belt misalignment. Things to Check Solution Console control board If I/O cables are all functioning properly, LEDs B & G are lit up, and machine still will not power up replace upper console control board Display set to wrong unit of measure. (English/Metric) Change display units. (See Console Display & Set Up section) Out of calibration.
Electrical and Mechanical troubleshooting guide Condition/Problem Hesitation or belt slipping when walking on unit. 34 Things to Check Solution Roller shaft bracket If belt adjustments don’t correct misalignment replace both belts and either or both roller shaft bracket depending on which belt(s) aren’t aligning. Belt tension If belt hesitates or slips when walking on unit it may be caused by either a loose walking belt or a loose drive belt.
Electrical and Mechanical troubleshooting guide Condition/Problem Things to Check Solution Knocking / squeaking noises Upper linkage bolts. when unit is operating. Unplug power from Unit. Wait 5-minutes to ensure no residual power remains. Located on the underneath side of each treadle there are bolts, one per side, that connect the treadles to the linkage arms. Push right treadle down to access left treadle and vice versa.
Electrical and Mechanical troubleshooting guide Condition/Problem Belts stop turning and “err LS” or “err OS” is displayed Things to Check Solution Virtual pivot. Access the virtual pivot by removing the rear step plastic and rear step. The virtual pivot will be under the rear roller and has 2 brackets (one on each treadle, which rolls on 4 cam followers (large bearings). Make sure all 4 brackets are rolling (turning) as the treadles pivot.
Electrical and Mechanical troubleshooting guide Condition/Problem Floors Climbed Display not updating. Things to Check Solution Electronics If all I/O cables are functioning properly, LED D indicates speed sensor is functioning, and err LS or OS persists problem is in either the upper electronics board or the motor controller board. With machine on check LED A on the controller board. If it is dimly lit replace upper electronics (000-4430). If it is not lit at all replace motor controller.
Electrical and Mechanical troubleshooting guide Condition/Problem Console keys wont function 38 Things to Check Solution Operation Verify that correct steps are being followed from Owner’s Manual operation steps. Cable connections Remove back cover from console and verify that all cable connections are secure. ROC keypad cable Remove ROC keypad and inspect cable for damage. If any damge is evident replace cable. If no damage evident replace both ROC keypad and cable.
tc5300/TC6000 diagnostics 7! 2 . ) . ' Always turn off the fitness machine and unplug the power cord from the wall outlet before removing or installing parts to avoid the risk of electrocution, shock or mechanical injury. $!.'%2 TC5300 and TC6000 Diagnostics How to access the LED Board It is possible that you will need to be able to locate the Lower LED Board during service on a TreadClimber ® fitness machine. !4 4 % . 4 ) / . The TC5300 /TC6000 Lower LED Board is located beneath the Rear Step Cover.
tc5300/TC6000 diagnostics Accessing the LED Board Tools Needed: • Phillips Screwdriver • 1/2 inch wrench Figure 1: NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 7! 2 . ) . ' AS LONG AS THE TREADCLIMBER® FITNESS MACHINE IS PLUGGED INTO A POWERED OUTLET AND THE POWER SWITCH IS ON, THE UNIT IS RECEIVING POWER, EVEN IF THE DISPLAY IS TURNED OFF.
tc5300/tc6000 diagnostics LED Diagnostics The function of each LED is as follows: A - Turns on when the incoming Pulse Width Modulation (PWM) signal is logical high. The LED will seem to become brighter as the incoming PWM approaches 100% because it is flashing at a greater rate than the human eye can see. This LED is speed sensitive, and will be on when the motor is turning.
tc5300/TC6000 diagnostics H - Turns on when excessive current passes through the FET. This LED implies that there is a short in the motor or motor wiring. Note: This is a WARNING light!! I - Turns on when AC power passes the relay and begins to charge the large capacitors. This indicates that the relay has energized correctly. Power button on console is on. J - Turns on dimly when power is first applied and becomes bright when the large capacitors are charged.
Appendix 1 - wiring schematic Bowflex® TreadClimber ® Service Manual 43
Appendix 2 - Walking belt adjustment Walking Belt Adjustment If either of the walking belts seem to be tracking excessively to one side or the other, adjustments can be made at the front roller of each treadle. Misalignment Test and Resolution Visual Test – Standing beside the unit, set the speed at 2 MPH (3.2 KPH). Standing in front of the unit you will see adjustment bolts on each end of each front roller.
Appendix 3 - calibration procedures Calibration Procedure You will need to re-calibrate the TreadClimber ® fitness machine in the event of a power outage or if you have replaced any electronic component on the machine. DO NOT STEP ON THE BELTS DURING THIS ENTIRE PROCESS. To calibrate: 1. Plug the machine into an outlet and turn on the power (in Owner’s Manual see Page 24: Turning on the Power). 2. Stand on the side foot support platforms or rubber floor mat, DO NOT STAND ON THE BELTS. 3.
Appendix 4 - Walking belt and deck lubrication !4 4 % . 4 ) / . Walking Belt and Deck Lubrication The TreadClimber ® fitness machine is equipped with a pre-lubricated, low maintenance deck and belt system. Belt friction may affect the function and life of the TreadClimber ® fitness machine. For the best results from your TreadClimber ® fitness machine, always remember to lubricate the treadles periodically with a silicone lubricant, using the following instructions: 1.
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: INTERNATIONAL OFFICES: E-mail: customerservice@nautilus.com For technical assistance and a list of distributors in your area, please call or fax one of the following numbers. • TECHNICAL/CUSTOMER SERVICE Nautilus, Inc.
For more information about our TreadClimber® or other Bowflex ® equipment for your home, visit www.TreadClimber.com or www.Bowflex.com. ©2007. Nautilus, Inc. All rights reserved. TreadClimber, Bowflex, the Bowflex Logo, StairMaster, and ROC are either registered trademarks or trademarks of Nautilus, Inc. All others are either registered trademarks or trademarks of their respective companies. Nautilus, Inc. 16400 S.E. Nautilus Drive, Vancouver, Washington, USA 98683, 1-800-628-8458, www.Nautilus.com.
