Bowflex TC5300 Service Manual
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Bowflex TC5300 Service Manual

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See also: Assembly Manual / Owner's Manual
Service Manual
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TC5300
TC6000
P/N: 001-6890 Rev B (06/2007)

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Summary of Contents for Bowflex TC5300

  • Page 1 Service Manual • TC5300 TC6000 P/N: 001-6890 Rev B (06/2007)
  • Page 3 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.

  • Page 4: Table Of Contents

    12.0 Locking Mechanism Adjustment ---------------------------- 28 13.0 Replacement of Lock-out Lever ----------------------------- 30 Electrical and Mechanical Troubleshooting Guide ---------------- 32 TC5300 and TC6000 Diagnostics ---------------------------------------39 Appendix 1 - Wiring Schematic -------------------------------------- 43 Appendix 2 - Walking Belt Adjustment ------------------------------ 44...

  • Page 5: Product Features

    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 ® ®...

  • Page 6: 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. The dimensions and general specifications for the Bowflex® TreadClimber fitness machine are as follows: ®...

  • Page 7: Important Safety Precautions

    4.5 MPH (7.2 KPH). Do not attempt to run on the TreadClimber ® ® fitness machine, but keep your highest speed at a brisk walk. 7. Do not wear any loose or dangling clothing, or jewelry while using the Bowflex TreadClimber fitness machine. Always keep ®...
  • Page 8 Bowflex TreadClimber fitness machine if they weigh in excess of 300 pounds (136 kgs). ® ® 14. Make certain that observers stand clear of the Bowflex TreadClimber fitness machine when it is in use. Extra care must be ® ®...
  • Page 9 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. If you do not have, or cannot find, or need to replace a warning label or product Owner’s Manual please call 1-800-NAUTILUS (800-628-8458) to obtain a new label or new manual. Label 1:”Warning: Obtain, read and understand the owner’s manual provided with this fitness equipment prior to use. Misuse or abuse of this equipment may lead to serious injury or death.

  • Page 10: Emergency Stop Procedures

    ® when not in use to prevent children or other persons from using the machine unsupervised. Safety Key TC6000 TC5300 Safety Keyhole Location Safety Keyhole Location REMOVE THE SAFETY KEY WHILE USING THE TREADCLIMBER FITNESS ® MACHINE ONLY IN AN EMERGENCY. WHEN THE KEY IS REMOVED, THE...

  • Page 11: Mechanical Service Guide

    1-7 Insert wires into new inlet making sure connections are correct (from front of plate: white - top left, black - top right, green - bottom). 1-8 Replace faceplate and front plastic. 1-9 Recalibrate machine according to Appendix 3. Bowflex TreadClimber Service Manual ® ®...

  • Page 12: Replacement Of Console With Handlebars

    2-1 Unplug machine from outlet. 2-2 Wait 5-minutes after unplugging machine to ensure there is no residual power. 2-3 TC5300 only: Remove the right and left upper upright plastics by removing 2 small screws from the inside of each upright (see Figure 1 & 2).
  • Page 13 2-9 Tighten the bolts using the 3/16 inch hex key. Tighten the front bolt first, followed by the 3 bolts on the inside of the uprights. 2-10 Recalibrate machine according to Appendix 3. Figure 6: Bowflex TreadClimber Service Manual ® ®...

  • Page 14: Replacement Of Upper Console

    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. 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 Figure 2: Console Back Removed TuRNED oFF.

  • Page 15: Roc Cable Replacement Instructions (Tc6000 Only)

    Be careful not to pinch new cable during assembly.(Fig. 4) 4-9 Connect the brown plug to the back of the Printed Circuit Board and test the unit. 4-10 Re-attach the lower console. 4-11 Re-connect remote HR plug. Figure 4: Figure 1: Bowflex TreadClimber Service Manual ® ®...

  • Page 16: Replacement Of Internal Wire In Right Upright

    5-1 Unplug machine from wall outlet. 5-2 Wait 5-minutes after unplugging machine to ensure there is no residual power. 5-3 TC5300 only: Remove the right and left upper upright plastic covers by removing 2 small screws from the inside of each upright (see Figure 1, 2 and 3).
  • Page 17 5-12 Re-attach both uprights to console using 4 button head bolts on each side. 5-13 Re-attach the right and left upper upright plastics as well as the right lower upright plastic cover. 5-14 Recalibrate machine according to Appendix 3. Bowflex TreadClimber Service Manual ® ®...
  • Page 18 mechanical service guide Figure 7: Figure 8: Figure 9: Figure 10:...

  • Page 19: Replacement Of Speed Sensor

    (wire is approximately 3 3/4 inches long and is located below left rear roller) see Figure 5 & 6. 6-6 Disconnect white cable connector from speed sensor wire that is attached to long black wire (see Figure 6). Bowflex TreadClimber Service Manual ® ®...
  • Page 20 mechanical service guide 6-7 Disconnect speed sensor plug from left treadle Figure 4: pivot bracket. 6-8 Insert 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.

  • Page 21: Replacement Of Step Sensor

    NOTE: The step sensor and grommet (red) should be 1/8 inch or less from the magnet on the teeter, but shouldn’t come in contact with teeter or magnet. Bowflex TreadClimber Service Manual ® ®...

  • Page 22: Replacement Of Motor Belt

    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. 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 Figure 2: Rear Plastic Covers removed.
  • Page 23 8-10 Recalibrate machine according to Appendix 3. Figure 6: Figure 5: Motor Pan Bolt Motor Pan Bolt Figure 7: Drive Pulley Bowflex TreadClimber Service Manual ® ®...

  • Page 24: Replacement Of Hydraulic Cylinders

    mechanical service guide 9.0 - REPLACEMENT oF HYDRAuLIC CYLINDERS Figure 1: Tools Needed: • 1/2 inch Wrench 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. AS LoNG AS THE TREADCLIMBER FITNESS ® MACHINE IS PLuGGED INTo A PoWERED ouTLET AND THE PoWER SWITCH IS oN, THE uNIT IS Figure 2: RECEIvING PoWER, EvEN IF THE DISPLAY IS...

  • Page 25: Replacement Of Belts

    (2 screws each). See Figures 4 & 5. NOTE: Before removing cast covers, you may need to loosen the first screw on the upper treadle plastic cover to get the cast cover off. Bowflex TreadClimber Service Manual ® ®...
  • Page 26 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 Remove the 4 front roller adjustment screws using a 3/16 Allen Key (see Figure 7).
  • Page 27 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. Figure 9: Figure 8: Figure 10: Figure 11: Bowflex TreadClimber Service Manual ® ®...
  • Page 28 mechanical service guide Figure 12: Figure 13: Cross Member Bolts Figure 14: Figure 15: Damage caused to treadle by rear step if not covered. Figure 16: Figure 17:...

  • Page 29: Replacement Of Virtual Pivot Assembly

    11-6 Loosen belts by loosening the front roller adjustment screws with provided Allen key (4 screws). 11-7 Remove lower hydraulic cylinders from the treadle frame with 3/16 Allen key (1 screw each side). See Figure 6. Bowflex TreadClimber Service Manual ® ®...
  • Page 30 mechanical service guide 11-8 Standing on the left side of the machine detach the Figure 4: treadle/teeter cross tube by removing 2 bolts with two 9/16 inch wrenches (see Figure 7). 11-9 Place a rag on the rear step frame to protect treadle plastic from damage.
  • Page 31 Figure 7: Figure 8: Cross Member Bolts Figure 10: Figure 9: Figure 11: Figure 12: Bowflex TreadClimber Service Manual ® ®...

  • Page 32: Locking Mechanism Adjustment

    mechanical service guide 12.0 - LoCKING MECHANISM ADJuSTMENT Tools Needed: Figure 1: • Phillips Screwdriver Right & Left Top Base • 1/2 inch wrench Plastic Covers • 3/16 Allen Wrench NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. Front Base Plastic Cover AS LoNG AS THE TREADCLIMBER FITNESS ®...
  • Page 33 12-8 Replace front base plastic (4 screws). 12-9 Plug power cord back into the front of the unit Faceplate and recalibrate (see Appendix 3 for Calibration Cable must run Procedure). through lockout lever Minor Adjustment Bowflex TreadClimber Service Manual ® ®...

  • Page 34: Replacement Of Lock-Out Lever

    mechanical service guide 13.0 - REPLACEMENT oF LoCK-ouT LEvER Tools Needed: Figure 1: • Phillips Screwdriver Right & Left Top Base • 7/16 inch wrench Plastic Covers NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. Front Base AS LoNG AS THE TREADCLIMBER FITNESS ®...
  • Page 35 13-9 Replace right and left top base plastic (3 screws each). 13-10 Replace front base plastic (4 screws). 13-11 Plug power cord back into the front of the unit and recalibrate (see Appendix 3 for Calibration Procedure). Bowflex TreadClimber Service Manual ® ®...

  • Page 36: Electrical And Mechanical Troubleshooting Guide

    If unit works with different magnet replace safety key. LED Diagnostic needed. Access diagnostic LEDs on motor controller board by following the instructions in the TC5300/6000 Diagnostics. Caution: Machine is on. Current is active!!. Check the B & G LEDs for the following: If neither B nor G are lit power is not reaching the motor controller.
  • Page 37 Walking belt misalignment. Tracking adjustment If either of the walking belts seem to be tracking excessively to one side or the other adjust belt at front of each treadle (see Walking Belt Adjustment, Appendix 2) Bowflex TreadClimber Service Manual ® ®...
  • Page 38 elecTrical and mechanical TroubleshooTing guide Condition/Problem 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. Hesitation or belt slipping Belt tension If belt hesitates or slips when walking when walking on unit.
  • Page 39 Front rollers. If knocking sound seems to be coming directly from one or both of the front rollers, remove and replace rollers. Bowflex TreadClimber Service Manual ® ®...
  • Page 40 elecTrical and mechanical TroubleshooTing guide Condition/Problem 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).
  • Page 41 I/O calbes. If no visible damage check continuity using a multi-meter. If a multi- meter is not available replace all three cables. Bowflex TreadClimber Service Manual ® ®...
  • Page 42 elecTrical and mechanical TroubleshooTing guide Condition/Problem Things to Check Solution Console keys wont function 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.

  • Page 43: Tc5300 And Tc6000 Diagnostics

    Lower LED Board during service on a TreadClimber ® fitness machine. The TC5300 /TC6000 Lower LED Board is located beneath the Rear Step Cover. Follow the directions on the next page to access the LED Board for diagnostics. With Removed Rear Step Cover...
  • Page 44 Tc5300/Tc6000 diagnosTics Accessing the LED Board Tools Needed: Figure 1: • Phillips Screwdriver • 1/2 inch wrench NOTE: If using a powered driver, it must be on the “LOW TORQUE” setting, otherwise it will strip screws. 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.
  • Page 45 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.
  • Page 46 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.

  • Page 47: Appendix 1 - Wiring Schematic

    1 - Wiring schemaTic Bowflex TreadClimber Service Manual ® ®...

  • Page 48: Appendix 2 - Walking Belt Adjustment

    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 –...

  • Page 49: Appendix 3 - Calibration Procedures

    Calibration Mode. NOTE: If your console display does not finish the calibration procedure by displaying “CAL ... PASS” proceed to the Electrical and Mechanical Troubleshooting Guide. When the Bowflex TreadClimber® fitness machine has completed calibration, you may begin your workout. ®...

  • Page 50: Appendix 4 - Walking Belt And Deck Lubrication

    ALWAYS USE A SILICONE-BASED LUBRICANT. NEVER USE A LUBRICANT lift each side of the belt LIKE WD-40 ON THE BOWFLEX® TREADCLIMBER FITNESS MACHINE, ® ® AS THIS COULD SERIOUSLY IMPACT PERFORMANCE. and apply a few drops of the lubricant.

  • Page 51: Important Contact Numbers

    • GERMANY and AUSTRIA OFFICE Nautilus GmbH Tel: +49-2204-610-27 Fax: +49-2204-628-90 • ITALY OFFICE Nautilus Italy s.r.l. Tel: +39-031-51-10-86 Fax: +39-031-34-24-97 • UNITED KINGDOM OFFICE Nautilus UK Ltd. Tel: +44-1908-267-345 Fax: +44-1908-267-346 Bowflex TreadClimber Service Manual ® ®...
  • Page 52 ©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.

This manual is also suitable for:

Tc6000

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