Bowflex Max Trainer M6 Service Manual
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Bowflex Max Trainer M6 Service Manual

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Table of Contents

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Mechanical / Modification Procedures
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Part Replacement
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Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc.
| Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |
ENGLISH VERSION ONLY
8020654.110118.A
Bowflex
Max Trainer
M6 / M6i
™
™
Service Manual
Page Number
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65
1
Service Manual
8020652.110118.A
ORIGINAL DOCUMENT -

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Summary of Contents for Bowflex Max Trainer M6

  • Page 1: Table Of Contents

    Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...

  • Page 2: Important Safety Instructions

    Warnings on this machine. Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, Max Intelligence, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. App Store is a service mark of Apple Inc.

  • Page 3: Safety Warning Labels And Serial Number

    SAFETY WARNING LABELS AND SERIAL NUMBER WARNING! • Injury or death is possible if caution is not used while using this machine. • Keep children and pets away. • Read and follow all warnings on this machine. • Refer to the Owner’s Manual for additional warnings and safety information.

  • Page 4: Specifications

    SPECIFICATIONS Maximum User Weight: 136 kg ( 300 lbs.) Total Surface Area (footprint) of equipment: 9648.8 cm Maximum Pedal Height: 48.5 cm ( 19.1 inches ) 163.1 cm (64.2”) 67.1 kg (148 lbs.) Machine Weight: Power Requirements: Input Voltage: 100-240V AC, 50-60Hz, 0.5A Output Voltage: 9V DC, 1.5A 116.6 cm...

  • Page 5: Moving / Leveling The Machine

    Moving the Machine The machine may be moved by one or more persons depending on their physical abilities and capacities. Make sure that you and others are all physically fi t and able to move the machine safely. Grasp the Aero Bars to carefully tilt the machine toward you onto the transport rollers. Be sure not to grab the Media Shelf. Be aware of the Handlebars and the weight of the machine before tilting the machine.

  • Page 6: Connectivity

    CONNECTIVITY Bluetooth Connectivity with the Bowflex™ Max Intelligence™ App ® The Bowflex™ Max Intelligence™ App syncs with your Bowflex™ Max Trainer™ machine to track total calories burned, time, and more. It records and stores every workout for quick reference. Track your results and share with friends and family. The App will also notify you if there is an update to your machine.

  • Page 7: Maintenance

    MAINTENANCE Read all maintenance instructions fully before you start any repair work. In some conditions, an assistant is required to do the necessary tasks. Equipment must be regularly examined for damage and repairs. The owner is responsible to make sure that regular maintenance is done.

  • Page 8: Maintenance Parts Exploded View

    Maintenance Parts...
  • Page 9 Dynamic Handlebar, Left Transport Wheel Power Cord Console Assembly (w/Aerobars) Stabilizer Arm Drive Assembly Media Capture Bar Leveler Crank Arm Dynamic Handlebar, Right Pedal Drive Pulley, Lower Crank Cover Foot Pad Fan Belt Shroud, Right Roller Disc Brake Speed Sensor Shroud, Right Fan Shroud, Left Fan Speed Sensor (behind Fan)

  • Page 10: Troubleshooting - Sections

    TROUBLESHOOTING Troubleshooting - Sections A. No Power / Display Will Not Turn On B. Buttons Do Not Respond C. Needle Does Not Move or Machine Goes to Sleep While in Use D. Resistance Does Not Respond E. Machine Seized Up F.

  • Page 11: No Power / Display Will Not Turn On

    No Power / Display Will Not Turn On Unplug the power adapter from both ends. Replace the Power Is the end of the BEGIN HERE Inspect the entire cord for any visible Adapter and Power adapter cord broken? wires, cuts, breaks or crimps. Inlet Plug.

  • Page 12: Buttons Do Not Respond

    Buttons Do Not Respond Cycle the power off/on. If the BEGIN HERE issue persists continue on with the troubleshooting. Is the display Go toTroubleshooting: completely blank with No Power no lights? Remove the console rear shroud (cover). Unplug and replug all connections into the back of the console.

  • Page 13: Needle Will Not Move / Machine Goes To Sleep While In Use

    Needle will Not Move or Machine Goes to Sleep While in Use Remove the hardware from the right lower round cover. To BEGIN HERE remove the right lower round cover, the power plug inlet wire must be gently released from the inside of the cover.

  • Page 14: Resistance Does Not Respond

    Resistance Does Not Respond Cycle the power off/on. If the issue persists Go to Troubleshoot- Does the console turn continue on with the BEGIN HERE ing: No Power troubleshooting. Remove the right side Go to Troubleshoot- Does the fan turn lower round cover.

  • Page 15: Machine Seized Up

    Machine Seized Up Attempt to rotate the Crank Are the Crank Arms BEGIN HERE Arms by hand. opposite each other 180*? Does the issue Issue resolved. Follow the “Replace the Crank persist? Arms” procedure to remove and reorient one Crank Arm so that they are 180* opposite each other as shown.

  • Page 16: Console Does Not Light Up Completely

    Console Does Not Light Up Completely Peel off the protective plastic BEGIN HERE film on the display. If the plastic film has already been removed and the problem remains, continue with troubleshooting. Go to Troubleshooting: Is the entire display No Power not lighting up? Remove console back cover (8 screws) and check all connec-...

  • Page 17: Machine Slips During Use

    Machine Slips During Use Refer to the “Replace The Drive Belt” procedure. BEGIN HERE Follow the directions until it tells you to loosen the Drive Belt Tensioner Screw. Loosen the screw, and adjust the Drive Belt Tensioner, so that it puts more tension on the drive belt.

  • Page 18: Rollers And Pedals

    Rollers and Pedals Is a clicking or rubbing noise being The noise is a normal function, caused by contact BEGIN HERE and is not harmful to the between the roller machine. wheel and the roller arm bracket? Remove both pedal Issue resolved.

  • Page 19: Noises - Main

    Noise Issues - Main What type of noise is BEGIN HERE Metallic Grinding or Rubbing Clicking, Clunking, or Squeaking, Squealing Rattling Around Inside Scraping Knocking or Chirping From Bottom of Machine Go to Troubleshoot- Go to Troubleshoot- Go to Troubleshoot- Go to Troubleshoot- Go to Troubleshoot- ing: Noise Issues -...

  • Page 20: Noises - Metallic Grinding Or Scraping

    Noise Issues - Metallic Grinding or Scraping BEGIN HERE Remove the user right side lower round cover (4 screws). Replace the Brake Are the magnets Have the Assembly making contact with magnets broken off the the metallic brake red plastic arm? disc? Carefully operate machine and Follow the “Adjust the Brake...
  • Page 21 Noise Issues - Rubbing / Belt If unsure, remove the tall plastic rear cover. Use the machine while Which side is the noise listening carefully. BEGIN HERE coming from, the left or If the machine is not making any right side? noise, check both belts starting with the user left side.

  • Page 22: Noises - Clicking, Clunking Or Knocking

    Noise Issues - Clicking, Clunking, or Knocking Remove the tall plastic rear cover. Tighten the 4 bolts that hold the top part of the rail BEGIN HERE NOTE: If the noise is assembly to the frame. Then coming from the fan area, tighten the 4 large bolts on the jump ahead to the FAN base assembly.

  • Page 23: Noises - Rubbing / Belt

    Noise Issues - Squeaking, Squealing, Creaking or Chirping Remove the rubber end cap, Re-attach the end caps where the pedal arm connects Does the noise loosely. If they are BEGIN HERE to the crank arm, on both sides persist? pushed on too tight, they of the machine.

  • Page 24: Contact Heart Rate Issues

    Contact Heart Rate Issues Ensure hands are centered on BEGIN HERE the Heart Rate (HR) sensors with equal pressure, and as little movement as possible without touching the metal frame. Explain that the HR may spike initially at a high rate, when first touching the contact plates.

  • Page 25: Upper (Drive) Pulley

    Upper (Drive) Pulley Begin by inspecting around the machine for any hardware that may Crank Puller: have fallen out of the machine. A Crank Puller is required to Next remove the rear shroud, and inspect the upper, or drive, pulley. A replace the drive pulley.

  • Page 26: Console Setup Mode

    CONSOLE SETUP MODE The Console Setup Mode lets you view maintenance statistics (Total Run Hours and Software Version) or fully reset the Console. Push and hold down the Volume and PAUSE/STOP buttons for 3 seconds while in the Power-Up Mode to go into the Console Setup Mode. Note: Push PAUSE/STOP to exit the Console Setup Mode and return to the Power-Up Mode screen.

  • Page 27: Replacement Procedure Skill Level

    REPLACEMENT PROCEDURE SKILL LEVEL Level I : Low - very little mechanical knowledge or exposure. Level II : Intermediate - some experience with mechanical procedures Level III : Advanced - knowledgeable about mechanical procedures To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and wait 5 minutes before cleaning, maintaining or repairing this machine.

  • Page 28: Adjust The Brake Assembly

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 29 Note: Your machine may not match the images provided exactly. 1. With power supplied to the machine, adjust the resistance to the maxi- mum setting. 2. When the machine has completed the adjustments to the resistance, unplug the AC Adapter from the wall outlet and machine. 3.
  • Page 30 Power Cable 6. At the maximum resistance setting, the outer edge of the Brake Magnet should line up with the outer edge of the Brake Disc. Brake Magnet Brake Disc Brake Disc Brake Magnet Brake Disc Brake Assembly...
  • Page 31 7. If the Brake Assembly needs to be adjusted, use a 8mm open ended Adjustment Barrel wrench to loosen the Brake Cable Securing Nut. Turn the Adjustment Bar- rel by hand until the magnet is placed correctly. Brake Cable Securing Nut 8.
  • Page 32 Note: The Brake Disc may have a slight “wobble”. This is normal and will not affect machine function. 11. Installation is the reverse procedure. 12. Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly assembled. Do not use until the machine has been fully assembled and inspected for correct performance in accordance with the Owner’s Manual.

  • Page 33: Replace The Brake Assembly

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 34 Note: Your machine may not match the images provided exactly. 1. With power supplied to the machine, adjust the resistance to the maxi- mum setting. 2. Unplug the AC Adapter from the wall outlet and machine. 3. Remove the Right Stabilizer Shroud from the machine (if equipped). Right Stabilizer Shroud 4.
  • Page 35 6. Using a #2 Phillips screwdriver, remove the 3 indicated screws from the Brake Disc. 7. Carefully remove the Brake Disc from the machine. Brake Disc Brake Assembly Magnets Brake Assembly 8. Place a piece of tape on the Brake Cable immediately above the Brake Arm.
  • Page 36 11. Using a 10mm hex wrench, remove the screws that connect the Brake Assembly and remove it. 12. Attach the new Brake Assembly, but do not fully tighten the hardware. 13. Attach the Brake Disc. 14. Reattach the Brake Spring and the Brake Cable to the Brake Arm, Brake Assembly and adjust to the tape marker.
  • Page 37 18. The Brake Magnets should be aligned with the Brake Disc and cen- tered around the Brake Disc. 19. If the Brake Assembly only needs to be slightly adjusted, loosen the front screw that secures the Brake Assembly using a 10mm hex wrench. Rotate the Brake Assembly until the Magnets are aligned and of equal Brake Disc distance from the Brake Disc.

  • Page 38: Replace The Console Assembly

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 39 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. Console Assembly 3.

  • Page 40: Replace The Crank Arm

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 41 Note: Your machine may not match the images provided exactly. 1. From the side with the Crank Arm that needs to be replaced, remove the indicated Cap. Note: The following photos show the removal of the Right Crank Arm. 2. Using a 6mm hex wrench, remove the hardware exposed from below the Cap.
  • Page 42 7. Using a #2 Phillips screwdriver, remove the 2 indicated screws from the Crank Cover. 8. Remove the Crank Cover from the machine. Crank Cover 9. Using a 9/16” or 14mm socket and wrench, remove the indicated nut from the Crank Assembly. 10.
  • Page 43 11. Carefully thread the Crank Puller into the Crank Arm. Be sure the Crank Puller has at least three rounds of threads inserted. 12. Using a 16mm wrench, turn the inner portion (the Bolt) of the Crank Puller clockwise. The Crank Arm will slide off as it is tightened. Note: Be aware that the Crank Arm will be loose and will need to be sup- ported.

  • Page 44: Replace The Drive Belt

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 45 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 3. Using a 5mm hex wrench, remove the indicated hardware from the Up- per Handlebars and remove them. Note: Be aware that the Upper Handlebars must be supported when Left Upper removing the hardware.
  • Page 46 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
  • Page 47 10. Using a #2 Phillips screwdriver, remove the indicated screw from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases. Then move the screwdriver to the bottom and gently pry until the Rear Shroud comes off.
  • Page 48 20. Using a #2 Phillips screwdriver, remove the screws from the Left Shroud. ( 9 screws on the Left Shroud) Remove the upper screws labeled ‘ * ’ last. Right Side Left Side 21. Using a 4mm hex wrench, remove the screw indicated by “A” from the Drive Belt Tensioner Arm.

  • Page 49: Replace Fan Belt

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 50 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the indicated hardware from the Right Upper Handlebar. Note: Be aware that the Right Upper Handlebar must be supported when removing the hardware.
  • Page 51 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
  • Page 52 10. Using a #2 Phillips screwdriver, remove the indicated screw (by arrow) from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases.
  • Page 53 19. Using a #2 Phillips screwdriver, remove the screws from the Right Shroud ( 3 screws on the Right Shroud). Remove the upper screws labeled ‘ * ’ last. Right Side 20. Using a #2 Phillips screwdriver, remove the 3 screws (indicated by arrows) from the Brake Disc.
  • Page 54 22. Turn the Fan Pulley while forcing the Fan Belt to the outside. Belt will come off of the Fan Pulley. Keep fingers out of any pinch opportunities when removing the Fan Belt. 23. Loop the new Fan Belt around the lower Pulley and start it on the face of the Fan Pulley.
  • Page 55 26. Grasp the Fan Pulley where the Fan Belt is engaged on it, and forcibly rotate the Fan Pulley until the Fan Belt is fully engaged. Keep fingers out of any pinch opportunities when rotating the Fan Pulley. 27. Put on eye protection and cut the Zip-Tie without damaging the new Fan Belt or Fan Pulley.

  • Page 56: Replace The Input/Output (I/O) Cable

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 57 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Remove the Right Stabilizer Shroud from the machine (if equipped). Right Stabilizer Shroud 3. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover.
  • Page 58 Note: Shrouds are removed for clarity. 5. Note how the I/O Cable routes through the machine. I/O Cable Route 6. Cut the two lower Zip-Ties without damaging the Cables. 7. Disconnect all the Cables that connect to the lower part of the old I/O Cable.
  • Page 59 10. Using a 5mm hex wrench, remove the 4 screws (2 on each side of the Console Mast) from the Console Assembly. 11. Carefully lift the Console Assembly and expose the Cable Connec- tions. Note: Do not crimp any of the Console Cables. This step may require two people.

  • Page 60: Replace The Servo Motor

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 61 Note: Your machine may not match the images provided exactly. 1. With power supplied to the machine, adjust the resistance to the maxi- mum setting. 2. Unplug the AC Adapter from the wall outlet and machine. 3. Remove the Right Stabilizer Shroud from the machine (if equipped). Right Stabilizer Shroud 4.
  • Page 62 6. Using a #2 Phillips screwdriver, remove the 3 indicated screws from the Brake Disc. 7. Carefully remove the Brake Disc from the machine. Brake Disc Fan Belt Brake Magnets 8. Using a 8mm open ended wrench, loosen the Brake Cable Secur- Adjustment ing Nut until the Brake Cable can be released from the Servo Motor Barrel...
  • Page 63 14. At the maximum resistance setting, the outer edge of the Brake Mag- net should line up with the outer edge of the Brake Disc. Brake Magnet Brake Disc Adjustment Barrel Brake Cable Securing Nut Brake Disc 15. If the Brake Assembly needs to be adjusted, use a 8mm open ended wrench to loosen the Brake Cable Securing Nut.
  • Page 64 17. The Brake Magnets should be aligned with the Brake Disc and centered around the Brake Disc. If they are not aligned and centered, then the Magnets are adding drag. 18. If the Brake Assembly only needs to be slightly adjusted, loosen the front screw that secures the Brake Assembly using Brake Disc a 10mm hex wrench.

  • Page 65: Replace The Shrouds

    Nautilus, Inc., www.NautilusInc.com, 5415 Centerpoint Parkway, Groveport, OH 43125 U.S.A. - Customer Service: North America (800) 605-3369, csnls@nautilus.com | outside U.S. www.nautilusinternational.com | Printed in China | © 2018 Nautilus, Inc. | Bowflex, the B logo, and Max Trainer are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. |...
  • Page 66 Note: Your machine may not match the images provided exactly. 1. Unplug the AC Adapter from the wall outlet and machine. 2. Using a 5mm hex wrench, remove the indicated hardware from the Right and Left Upper Handlebar. Note: Be aware that the Right and Left Upper Handlebar must be sup- ported when removing the hardware.
  • Page 67 5. Using a #2 Phillips screwdriver, remove the indicated (by ovals) screws and only loosen the lowest indicated screw (arrow) from the Right Fan Cover. Note: Loosen the lowest screw by at least 3 full rotations. 6. The Right Fan Cover has a tab that needs to be pushed upward to clear the loosened screw.
  • Page 68 10. Using a #2 Phillips screwdriver, remove the indicated screw (by arrow) from the Rear Shroud. 11. Carefully remove the Rear Shroud from the machine. Place a standard screwdriver behind and near the middle of the Rear Shroud and gently pry until it releases.
  • Page 69 Right Side Left Side 20. Using a #2 Phillips screwdriver, remove the screws from the Right and Left Shrouds. ( 3 screws on the Right Shroud, 9 on the Left Shroud) Remove the upper screws labeled ‘ * ’ last. 21.

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