Bowflex TreadClimber TC20 Service Manual
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Bowflex TreadClimber TC20 Service Manual

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See also: Assembly & Owners Manual , Owner's Manual

Table of Contents

Section Code
Section
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Part Replacement
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. www.nautilusinternational.com | © 2011 Nautilus, Inc. | ® indicates trademarks registered in the United
States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
8017487.120117.A
Bowflex
TreadClimber
®
Service Manual
TC20
®
Page Number
2
3
3
4
4
5
5
7
8
10
12
14
18
21
22
24
26
29
32
37
40
44
49
52
57
63
70
72
76
Service Manual
004-4702.120117.G

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Summary of Contents for Bowflex TreadClimber TC20

  • Page 1: Table Of Contents

    Nautilus, Inc., (800) 605-3369, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. www.nautilusinternational.com | © 2011 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.

  • Page 2: Important Safety Instructions

    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 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, the B logo, and TreadClimber are trademarks owned by or licensed to Nautilus, Inc.

  • Page 3: Safety Warning Labels And Serial Number

    SAFETY WARNING LABELS AND SERIAL NUMBER under Motor Cover • • on inside of Treadles Serial Number Product Speci cation -Moving parts can crush and cut. -Keep guards in place. -Lock out power before servicing. under Motor Cover 002-2268 SPECIFICATIONS Maximum User Weight: 300 lbs (136 kgs) Power Requirements:...

  • Page 4: Moving Your Machine

    Moving Your Machine The TreadClimber fitness machine weighs approximately 200 lbs (91 kg) when fully assembled and requires caution when being moved. Use the ® Transport Handle found under the front of the machine to move it. To get access to the Transport Handle, turn the Levelers until you have sufficient clearance between the machine and floor. Adjustments Your machine can be rolled on the transport wheels to a new location. Lower your machine slowly into its new location without injury to your head or fingers. Do not use the uprights, handlebars, or the Console to lift or move the machine. Injury to you or damage to the machine can occur.

  • Page 5: Maintenance

    We recommend that you use one of the following: • Lube-N-Walk Treadmill Lubrication Kit (available from www.bowflex.com or your local specialty fitness dealer) ® • 100% pure silicone, available at most hardware and auto parts stores. As you use your fitness machine, the Console will show “LUbE” at set times. This is only a reminder and should be added to your inspection schedule.
  • Page 6 2. Carefully lift each belt and apply silicone lubricant in the center of the Treadle deck along the entire reachable length of the deck. Apply 0.5 to 1.5 oz. of the lubricant on the deck underneath each belt. NOTICE: Always use a 100% pure silicone lubricant. Do not use a degreaser like WD-40 or a petroleum based product as this could ®...

  • Page 7: Walking Belt Adjustment

    Walking Belt Alignment The walking belts need to be adjusted if they are out of center enough to cause a rubbing or scraping sound. Adjustments can be made at the Front Roller of each Treadle. Adjusting the Walking Belts – While operating the machine, notice where the belts run on each Treadle. The Walking Belt Adjustment Bolts are on the front end of each Roller.

  • Page 8: Maintenance Parts

    Maintenance Parts Console / Handlebar Assembly Right Junction Cover Cylinder Power Cord Safety Key Heart Rate Strap Rear Cover Right Side Cover Right Upright Left Junction Cover Left Upright Treadle Assembly Cylinder Pivot Cover Base Motor Cover Left Side Cover Handle...
  • Page 9 Maintenance Parts (Treadle Assembly) Drive Belt Treadle Stop Drive Motor Front Roller Lower Walking Belt Guide Walking Belt Adjustment Walking Screw Belt Adjustment Bracket Walking Belt Guide Right Side Foot Platform IGUS Bushing A/C Inlet Motor Control Board Rear Roller...

  • Page 10: Troubleshooting

    TROUBLESHOOTING Condition/Problem Things to Check Solution Unit will not turn on, power switch Outlet Make sure outlet is functioning correctly. Verify this by plugging another does NOT light up device (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.
  • Page 11 Condition/Problem Things to Check Solution Belts stop turning while in use Safety key Plug Safety Key into Console (See Safety Key -Emergency Stop Procedures within Features section). Motor overload Unit may be overloaded and drawing too much current, causing unit to shut power down to protect motor.

  • Page 12: Console Error Codes

    ERROR CODES • If the error code has never appeared before, the first step should always be to power the machine off/on, and see if the code re- appears. If the code re-appears, or has been seen before, then proceed with the steps below. •...
  • Page 13 Over speed condition 1. If error occurs when machine is powered up or when start button is pressed, replace MCB 2. If error occurs due to pushing belts beyond motor speed, advise not to push belts beyond motor speed 3. Seek advanced troubleshooting assistance Motor wiring 1.

  • Page 14: Console Service Mode

    Console Service Mode The Console has a Service Mode. Some options in the Service Mode can be adjusted to the users preferences, but most are helpful for service of the machine. To access the Service Setup Mode, hold down the Increase and Decrease buttons for 2 seconds when in Idle NOTE: The numbering here does not represent the Menu # in service mode. See Owner’s Manual for the ...
  • Page 15 Distance in TIME  diSt Total Distance Displays total distance. segment  Distance in  DISTANCE  segment      8. Motor Current History: Displays the average motor current for the current maintenance    HiSt Motor Current History * Displays the average motor current for the current maintenance interval. Push the interval. Push the decrease button to view the average of previous intervals. Every 40 mac decrease button to view the average of previous intervals. Every 40 machine hours, the hours, the interval increases. ...
  • Page 16   9. Hardware Type: Displays the hardware type. Currently all Treadclimbers are set to 32.   Curr Motor Current * Displays the instantaneous motor current. This menu can be used to troubleshoot ma- chine for high current/high friction. 10. Motor Current: Displays the instantaneous motor current. This menu can be used to  troubleshoot machine for high current/high friction. WARNING: pressing STOP in this men Pressing STOP in this menu will cause the machine to stop right away. User cause the machine to stop right away. User should no be on the machine when stopped is should no be on the machine when stopped is pressed.
  • Page 17 Workout Time – in  TC20LOG.CSV Time segment    LOOP Loop Back * Test to see if the Console is receiving data. (Currently not used and will display FAIL after a few seconds if entered.) 18. Str(MENU #13 in TC20): Set Time Reference, Only available in TC20 machines. Here, the user  Set Time Reference Sets the current day and time as the start of the workout week for all users. can reset their workout statistics/Go Coach time reference back to default date. ...

  • Page 18: Console Error Code Troubleshooting

    Console Error Code Troubleshooting Error Message Description Resolution Console Service Mode Option Assist Motor Control Board (MCB) saw H03. Critical Motor Current 1. What version of code? Option 8, 10, 15 Critical Current 2. Does this happen within a few seconds after the belts starts moving? with user on it? without user on it? If yes, replace Motor Control Board (MCB).
  • Page 19 Error Message Description Resolution Console Service Mode Option Assist H16. Backup protecion saw over Backup Monitor saw over speed 1. Did this issue happen as soon as workout was 8, 10, 15 Speed about to start? -If YES: Check wiring and if all is well, replace MCB. -If NO: Was there an H07 error as well? Yes- Troubleshoot H07.
  • Page 20 H28. Backup Has relay On with- Backup Monitor had relay ON without 1. Restart machine. Does the error happen still? out Permission permission 2. Replace MCB. H29. Possible Stuck Relay MCB wanted relay OFF but did not 1. Turn off machine and wait a couple of minutes. Turn 6, 7, 8, 16 see bus volts dropping.

  • Page 21: 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...

  • Page 22: Replacing The Bezel Electronics Assembly

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 23 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.

  • Page 24: Replacing The Console Assembly / Console Shroud

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 25 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.

  • Page 26: Replacing The A/C Inlet

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 27 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 28 4. On the Motor Control Board, disconnect the Motor Power Wires by pulling straight out on the Connectors – do not pull on the wire itself. Note: The Motor Control Board is located under the right Treadle. AC Power Wires Motor Power Wires Grounding Wire 5.

  • Page 29: Replacing The Drive Belt

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 30 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 31 6. Tilt unit carefully onto the right side. Do not move the machine without aid. Injury to you or damage to the machine can occur. The Treadles and Walking Belts can abruptly move. To avoid possible serious injury, keep hands away from the inside of the Treadles and the edges of the Walking Belts.

  • Page 32: Replacing The Motor

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 33 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 34 6. Remove the 5 indicated screws using a #2 Phillips screwdriver from the left Side Cover. 7. Slide the left Side Cover off of the machine. 8. On the Motor Control Board, disconnect the Motor Power Wires by pulling straight out on the Connectors – do not pull on the wire itself. Push the loose wires through to the Motor compartment.
  • Page 35 10. Remove the indicated nuts and washers using a 5 mm wrench from the Motor Assembly. There are two in front (shown) and two behind (not shown) the Motor Assembly. 11. Disconnect the Tach Cable from the Motor Control Board. Motor Control Board Tach Cable...
  • Page 36 13. Installation is the reverse procedure. Drive Belt Replacement: Wrap the new Drive Belt around the Motor Pulley. Start the Drive Belt on the Drive Pulley and roll it in a clockwise motion. Be sure the Belt does not come off of the Motor Roller.

  • Page 37: Removing The Treadle Assembly

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 38 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 39 5. Remove the lower mounting bolt from the Cylinders. Leave the tops attached. 6. Disconnect the Cylinder from the Treadle, and lower the Treadle gently. The Treadle will fall abruptly if not supported. Keep hands away from the inside of the Treadles to avoid possible serious injury. 7.

  • Page 40: Replacing The Motor Control Board

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2012 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 41 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 42 6. Tilt unit carefully onto the left side. Do not move the machine without aid. Injury to you or damage to the machine can occur. The Treadles and Walking Belts can abruptly move. To avoid possible serious injury, keep hands away from the inside of the Treadles and the edges of the Walking Belts.
  • Page 43 INPUT/ OUTPUT (I/O) CABLE 16. Remove the Motor Control Board and replace. AC POWER WIRES (not provided on newer machines) 17. Re-install the two Phillips head screws into the new Motor Control TACH Board. MOTOR POWER WIRES BLACK 18. Connect AC Power Wires. MOTOR CONTROL BOARD 19.

  • Page 44: Replacing The Walking Deck

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 45 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 46 7. Tilt the machine carefully onto the right side. Do not move the machine without aid. Injury to you or damage to the machine can occur. The Treadles and Walking Belts can abruptly move. To avoid possible serious injury, keep hands away from the inside of the Treadles and the edges of the Walking Belts.
  • Page 47 15. With the Walking Belt loose, shift the belt to the center of the machine and remove the 3 deck screws and 1 belt guide screw using a #2 Phillips screwdriver. 16. Shift the belt to the outside and remove the 4 deck screws using a #2 Phillips screwdriver.
  • Page 48 21. With the Belt Tensioning Screws and Brackets replaced, check the walking belt tension. To check, pull the belt upward at it’s mid- point and measure the distance to the deck. If the distance is more than an inch, the belt is loose. To tighten, turn both bolts clockwise one-half a turn and check tension again.

  • Page 49: Replacing The Front Roller

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 50 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 51 10. Remove the Belt Tensioning Screws and Brackets using a 5 mm hex wrench. NOTE: Be sure to record how many turns it takes to remove the screws to assist with reassembly. Also note the orientation of the Brackets. The larger Bracket is to the outside of the machine.

  • Page 52: Replacing The Rear Roller

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 53 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 54 6. While holding a 13 mm (1/2”) wrench on the Right Rear Roller Bolt steady, turn another 13 mm (1/2”) wrench on the Drive Pulley Bolt counter-clockwise. Remove the Drive Pulley. Drive Pulley Bolt Right Rear Roller Bolt 7. Loosen the Belt Tensioning Screws on both Treadles using a 5 mm hex wrench (total of 4 screws).
  • Page 55 10. Remove the Snap Rings from both sides of the Rear Roller. To avoid possible injury, be sure to wear eye protection before removing the Snap Ring. Note: The Snap Ring may be behind the Right Side Bearing Plate on some Snap Ring machines.
  • Page 56 Walking Belt Adjustment The walking belts need to be adjusted if they are out of center enough to cause a rubbing or scraping sound. Adjustments can be made at the Front Roller of each Treadle (Item A). Belt Alignment Check – Stand adjacent to the unit and set the speed to 1.5 MPH.

  • Page 57: Replacing The Walking Belt

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2013 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 58 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 59 6. Using a #2 Phillips screwdriver, remove the 5 indicated screws from the left Side Cover. 7. Using a 5 mm hex wrench, remove the lower mounting bolt from the Cylinder. Leave it attached at the top. 8. Disconnect the Cylinder from the Treadle, and lower the Treadle gently.
  • Page 60 14. Using a 5 mm hex wrench, remove the Belt Tensioning Screws and Brackets from the Front Roller. NOTE: Be sure to record how many turns it takes to remove the screws to assist with reassembly. Also note the orientation of the Brackets.
  • Page 61 19. Using Cir-Clip Pliers, remove the Snap Ring from the Rear Roller Assembly. To avoid possible injury, be sure to wear eye protection before Snap Ring removing the Snap Ring. 20. Using a 13 mm (1/2”) wrench and a 13 mm (1/2”) socket, remove the 2 indicated bolts from the Left Side Bearing Plate.
  • Page 62 27. With the Belt Tensioning Screws and Brackets replaced, check the walking belt tension. To check, pull the belt upward at it’s midpoint and measure the distance to the deck. If the distance is more than an inch, the belt is loose. To tighten, turn both bolts clockwise one-half a turn and check tension again.

  • Page 63: Replacing The Virtual Pivot

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 64 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 65 5. Remove the lower mounting bolt from the Cylinders. Leave the tops attached. 6. Disconnect the Cylinder from the Treadle, and lower the Treadle gently. The Treadle will fall abruptly if not supported. Keep hands away from the inside of the Treadles to avoid possible serious injury. 7.
  • Page 66 9. Using a #2 Phillips screwdriver, remove the 3 indicated screws from the right Pivot Cover. 10. Remove the right Pivot Cover and Spacer. 11. Remove the 5 indicated screws using a #2 Phillips screwdriver from the left Side Cover. 12.
  • Page 67 14. While holding a 13 mm (1/2”) wrench on the Right Rear Roller Bolt steady, turn another 13 mm (1/2”) wrench on the Drive Pulley Bolt counter-clockwise. Note the orientation of the Drive Pulley with the Round Magnet on the inside. 8.
  • Page 68 17. Remove the 4 indicated screws using two 13 mm (1/2”) wrenches. 18. Disconnect the Tach Cable from the Motor Control Board. 19. With the help of another person, invert the Treadle Assembly. Do not move the machine without aid. Injury to you or damage to the machine can occur.
  • Page 69 IGUS ( 21. Install the “hat” shaped) bushings into the pivot arms. 22. Install the metal spacers/ washers into the bushings. 23. Add the washers to both sides of the Center Block as the bolt is installed. Tighten only until the nut has bottomed out on the metal spacers/ washers. Note: Do not overtighten.

  • Page 70: Replacing The Hydraulic Cylinder (Shocks)

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 71 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.

  • Page 72: Replacing The Lower And Upper I/O Cables

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2014 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 73 To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power cord from the wall outlet and the machine and wait 5 minutes before cleaning, maintaining or repairing the machine. Place the power cord in a secure location.
  • Page 74 8. Disconnect the Cylinders from the Uprights, and lower the Cylinders and Treadles gently. The Treadle will fall abruptly if not supported. Keep hands away from the inside of the Treadles to avoid possible serious injury. 9. Using a 5 mm hex wrench, remove the five bolts in the indicated areas on the left side of the Console/Handlebar/Upright Assembly.
  • Page 75 11. The connection of the lower and upper I/O Cable is now exposed. Disconnect the cables and gently pull the lower I/O Cable out while pulling the new lower I/O Cable in place. Note: Do not crimp the cables. 12. Remove the indicated Phillips head screw and the Console Access Panel from the Console Assembly.

  • Page 76: Replacing Treadle Assembly-Ver1 With Ver2

    Nautilus, Inc., (800) NAUTILUS / (800) 628-8458, www.NautilusInc.com - Customer Service: North America (800) 605-3369, outside U.S. +01-360-859-5180 | © 2013 Nautilus, Inc. | ® indicates trademarks registered in the United States. These marks may be registered in other nations or otherwise protected by common law. Bowflex, and the B logo are trademarks owned by or licensed to Nautilus, Inc.
  • Page 77 Parts ( 3 BOXES ) BOX 1 Item Description Hardware Card Motor Cover BOX 2 Item Description Treadle Assembly BOX 3 Item Description Base Assembly Upright, Right Upright, Left Hardware Item Description Item Description Button Head Hex Screw, M8x20 Phillips Head Screw, Self Tapping M4x16 Lock Washer, M8x14 Flat Washer, M8x24 Hex Head Screw, M8x20...
  • Page 78 SECTION A: Remove Parts from Current Machine Assembly Be sure to place all parts and hardware in a secure location away from build area. Do not dispose of any parts until the assembly of the new machine is complete. Unused parts may be discarded or returned to Nautilus. .
  • Page 79 3. Remove the Transport Handle from the Treadle Assembly Note: Place the Transport Handle and Hardware in a secure location so they can be re-attached on the final assembly. 5 mm...
  • Page 80 4. Remove the Cylinders from the Treadle Assembly and the Uprights The Treadles do not have a locking mechanism and can move freely. Take care not to allow harm or injury to occur when lifting the Treadles. Note: Place the Cylinders in a secure location so they can be re-attached on the final assembly. 5 mm...
  • Page 81 5. Carefully remove the Console/Handlebar/Upright Assembly from the Base Assembly. 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. Note: Do not crimp or pull the Cables.
  • Page 82 7. Remove the Console/Handlebar Assembly from the Uprights. Note: Place the Console/Handlebar Assembly and Junction Covers in a secure location so they can be re-attached on the final assembly. 5 mm...
  • Page 83 8. Remove the Pivot Covers and Spacers from the Treadle Assembly Note: Place the Pivot Covers in a secure location so they can be re-attached on the final assembly. Be sure to note the orientation of the Spacers and Hardware for replacement purposes.
  • Page 84 9. Remove the Side Covers from the Treadle Assembly Note: Place the Side Covers in a secure location so they can be re-attached on the final assembly. Be sure to note the orientation of the Hardware for replacement purposes. SECTION B: Begin the New Machine Assembly 10. Using the Base Assembly supplied with the replacement kit, attach the Transport Handle to the Base Assembly. Note: Transport Handle and Hardware were removed from previous assembly and not included in Replacement Kit (*). 5 mm...
  • Page 85 11. Cut open the end of Box 2 and move the new Treadle Assembly beside the Base Assembly. Some components of the machine can be heavy or awkward. Use a second person when doing the assembly steps involving these parts. Do not do steps that involve heavy lifting or awkward movements on your own.
  • Page 86 12. Attach the Treadle Assembly to the Base Assembly Some components of the machine can be heavy or awkward. Use a second person when doing the assembly steps involving these parts. Do not do steps that involve heavy lifting or awkward movements on your own. Note: Do not crimp the Lower I/O Cable.
  • Page 87 13. Attach the Side Covers to the Treadle Assembly Note: Be sure to use indicated Hardware that was supplied in the Replacement Kit. Side Covers were removed from previous assembly and not included in Replacement Kit (*).
  • Page 88 14. Attach the Pivot Covers and Spacers to the Treadle Assembly Note: Be sure to use indicated Hardware that was supplied in the Replacement Kit. Pivot Covers were removed from previous assembly and not included in Replacement Kit (*).
  • Page 89 15. Insert the Lower I/O Cable into the Base Assembly and then Route to Front. Note: Be sure to route the cable into the side opening of the Base Assembly. Do not crimp the Lower I/O Cable. * Treadles removed for clarity.
  • Page 90 16. Attach the Junction Covers and Uprights to the Console/Handlebar Assembly In order to avoid possible serious injury, when inserting the tube ends into the Console/Handlebar Assembly be careful to avoid fingers or hands being caught or pinched. Note: Do not crimp the Console I/O Cable. Be sure to use indicated Hardware that was supplied in the Replacement Kit. The Junction Covers and Console/Handlebar Assembly were removed from previous assembly and not included in Replacement Kit (*).
  • Page 91 17. Connect the I/O Cable to the Console I/O Cable Note: Do not crimp the I/O Cable. 18. Attach the Console/Handlebar/Upright Assembly to the Base Assembly In order to avoid possible serious injury, when inserting the tube ends into the Base Assembly be careful to avoid fingers or hands being caught or pinched. Be sure the excess length of the I/O Cable goes into the Upright and does not get crimped. Note: Do not crimp the I/O Cables.
  • Page 92 19. Attach Cylinders to Treadles and then Uprights The Treadles do not have a locking mechanism and can move freely. Take care not to allow harm or injury to occur when lifting the Treadles. Note: The settings dial on the cylinders must be up, with the white arrow to the inside of the machine. Attach to Treadles before the Uprights. Be sure to use indicated Hardware that was supplied in the Replacement Kit.
  • Page 93 20. Attach the Motor Cover to the Base Assembly Note: Be sure the safety tabs on the Motor Cover snap onto the Base Assembly. Be sure to use the Motor Cover that was supplied with the Replace- ment Kit.
  • Page 94 21. Secure the Motor Cover to the Base Assembly Note: Be sure to use indicated Hardware that was supplied in the Replacement Kit. 22. Attach the Rear Cover to the Treadle Assembly Note: Be sure the safety tabs on the upper-inside of the Rear Cover snap onto the Base Assembly. Be sure to use indicated Hardware that was sup- plied in the Replacement Kit.
  • Page 95 23. Connect Power Cord to Treadle Assembly Note: The TC20 TreadClimber fitness machine is designed to plug directly into a properly wired and grounded three prong 120V outlet. If you con- ® nect the machine to an outlet with GFI (ground fault interrupt) or AFI (arc fault interrupt), machine operation can cause the circuit to trip. The Power Cord was removed from previous assembly and not included in Replacement Kit (*). 24.

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