Bowflex TreadClimber TC20 Service Manual Download Page 27

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NOTICE:

This document provides instructions for the replacement of the A/C Inlet on the Bowflex

TC20 fitness machine.

If you need assistance, please call

Bowflex

Customer Service at 1-800-605-3369.

1. Remove the 2 indicated screws from the Rear Cover using a #2 Phillips screw-

driver.

2. Remove the Rear Cover.

3. Using a #2 Phillips screwdriver, remove the two indicated screws from the

Motor Cover. Lift up on the front of the Motor Cover, releasing it from the Base

Assembly. Slide the Motor Cover out from beneath the Treadles.

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.

Motor Cover

Summary of Contents for TreadClimber TC20

Page 1: ...ion 5 1 Walking Belt Adjustment 7 1 Maintenance Parts 8 1 Troubleshooting 10 1 Console Error Codes 12 1 Console Service Mode 14 1 Console Error Code Troubleshooting 18 1 Replacement Procedure Skill Le...

Page 2: ...id the warranty Be sure that all warning stickers and instructional placards applied to the product stay present and in good condition when doing maintenance or replacing components If necessary reque...

Page 3: ...3 cm 55 139 7 cm 31 5 80 cm Maximum User Weight 300 lbs 136 kgs Power Requirements Operational Voltage 120VAC 60 Hz Operating Current 10A max This product its packaging and components contain chemica...

Page 4: ...cally fit and able to move the machine safely Place the machine on a clean hard level surface free from unwanted material or other objects that may hamper your ability to move freely A rubber mat shou...

Page 5: ...Frame Monthly Make sure all bolts and screws are tight Tighten if necessary NOTICE Do not clean with a petroleum based solvent or an automotive cleaner Be sure to keep the Console free of moisture Wal...

Page 6: ...g Belts procedure if necessary 3 Connect the power cord back into the machine and then into the wall outlet 4 Stay to one side of your machine 5 Switch on your machine and start the belts at the slowe...

Page 7: ...ncrements If the belt tracks too far to the left do the same thing on the left adjustment bolt Note Do not turn the bolts counterclockwise when you adjust the belt alignment Belt Tension Check Check t...

Page 8: ...eart Rate Strap Rear Cover Treadle Assembly Base Right Upright Left Upright Motor Cover Console Handlebar Assembly Handle Right Side Cover Left Side Cover Right Junction Cover Cylinder Pivot Cover Lef...

Page 9: ...ing Belt Adjustment Bracket Front Roller Lower Walking Belt Guide Treadle Stop Drive Belt Drive Motor Walking Belt Guide IGUS Bushing A C Inlet Rear Roller Motor Control Board Right Side Foot Platform...

Page 10: ...f the fitness machine Chest strap transmitter Test chest strap with another HR monitoring device such as HR watch or a machine at a gym If transmitter has good skin contact and still is not found to b...

Page 11: ...verload Unit may be overloaded and drawing too much current causing unit to shut power down to protect motor Consult belt lubrication schedule to determine if belts need lubrication check walking belt...

Page 12: ...other codes first and restart macine 2 Replace console C08 Wrong MCB 1 Replace MCB with correct part for machine H03 Critical motor current 1 Check that all MCB wiring is secure 2 Replace MCB H05 Comm...

Page 13: ...ackup monitor error 1 If error has occurred multiple times replace MCB H22 Voltage issue 1 If error has occurred multiple times replace MCB H23 No tach signal 1 Check motor power wire connection and t...

Page 14: ...ECREASE button will show you the second to the latest error and so on Pressing INCREASE will show you the oldest error The time is reference to machine time hours TC20 Error Time Hour in TIME segment...

Page 15: ...CE segment 8 HiSt Motor Current History Displays the average motor current for the current maintenance interval Push the decrease button to view the average of previous intervals Every 40 machine hour...

Page 16: ...to complete stop This is used to deter mine how smooth the machine is as far as mechanical friction goes Pressing STOP in this menu will cause the machine to stop right away User should no be on the m...

Page 17: ...e as console Coast down Time in DISTANCE segment Speed in SPEED segment Workout Time in Time segment Console Serial Number in this image is 3572 15 dSn Drive Serial Number This menu will display the s...

Page 18: ...user backpushing the belt or intentionally pushing back on the belts Avoid pushing back on the belts 4 Contact Customer Service and file an Advanced Troubleshooting Form 8 10 15 H08 No Tach is Plugge...

Page 19: ...n relay Does this happen all the time If YES replace MCB If NO restart machine contact Customer Service and file an Advanced Troubleshooting Form 15 H22 Supply too High MCB Saw that the power supply i...

Page 20: ...r Service and file an Advanced Troubleshooting Form 6 7 8 16 H30 Possible ESTOP detection out of sync Console ESTOP detection might be out of sync with MCB 1 Check and make sure the E Stop is plugged...

Page 21: ...MENT 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 p...

Page 22: ...affic and exposure to bystanders Disconnect all power and allow to sit for 5 minutes before you service this machine Some components of the equipment can be heavy or awkward Enlist the service of a se...

Page 23: ...Upper I O Cable 8 Replace the Console Access Panel and secure with the Phillips head screw 9 Final Inspection Inspect your machine to ensure that all hardware is tight and components are properly asse...

Page 24: ...use only genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure...

Page 25: ...procedure 6 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 cor...

Page 26: ...lus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stic...

Page 27: ...Lift up on the front of the Motor Cover releasing it from the Base Assembly Slide the Motor Cover out from beneath the Treadles To reduce the risk of electrical shock or unsupervised usage of the equi...

Page 28: ...avoid possible serious injury keep hands away from the inside of the Treadles and the edges of the Walking Belts 7 Remove the 4 indicated screws from the A C Inlet housing using a 2 Phillips screwdriv...

Page 29: ...ilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning sti...

Page 30: ...e Assembly Slide the Motor Cover out from beneath the Treadles 4 Using a 2 Phillips screwdriver remove the 3 indicated screws from the left Pivot Cover 5 Remove the left Pivot Cover and Spacer To redu...

Page 31: ...ep fingers out of any pinch opportunities when turning the Pulleys 12 Roll the Drive Pulley clockwise until the Drive Belt is fully installed Continue to roll the Belt forward while adding side pressu...

Page 32: ...cement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stickers and...

Page 33: ...Assembly Slide the Motor Cover out from beneath the Treadles 4 Using a 2 Phillips screwdriver remove the 3 indicated screws from the left Pivot Cover 5 Remove the left Pivot Cover and Spacer To reduce...

Page 34: ...wdriver detach the Grounding Wire from the Base Assembly Note The Motor Control Board is located under the right Treadle 9 Remove the Drive Belt Turn the Drive Pulley clockwise while forcing the Drive...

Page 35: ...g 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 12 Remove and replace with th...

Page 36: ...any pinch opportunities when turning the Pulleys Roll the Drive Pulley clockwise until the Drive Belt is fully installed Continue to roll the Belt forward while adding side pressure with fingers to a...

Page 37: ...us replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stick...

Page 38: ...m beneath the Treadles 4 On the Motor Control Board disconnect the Lower Input Output I O Cable by pulling straight out on the Connectors do not pull on the wire itself Push the cable out of the Motor...

Page 39: ...machine Note THIS STEP REQUIRES TWO PEOPLE 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 serio...

Page 40: ...ine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all war...

Page 41: ...ssembly Slide the Motor Cover out from beneath the Treadles 4 Using a 2 Phillips screwdriver remove the 3 indicated screws from the right Pivot Cover 5 Remove the right Pivot Cover and Spacer To reduc...

Page 42: ...crewdriver from the right Side Cover 9 Remove the right Side Cover 10 Record the location of where each wire connects to the Control Board You will have to reattach each wire to the new Control Board...

Page 43: ...er and secure with the lower Cylinder mounting bolt 24 With assistance carefully set the machine upright Do not move the machine without aid Injury to you or damage to the machine can occur The Treadl...

Page 44: ...replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and...

Page 45: ...r releasing it from the Base Assembly Slide the Motor Cover out from beneath the Treadles 5 Using a 2 Phillips screwdriver remove the 3 indicated screws from the right Pivot Cover 6 Remove the right P...

Page 46: ...r remove the 5 indicated screws from the Side Cover 11 Slide the Side Cover off of the machine 12 Using the 5 mm hex wrench loosen the Belt Tensioning Screws on both Treadles 2 screws on each Treadle...

Page 47: ...iver 16 Shift the belt to the outside and remove the 4 deck screws using a 2 Phillips screwdriver 17 Lift the belt slightly and slide the Walking Deck out from under the belt 18 Slide the new deck in...

Page 48: ...into an appropriately rated outlet Note The TC20 TreadClimber fitness machine is designed to plug directly into a properly wired and grounded three prong 120V outlet If you connect the machine to an...

Page 49: ...s replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning sticke...

Page 50: ...e To avoid possible serious injury keep hands away from the inside of the Treadles and the edges of the Walking Belts 6 Remove the lower mounting bolt from the Cylinder Leave attached at top 7 Disconn...

Page 51: ...ght use a 5 mm Hex Key to turn the right adjustment bolt clockwise on that belt in full turn increments If the belt tracks too far to the left do the same thing on the left adjustment bolt Note Do not...

Page 52: ...re Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stickers and instructional placards...

Page 53: ...crewdriver from the left Side Cover 4 Slide the left Side Cover off of the machine 5 Remove the Drive Belt Turn the Drive Pulley clockwise while forcing the Drive Belt to the outside Belt will come of...

Page 54: ...ve Pulley Bolt counter clockwise Remove the Drive Pulley 7 Loosen the Belt Tensioning Screws on both Treadles using a 5 mm hex wrench total of 4 screws NOTE Be sure to record how many turns it takes t...

Page 55: ...t Side Bearing Plate before attempting to remove the Snap Ring 11 Using a 13 mm 1 2 wrench and a 13 mm 1 2 socket and wrench remove the 2 indicated bolts from the Left Rear Roller Bracket 12 Remove th...

Page 56: ...clockwise when you adjust the belt alignment Belt Tension Adjustment Check the belt tension only when the machine is unplugged From the belt s midpoint a correctly tensioned belt should only have an i...

Page 57: ...ware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and void the warranty Be sure that all warning stickers and instructional placards app...

Page 58: ...ssembly Slide the Motor Cover out from beneath the Treadles 4 Using a 2 Phillips screwdriver remove the 3 indicated screws from the right Pivot Cover 5 Remove the right Pivot Cover and Spacer To reduc...

Page 59: ...ide the Side Cover off of the machine 10 Reconnect the Cylinder to the Treadle and re install the lower mounting bolt Repeat the previous five steps to the right side of the machine 11 Using a 2 Phill...

Page 60: ...sembly Also note the orientation of the Brackets The larger Bracket is to the outside of the machine 15 Remove the Front Roller from the belt 16 While holding a 13 mm 1 2 wrench on the Right Rear Roll...

Page 61: ...de Bearing Plate 21 Remove the Left Rear Roller Bracket from the Rear Roller 22 Remove the lower Cylinder bolt using a 5 mm hex wrench 23 Disconnect the Cylinder from the Treadle and lower the Treadle...

Page 62: ...into an appropriately rated outlet Note The TC20 TreadClimber fitness machine is designed to plug directly into a properly wired and grounded three prong 120V outlet If you connect the machine to an...

Page 63: ...ent parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that all warning stickers and ins...

Page 64: ...m beneath the Treadles 4 On the Motor Control Board disconnect the Lower Input Output I O Cable by pulling straight out on the Connectors do not pull on the wire itself Push the cable out of the Motor...

Page 65: ...Treadle Assembly 8 Carefully lift the front of the Treadle Assembly onto the Transport Wheels Roll the Treadle Assembly off of the rear of the machine Note THIS STEP REQUIRES TWO PEOPLE Do not move th...

Page 66: ...ed screws using a 2 Phillips screwdriver from the left Side Cover 12 Slide the left Side Cover off of the machine 13 Remove the Drive Belt Turn the Drive Pulley clockwise while forcing the Drive Belt...

Page 67: ...Tensioning Screws on both Treadles using 5 mm hex wrench total of 4 screws NOTE Be sure to record how many turns it takes to loosen the screws to assist with reassembly 15 Remove the 3 indicated bolt...

Page 68: ...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 The Treadle will fall abrupt...

Page 69: ...the metal spacers washers Note Do not overtighten Excessive tightening will cause the metal spacer to crack 24 Remaining assembly is the reverse procedure 25 Installation is the reverse procedure 26...

Page 70: ...ly genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that...

Page 71: ...e up and to the inside of the ma chine Be sure to attach the cylinder to the Treadle before the Upright 5 Final Inspection Inspect your machine to ensure that all hardware is tight and components are...

Page 72: ...ly genuine Nautilus replacement parts and hardware Failure to use genuine replacement parts can cause a risk to users keep the machine from operating correctly and will void the warranty Be sure that...

Page 73: ...ard Note The Motor Control Board is located under the Right Treadle 5 Plug in the new lower I O Cable to the Motor Control Board 6 Using a piece of wire or string connect the loose ends of the new low...

Page 74: ...ole Handlebar Upright Assembly Repeat on the right side of the Console Handlebar Upright Assembly 10 Remove the Console Handlebar Upright Assembly from the Base Assembly and gently lower it to the flo...

Page 75: ...er I O Cable as it is routed Note Do not crimp the cables 17 Gently pull the old lower I O Cable from the front of the Base Assembly toward the upper I O Cable Be sure not to crimp the new lower I O C...

Page 76: ...Do not try to do heavy or awkward steps on your own Use only replacement parts and hardware that are supplied or approved by Nautilus Failure to use Nautilus approved replacement parts can adversely...

Page 77: ...Head Screw M8x20 H 10 Phillips Head Screw M4x10 D 16 Flat Washer M8x18 I 2 Spacer E 2 Phillips Head Screw M4x40 J 10 Flat Washer M4x10 A B C D E F G H Parts 3 BOXES BOX1 Item Qty Description 1 1 Hard...

Page 78: ...parts may be discarded or returned to Nautilus 1 Remove the Power Cord from the Treadle Assembly Disconnect all power and allow to sit for 5 minutes before you service this machine Note Place the Powe...

Page 79: ...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 12 X2 5 mm...

Page 80: ...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...

Page 81: ...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 cr...

Page 82: ...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 X6 5 mm...

Page 83: ...d 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 re...

Page 84: ...Be sure to note the orientation of the Hardware for replacement purposes X6 X4 2 2 SECTION B Begin the New Machine Assembly 10 Using the Base Assembly supplied with the replacement kit attach the Tran...

Page 85: ...e 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 mov...

Page 86: ...hen 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 Untie the Pull Cable from the rear...

Page 87: ...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: ...rs 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...

Page 89: ...sert 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...

Page 90: ...nto 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 Repla...

Page 91: ...id 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 Upr...

Page 92: ...adles 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...

Page 93: ...3 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: ...Kit X2 2 F 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 s...

Page 95: ...ound 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 Final Inspectio...

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Bowflex TreadClimber TC20, Service Manual

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