Bowflex Max Total 16/40 User manual

1
8027711.071522.B
8027706.071522.B
Service Manual
Table of Contents
Nautilus, Inc., [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. www.nautilusinternational.com | Printed in China | © 2020 Nautilus, Inc.
| Bowflex, the B logo, and Max Total are trademarks owned or licensed by Nautilus, Inc., registered or otherwise protected by common law in the United States and other nations. | The Bluetooth® word mark and
logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc. is under license. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
Bowflex™Max Total™16/40
Service Manual
™
™
Section Code Section Page Number
1 Important Safety Instructions 2
1 Safety Warning Labels and Serial Number 3
 1  Specications      4
1 Moving / Leveling the Machine 5
1 Bluetooth®Heart Rate Armband 6
1 Maintenance 8
1 Maintenance Parts Exploded View 9
1 Troubleshooting - Sections 11
1 No Power / Display Will Not Turn On 12
1 Machine Goes to Sleep While in Use 13
 1   ResistanceDoesNotRespond    14
1 Machine Seized Up 15
1 Machine Slips During Use 16
1 Rollers and Pedals 17
1 Noises - Main 18
1 Noises - Metallic Grinding or Scraping 19
1 Noises - Rubbing / Belt 20
1 Noises - Clicking, Clunking or Knocking 21
1 Noises - Squeaking, Squealing or Chirping 22
1 Contact Heart Rate Issues 23
1 Bluetooth®HeartRateIssues    24
1 Upper (Drive) Pulley 25
1 Power Off and Restart the Machine 26
1 Replacement Procedure Skill Level 27
  Mechanical/ModicationProcedures
2 Adjust the Brake Assembly 28
3 Adjust the Leg Assembly Alignment 33
 4  ModifytheResistanceKnobCable    36
Part Replacement
 5  ReplacetheBrakeAssembly     40
 6  ReplacetheConsoleAssembly     46
 7  ReplacetheConsoleRearPanel     49
8 Replace the Crank Arm, Left 53
9 Replace the Crank Arm, Right 57
10 Replace the Drive Belt 62
11 Replace the Drive Pulley 67
 12  ReplacetheDrivePulleyHardware    74
13 Replace the Fan Assembly 79
 14  ReplacetheFanBelt      82
15 Replace the Fan Pulley 89
16 Replace the Frame Assembly 97
17 Replace the Handlebar Pivot Assembly 106
18 Replace the Mid Mast Cables 108
19 Replace the PCBA Board 113
20 Replace the Power Inlet 119
21 Replace the Roller Wheel Assembly 122
 22  ReplacetheServoMotor     124
23 Replace the Shrouds 129
 24  ReplacetheSpeedSensorAssembly    134
25 Replace the Static Handlebar Assembly 136
 26  ReplacetheUpperBodySensorAssembly    140
 27  ReplacetheWiringHarness,Main    148

2
8027709.071522.B
Service Procedures
Important Safety Instructions
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and
understand all Warnings on this machine.
Before servicing or using this equipment, obey the following warnings:
Read and understand the Service Manual before working on the machine. Failure to obey the instructions and safety warnings
could cause injury to the service technician or bystanders.
!To reduce the risk of electrical shock or unsupervised usage of the equipment, always unplug the power
cord from the wall outlet and/or the machine before cleaning, maintaining or repairing the machine. Place
the power cord in a secure location.
• Keep bystanders and children away from the product being serviced at all times.
• Makesurethattherepairisdoneinanappropriateworkspaceawayfromfoottrafcandexposuretobystanders.
• 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.
• Use only replacement parts and hardware that are supplied or approved by Nautilus. Failure to use Nautilus-approved replacement parts can
adversely affect the safety and functionality of the equipment creating a risk to users and will void 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 at any time the Warning labels become loose, unreadable or dislodged, replace the labels. If purchased in US/Canada,
contact Customer Service for replacement labels. If purchased outside US/Canada, contact your local distributor for them.
• Do not try to change the design or functionality of the machine being serviced as this can adversely affect user safety and will void the warranty.
• Donotputthemachinebackinserviceuntilallshrouds,instructions,warninglabelsandcorrectfunctionalityhavebeenveriedandtestedfor
correct performance.
•SAVE THESE INSTRUCTIONS.
This icon means a potentially hazardous situation which, if not avoided, could result in death or serious injury. Read and understand
all Warnings on this machine.
Nautilus, Inc., [phone], www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. www.nautilusinternational.com | Printed in China | © 2019 Nautilus, Inc. | Bowflex, the
B logo, and Max Total 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. The Bluetooth® word
mark and logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by Nautilus, Inc. is under license. | ORIGINAL DOCUMENT - ENGLISH VERSION ONLY
™
™
NOTICE: Thisdocumentprovidesimportantsafetyinstructions,adjustments,andgeneraltroubleshootinginformationforthemaintenanceoftheBowex™Max
Total™16/40.
If you need assistance, please contact Customer Service (if purchased in US/Canada) or your local distributor (if purchased outside US/Canada). To nd your local
distributor, go to: www.nautilusinternational.com
Important Safety Instructions and General Troubleshooting
Information for the Bowflex™Max Total™16/40

3
SAFETY WARNING LABELS AND SERIAL NUMBER
FCC Compliance
Changes or modications to this unit not expressly approved by the party responsible for compliance could void the user’s
authority to operate the equipment.
The machine and power supply comply with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not
cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
Note: This machine and power supply have been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of
the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may
cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio
or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one
or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
This product complies with the European Radio Equipment Directive 2014/53/EU
ProductSpecicationLabelandSerialNumberLabel
(under Right Stabilizer Shroud)
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.
• The heart rate displayed is an approximation and should be used
for reference only.
•Notintendedforusebyanyoneunder14yearsofage.
• The maximum user weight for this machine is 136 kg. (300 lbs)
• This machine is for home use only.
• Consult a physician prior to using any exercise equipment.
(Label on machine is available in English and French Canadian
only.)
Console Serial Number Label

4
SPECIFICATIONS
For safe operation, the location must be on a hard, level surface. Allow a
workoutareaofaminimum139.2cm(54.8in)x186.2cm(73.3in).Keep the
workoutareaclear0.6m(24in)alongthesideusedtoaccessthemachineand
to the rear of the machine. Be sure that the workout space you are utilizing has
adequate height clearance, taking into consideration the height of the user and
themaximumpedalheightofthetnessmachine.
Maximum User Weight: 136 kg ( 300 lbs.)
Total Surface Area (footprint) of equipment: 9648.8cm2(1494.5in2)
Maximum Pedal Height:  48.5cm(19.1inches)
Machine Weight: approx. 70.5kg(155.4lbs.)
Power Requirements:
(AC Adaptor)
 InputVoltage:  100-240VAC,50-60Hz,1.5A
Output Voltage: 12V DC, 5A
Heart Rate Armband: 1 Lithium Polymer battery (not replaceable)
DO NOT dispose of this product as refuse. This product is to be recycled. For
proper disposal of this product, please follow the prescribed methods at an
approved waste center.
166 cm
(65.7 in)
125 cm
(49.3 in) 78.2 cm
(30.8 in)
1.86 m (73.3 in)
1.39 m
(54.8
in)
0.6 m
(24 in)
0.6 m
(24 in)

5
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  t and able to move the machine safely.
1. Grasp the Main Bar of the Static Handlebar Assembly to carefully tilt the
machine toward you onto the transport rollers. Be sure not to grab the
Console Display.
Be aware of the Handlebars and the weight of the machine before
tilting the machine.
2. Push the machine into position.
3. Carefully lower the machine into position.
NOTICE: Be careful when you move the machine. All abrupt motions can affect the computer operation.
Leveling the Machine
The machine needs to be leveled if your workout area is uneven or if the Rail Assembly is
slightlyofftheoor.Toadjust:
1. Place the machine in your workout area.
2. Loosen the locking nuts and adjust the levelers until they are evenly balanced in
contactwiththeoor.
Do not adjust the levelers to such a height that they detach or unscrew from
the machine. Injury to you or damage to the machine can occur.
3. Tighten the locking nuts.
Make sure the machine is level and stable before you exercise.
Media Rack (Optional Accessory)
AnoptionalaccessorycanbeaddedtoyourtnessmachinethatwillholdadditionalmediaabovetheConsole.The
optional Media Rack easily attaches to your machine, adding more space for media and devices.
To order the optional Media Rack, contact Customer Service (if in US/Canada) or your local distributor (if outside
US/Canada).