Bowflex TREADCLIMBER 1000 User manual

Assembly Manual
®®
Nautilus®Bowflex®Schwinn®Fitness Universal®
Bowflex®TreadClimber®1000, 3000 & 5000
001-7142.021411.D
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http://www.bowflex.com
Nautilus, Inc., (800) NAUTILUS / [phone], www.NautilusInc.com - Customer Service: North America [phone], tcinquiries@
nautilus.com | outside U.S. +01-360-859-5180, [email protected] | Printed in China | © 2007 Nautilus, Inc., All rights reserved.
™ and ® indicate a trademark or registered trademark. Nautilus, Inc. (www.NautilusInc.com) trademarks include NAUTILUS®,
BOWFLEX®, SCHWINN® and UNIVERSAL® and respective logos. Other trademarks are the property of their respective owners.

Table of Contents
Important Safety Instructions.........................................................................................................................................1
Product Specifications....................................................................................................................................................2
Before You Assemble.......................................................................................................................................................3
Basic Assembly Principles................................................................................................................................3
Select Your Workout Area.................................................................................................................................3
Machine Mat .......................................................................................................................................................3
Parts....................................................................................................................................................................................4
Hardware ...........................................................................................................................................................................6
Assembly............................................................................................................................................................................7
Put the Treadles on the Base............................................................................................................................7
Connect the Speed and Step Sensor Wires ..................................................................................................8
Lock the Treadles................................................................................................................................................9
Attach the Drive Belt..........................................................................................................................................9
Attach the Uprights ..........................................................................................................................................10
Attach the Upright Junction Covers..............................................................................................................11
Attach the Console/Handlebar Assembly ....................................................................................................12
Attach the Cosmetic Plugs..............................................................................................................................13
Attach the Hydraulic Cylinders ......................................................................................................................13
Inspect the Assembly ......................................................................................................................................14
Attach the Frame Covers.................................................................................................................................14
Attach the Rear Cover......................................................................................................................................15
Attach the Drive Covers ..................................................................................................................................15
Attach the Side Foot Support Platforms........................................................................................................16
Apply Decals .....................................................................................................................................................16
Final Inspection ................................................................................................................................................17
Attach the Power Cord ....................................................................................................................................17
Speed Sensor Verification (TC1000 only)..................................................................................................... 18
Calibration (TC3000 & TC5000)........................................................................................................................19
If Calibration Fails.............................................................................................................................................20
Explanation of Calibration Display Messages .............................................................................................20
Exploded Views ..............................................................................................................................................................21

Assembly Manual 1
Important Safety Instructions
• Keepbystandersandchildrenawayfromtheproductyouareassemblingatalltimes.
• Donotconnectpowersupplytothemachineuntilinstructedtodoso.
• Donotassemblethismachineoutdoorsorinawetormoistlocation.
• Makesureassemblyisdoneinanappropriateworkspaceawayfromfoottrafficandexposureto
bystanders.
• 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.
• Setupthismachineonasolid,level,horizontalsurface.
• Donottrytochangethedesignorfunctionalityofthismachine.Thiscouldcompromisethesafetyof
this machine and will void the warranty.
• Ifreplacementpartsarenecessary,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 void the warranty.
• Donotusethemachineuntilthemachinehasbeenfullyassembledandinspectedforcorrect
performance in accordance with the Owner’s Manual.
• ReadandunderstandthecompleteOwner’sManualsuppliedwiththismachinebeforefirstuse.
KeeptheOwner’sandAssemblyManualsforfuturereference.
• Do all assembly steps in the sequence given. Incorrect assembly can lead to injury.
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.
Carefully read and understand the Assembly Manual.
Obey the following warnings:

2Assembly Manual
Product Specifications
TC1000 TC3000 TC5000
Physical Dimensions
Length 46 in. (117 cm)
Width 28.5 in. (72.5 cm)
Height 55.25 in. (140.5 cm)
Assembled Weight 185 lbs. (84 kg)
Shipping Weight 220 lbs. (100 kg)
System Capacities
Maximum Weight Capacity 300 lbs (136 kg)
Speed
TC1000 0.5 to 3.8 mph (0.8 to 6.1 kmh )
TC3000 and TC5000 0.7 to 4.0 mph (1.1 to 6.4 kmh)
Treadmill Incline 0% grade
Workout Resistance Levels 1 to 12
Warranty Length See the Warranty sheet for full information per machine type.
Component Specifications
Belt 7.75 in. x 38.5 in. (19.5 cm x 98 cm)
Motor 0.5 hp continuous duty
Frame Powder-coated steel
Operational Voltage 95to130VAC50-60Hz
Operational Current 12A Max
Regulatory Approvals Marks
c-ETL-US The standard for Safety for Motor-Operated Massage and Exercise Machines
UL 1647, 3rd Ed. and Motor-Operated Appliances
CAN/CSA-C22.2 No. 68-92

Assembly Manual 3
Basic Assembly Principles
Here are a few basic assembly tips that can make assembly of the Bowflex®TreadClimber®exercise machine quick and
easy.
1. Gather the pieces needed for each step prior to starting the step.
2. Turning towards the right tightens all the bolts and locknuts on your
Bowflex
®
TreadClimber
®
. Turning towards the left,
loosens them.
3. All of the tools needed for assembly of your Bowflex
®
TreadClimber
®
exercise machine have been included. These tools
are only designed for one use. If damaged, substitute any commonly available 9/16” wrench and #2 screwdriver.
Note: A utility knife or scissors is necessary during the unpacking and assembly process
(not included).
Select Your Workout Area
Select where you are going to put your Bowflex
®
TreadClimber
®
exercise machine carefully. The best place for your
TreadClimber
®
machine is on a hard, level surface. You will need at least 20 inches (0.5 meters) on each side and in front
of your TreadClimber
®
machine, and at least 36 inches (0.75 meters) behind it for dismount.
Make sure that the location you choose has a 10A power outlet within reach of the TreadClimber
® machine power cord,
preferably to the right side of the machine where you will be less likely to step on the cord during dismount.
Note: The TreadClimber
® machine is designed to plug into a grounded, non-GFI outlet only. To determine if your outlet
or circuit breaker is GFI, look for a test and reset button on them. If they have the test and reset button, it is a GFI
outlet or circuit breaker.
Further, if you ever perform any repairs on your TreadClimber
® machine that require you to lay it on its side, you will need
at least 60 inches (1.5m) to one side of your workout area.
Machine Mat
The Bowflex®TreadClimber®Machine Mat is an optional accessory for the TreadClimber®machine that helps keep your
workout area free from debris and dust. The rubber machine floor mat provides a non-slip surface when mounting and
dismounting the TreadClimber®machine, limits static discharge when you touch the machine, and greatly reduces the
possibilityofdisplayorrunningerrors.Arubberizedmatwillprotectyourflooringwhenyouareperformingrepairsor
maintenance. Put your Bowflex®TreadClimber®Machine Mat in your selected workout area before beginning assembly to
protect your floors and your TreadClimber®machine from damage.
Before You Assemble

4Assembly Manual
Parts
Box 1 contains:
Qty: 1
Descr: Control Panel/Handlebar Assembly
Qty: 2
Descr: Left and Right Side Foot Support Platform
Qty: 1
Descr: Right Side Plastic Frame Cover
Qty: 1
Descr: Left Side Plastic Frame Cover
Qty: 1
Descr: Left Side Plastic Drive Cover
Qty: 1
Descr: Right Side Plastic Drive Cover
Qty: 2
Descr: Left & Right
Hydraulic
Cylinder
Qty: 1
Descr: Left
Upright
Support
Qty: 1
Descr: Rear Cover
Qty: 2
Descr: Plastic Upright Junction Covers
Qty: 1
Descr: Right
Upright
Support

Assembly Manual 5
Box 1 also contains:
Qty:1 Owner’s Manual Bag
Contains the following:
• TheBowflex®TreadClimber® Assembly Guide and Owner’s
Manual
• (1)DriveBelt
• PowerCord
• (2)TreadleDecals
• (2)DriveCoverDecals
• TreadClimber®SafetyKey*Note:TC1000SafetyKeyplugged
into console for shipping.
• HeartRateMonitorChestStrap(TC5000Only)
• (1)#2PhillipsScrewDriver
Qty:1 Assembly Hardware Bag
Contains the following:
•(1)#2PhillipsScrewdriver
•(2)5/16"x11/2"ButtonHeadScrew
•(1)3/16"HexKey
•(12)5/16"FlatWashersSAE (smaller O.D.)
•(1)5/32"HexKey
•(2)5/16"AcornNut
•(1)9/16"OpenEndWrench
•(6)1/4"x1"FlatHeadScrew
•(2)5/16"FlatWashers
•(4)3/8"CosmeticPlugs
•(14)5/16"x1"ButtonHeadScrew
•(16)#10Phillips
Note: Occasionally extra parts are included.
Parts
Box 2 contains the TreadClimber®treadles
Box 3 contains the TreadClimber®base
Qty: 1
Descr: TreadClimber®Treadle Assembly
Qty: 1
Descr: TreadClimber®Base
Cylinder Stud

6Assembly Manual
Qty: 1
Descr: #2 Phillips Screwdriver
Qty: 1
Descr: 3/16” Hex Key
Qty: 1
Descr: 9/16” Open End Wrench
Qty: 1
Descr: 5/32” Hex Key
Qty: 6
Descr: 1/4” x 1” Flat Head Screw
Qty: 2
Descr: 5/16” x 1 1/2” Button Head Screw
Qty: 16
Descr: #10 Phillips Head Screw
Qty: 14
Descr: 5/16” x 1” Button Head Screw
Qty: 2
Descr: 5/16” Flat Washer
Qty: 12
Descr: 5/16” Flat Washer SAE
Qty: 4
Descr: 3/8” Cosmetic Plugs
Qty: 2
Descr: 5/16” Acorn Nut
Hardware
Tools:
Parts:
Qty: 1
Descr: Drive Belt
Qty: 1
Descr: Safety Key with Clip (Models TC3000 & TC5000 only.)
Hardware:

Assembly Manual 7
Assembly
Figure 1-1
Step 1: Put the Treadles on the Base
Parts:
  • TreadClimber®Base Assembly
  • TreadClimber®Treadle Assembly
Hardware:
  • (4)3/8”X11/4”HexBolts(preassembled)
Note: Hardware is only hand tightened. Finish tightening
the hardware in Step 1-5 below.
Tools:
  • 9/16”OpenEndWrench(included)
  • Scissorsorothercuttingtool
  • Ruler
Note: This step requires two people.
1-1 Unlock the latch lever (see Figure 1-1).
1-2 With assistance, lower the tower treadle assembly onto
base.
1-3 Align roller casting flush to the base (See Figure 1-2)
1-4 Use a ruler to center the treadles between the upright
bases.
1-5 Tighten the (4) 3/8” x 1 1/4” Hex Bolts on the rear roller
casting and base with the 9/16” open end wrench (See
Figure 1-3).
Note: Tighten the outside bolts on the rear roller casting first,
then the inner bolts.
1-6 Cutthetreadleziptielocatedunderneaththetreadles.
Roller casting aligned to lie flush on
base
Figure 1-2
Figure 1-3

8Assembly Manual
Assembly
Figure 2-1
Step 2: Connect the Speed Sensor Wires
Parts:
  • TreadClimber®Base and Treadle assembly from Step 1
2-1 Find the wires labeled ‘Speed Sensor Wire’ and connect
them (see Figure 2-1). The Speed Sensor is located
directly above the Speed Sensor Wire.
Step 3: Connect the Step Sensor Wires
Parts:
  • TreadClimber®Base and Treadle assembly from Step 2
Note: The TC1000 is not equipped with the step sensor function. Tuck
the unused step sensor wire through the hole in frame and
continue to the next step.
3-1 Connect the Step Sensor Wires (See Figure 3-1). Push any
excess wire through holes in frame (See Figure 3-2).
Figure 3-1
Speed Wire
Figure 3-2

Assembly Manual 9
The treadles might unlock during workout if they are not fully engaged.
Assembly
Step 5: Attach the Drive Belt
Parts:
  • TreadClimber®Base and Treadle assembly from Step 4
  • (1)DriveBelt
Tools:
  • 3/16”HexKey(included)
5-1 Position the drive belt over the roller pulley and the motor
pulley (See Figure 5-1).
5-2 Make sure that the belt is installed correctly into the grooves
of the pulleys (See Figure 5-2).
5-3 Remove the motor shipping bolt from the motor pan with
the 3/16” hex key (See Figure 5-3).
Note: Removing the shipping bolt will make the drive belt tight with
spring-loaded tension. Be sure to keep the bolt in a safe place
in case the machine must be disassembled for shipping or part
replacement.
5-4 Put the unit in the upright position.
Figure 5-1
Figure 5-2
Figure 5-3
Figure 4-1
Lever in locked position
Step 4: Lock the Treadles
Parts:
  • TreadClimber®Base and Treadle assembly from Step 3
4-1 Line up the treadles parallel to each other.
4-2 Move the locking lever down and to the left and then up into
the locked position until it clicks (See Figure 4-1).
4-3 From the front of the machine, press down on each treadle
individually until they lock into the down position.

10 Assembly Manual
Assembly
Figure 6-1
Step 6: Attach the Uprights
Parts:
  • TreadClimber® Base and Treadle assembly from Step 5
  • (1)LeftUprightSupport&HydraulicCylinder
  • (1)RightUprightSupport&HydraulicCylinder
Hardware:
  • (2)5/16”x1”ButtonHeadScrews
Tools:
  • 3/16”HexKey
6-1 Install a 5/16” x 1” button head screw halfway into the
outside of the left and right lower upright brackets of the
base assembly (See Figure 6-1).
6-2 Put the left upright on the left upright bracket (see Figure
6-2) so that it rests on the button head screw (Figure 6-3).
The cylinder bracket will be at the top and face the rear of
the machine.
Note: Make sure the decal on the upright support faces outward from
the machine.
6-3 Repeat on the opposite side.
Figure 6-2 - Right upright shown
Figure 6-3

Assembly Manual 11
Assembly
Figure 7-1
Step 7: Attach the Upright Junction Covers
Parts:
  • TreadClimber®Base and Treadle assembly from Step 6
  • (2)PlasticUprightJunctionCovers
7-1 Put the plastic upright junction cover on the top of the left
upright support (See Figure 7-1).
Note: Make sure the plastic upright junction cover extends
to the rear of the machine.
7-2 Repeat on opposite side.

12 Assembly Manual
Assembly
Figure 8-1
Step 8: Attach the Console/
Handlebar Assembly
Parts:
  • TreadClimber®Base and Treadle assembly from Step 7
  • Console/HandlebarAssembly
Hardware:
  • (6)5/16”x1”ButtonHeadScrews
  • (6)5/16”FlatWashersSAE
Tools:
  • 3/16”HexKey(included)
Note: This step requires two people.
8-1 Lift and position the console/handlebar assembly above
the upright supports (See Figure 8-1).
8-2 Put the console/handlebar assembly cable through the
top of the right upright support (See Figure 8-2). Make
sure that the cable extends through the bottom of the right
upright.
8-3 Put both sides of the console/handle bar brackets into the
tops of the upright supports at the same time. Do not crimp
the cable.
8-4 Tighten the hardware with the 3/16” hex key (See Figure
8-3).
8-5 Connect the cable from the upright support to the cable on
the right side of the base upright bracket (See Figure 8-4).
8-6 One person will hold the Console/Handlebar assembly
while the second person removes the 5/16” x 1” button
head screw at the base of the support from each side.
8-7 Lower the upright on to the upright bracket base. Do not crimp
the cables. Drop the upright until flush with the base frame.
8-8 Attach the upright with (6) 5/16” x 1” button head screws
and (6) 5/16” flat washers SAE.
Note: Tighten the front (2) screws first (1 per upright) and then
the (4) side screws, two per outer side of upright (See
Figure 8-5).
Figure 8-2
Figure 8-3
Figure 8-4
Figure 8-5

Assembly Manual 13
Assembly
Figure 10-1
Figure 10-2
Step 10: Attach the Hydraulic Cylinders
Parts:
  • TreadClimber®Base and Treadle assembly from Step 9
Hardware:
  • (2)5/16”x11/2”ButtonHeadScrews
  • (2)5/16”AcornNuts
  • (2)5/16”x1”ButtonHeadScrews(preassembled)
  • (2)5/16”FlatWashers(preassembled)
Tools:
  • 3/16”HexKey(included)
  • 9/16”OpenEndWrench(included)
Note: This step requires two people.
10-1 Attach the hydraulic cylinder to the upright bracket with (1) 5/16”x 1 1/2”
Button Head Screw and (1) 5/16” Acorn Nut (Figure 10-1).
Note: Make sure that the single white arrow, located on the Workout Level
Setting Dials at the top of the hydraulic cylinders, is pointing up and to
the rear of the machine.
10-2 Remove the pre-installed (1) 5/16” x 1” Button Head Screw and (1) 5/16”
Flat Washer from treadle. Lift treadle and slide the lower shock eyelet
onto the treadle stud.
10-3 Attach the hydraulic cylinder with the (1) 5/16” x 1” button head screw
and (1) 5/16” flat washer (Figure 10-2).
10-4 TightenthehardwarewiththeHexKeyandOpenEndWrench.
Figure 9-1
Step 9: Attach the Cosmetic Plugs
Hardware:
  • (4)CosmeticPlugs
9-1 Insert the cosmetic plugs into the holes on the inside of the left
upright support (See Figure 9-1).
9-2 Repeat on opposite side.

14 Assembly Manual
Assembly
Figure 12-1
Figure 12-2
Step 12: Attach the Frame Covers
Parts:
  • TreadClimber®Base and Treadle assembly from Step 11
  • (1)LeftPlasticFrameCover
  • (1)RightPlasticFrameCover
Hardware:
  • (6)#10PhillipsHeadScrews
Tools:
  • #2PhillipsHeadScrewdriver(included)
12-1 Attach the left and right Plastic Frame Covers to the sides
of the base frame with (6) #10 Phillips Head Screws (3 per
side) and the provided #2 Phillips screwdriver (See Figures
12-1 and 12-2).
Step 11: Inspect the Assembly
11-1 Remove the plastic film from the console face.
11-2 Inspect all of the attachments and securely tighten all of
the bolts before proceeding to Step 12.

Assembly Manual 15
Figure 13-1
Figure 13-2
Step 13: Attach the Rear Cover
Parts:
  • TreadClimber®Base and Treadle assembly from Step 12
  • (1)RearCover
Hardware:
• (4)#10PhillipsHeadScrews
Tools:
 • #2PhillipsHeadScrewdriver(included)
13-1 Attach the rear cover to the back of the frame with the (4)
#10 Phillips Head Screws (2 per side) and the provided #2
Phillips Head Screwdriver (See Figure 13-1 and 13-2).
Assembly
Figure 14-1
Step 14: Attach the Drive Covers
Parts:
  • TreadClimber®Base and Treadle assembly from Step 13
  • (1)LeftPlasticDriveCover
  • (1)RightPlasticDriveCover
Hardware:
  • (6)#10PhillipsHeadScrews
Tools:
  • #2PhillipsHeadScrewdriver(included)
14-1 Attach the left and right Plastic Drive Covers to the sides of the
base with (6) #10 Phillips Head Screws (3 per side) and the provided
#2 Phillips screwdriver (See Figures 14-1). Install upper screw first.
Note: Do not tighten hardware until all screws have been installed.

16 Assembly Manual
Illustration 16-A:
TreadClimber®Drive and
Treadle Decals
Treadle decal
1 per side
Drive decal
1 per side
Figure 16-1
Step 16: Apply Decals
Parts:
 • TreadClimber®BaseandTreadleassemblyfromStep15
 • (2)TreadleDecals
 • (2)DriveCoverDecals
Tools:
 • #2PhillipsHeadScrewdriver(included)
16-1 Clean the application surface with a wet cloth and dry
thoroughly with a towel.
16-2 Remove the backing on the decal.
16-3 Center the decal on the appropriate application surfaces
(See Figure 16-1) for locations.
16-4 Rub the decal onto the surface to force out the air bubbles.
Assembly
Figure 15-1
Figure 15-2
Step 15: Attach the Side Foot
Support Platforms
Parts:
  • TreadClimber®Base and Treadle assembly from Step 14
  • (1)LeftFootSupportPlatform
  • (1)RightFootSupportPlatform
Hardware:
  • (6)1/4”x1”FlatHeadScrews
Tools:
  • 5/16”HexKey(included)
15-1 Attach the right and left side foot support platforms to each treadle
with (6) 1/4” x 1” Flat Head Screws (3 per side). (See Figures 15-1
and 15-2.)