Bowflex BXT116 User manual

8016496.051518.B
8016495.051518.B
Service Manual
Table of Contents
Nautilus, Inc., www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. www.nautilusinternational.com | Printed in China | © 2017 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.
Bowflex®BXT116
Service Manual
Section Code Section Page Number Section Code Section Page Number
1 Important Safety Instructions 2
1 Safety Warning Labels and Serial Number 3
 1 Specications 4
1 Grounding Instructions 5
1 Emergency Stop Procedure 5
1 Moving and Storing the Machine 6
1 Unfolding the Machine 8
1 Leveling the Machine 9
1 Treadmill Belt (break in period) 9
1 Connectivity 10
1 Maintenance 11
1 Cleaning 11
1 Adjusting the Belt Tension 12
1 Aligning the Walking Belt 12
1 Lubricating the Walking Belt 13
1 Heart Rate Chest Strap Battery Replacement 14
1 Maintenance Parts 15
1 Troubleshooting 17
1 Machine Settings Mode 29
1 Engineering Mode 30
1 Electrical Wiring Diagram 31
1 Demonstration Mode 32
1 Replacement Procedure Skill Level 32
 Mechanical/ModicationProcedures
2 Demonstration Mode 33
3 Adjust the Deck Release Assembly 34
4 Adjust the Walking Belt 38
5 Correct the Clunking Noise 40
Part Replacement
6 Replace the Bottom Motor Cover 45
7 Replace the Circuit Breaker 49
8 Replace the Console Assembly 53
9 Replace the Deck Release Assembly 56
10 Replace the Deck Suspension 62
11 Replace the Deck Wheel 66
12 Replace the Drive Belt 70
13 Replace the Front Roller 75
14 Replace the Incline Motor Assembly 81
15 Replace the Lift Shock Assembly 87
16 Replace the Lower I/O Cable 91
17 Replace the Lower Side Rail 99
18 Replace the Middle I/O Cable 103
19 Replace the Motor 108
20 Replace the Motor Control Board (MCB) 115
21 Replace the Motor Control Board Cover 120
22 Replace the Motor Cover 123
23 Replace the Motor Mount 126
24 Replace the Power Inlet 131
25 Replace the Rear Roller 135
26 Replace the Rear Roller Cover 140
27 Replace the Right Upright 143
28 Replace the Rocker Switch (On/Off) 147
29 Replace the Side Rail 151
30 Replace the Speed Sensor Assembly 155
31 Replace the Transport Wheel 160
32 Replace the Walking Belt 163
33 Service or Replace the Walking Deck 173

2
8016497.051518.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 and wait 5 minutes 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 necessary, request replacement warning stickers or placards from Nautilus customer service.
• 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.
NOTICE: This document provides important safety instructions, adjustments, and general troubleshooting information for the maintenance of the Bowex®BXT116 Tread-
mill.
If you need assistance, please call Nautilus Customer Service at 1-800-605-3369.
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., www.NautilusInc.com - Customer Service: North America [phone], [email protected] | outside U.S. www.nautilusinternational.com | Printed in China | © 2017 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,BowexResultsSeries,andBowexConnectaretrademarksownedbyorlicensedto
Nautilus, Inc. Polar®, OwnCode®, iTunes®, GoogleTM, MyFitnessPal®, Under Armour, WD-40®, and Lube-N-Walk®are trademarks of their respective owners. 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.
Important Safety Instructions and General Troubleshooting
Information for the
Bowflex®BXT116 Treadmill

3
SAFETY WARNING LABELS AND SERIAL NUMBER
CAUTION
RiskofInjurytoPersons-ToAvoidinjury,useextremecaution
when stepping onto or off of a moving belt. Read instruction
manual before using.
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375lbs(170kg.)
• This machine is for home use only.
•Consultaphysicianpriortousinganyexerciseequipment.
Serial Number and
ProductSpecication
WARNING!
- Moving parts can crush and cut.
- Keep guards in place.
- Lock out power before servicing.
WARNING!
HAZARDOUS VOLTAGE.
- Contact may cause electrical shock or burn.
- Turn off and lock out power before servicing.
REVISIONS
ECO REVISION REV DESCRIPTION APPROVED DATE
TITLE.
PART NO.
REV.
SHEET 1 OF 1 SCALE: 1:1
DO NOT SCALE DRAWING
1. ALL ITEMS MUST BE RoHS COMPLIANT
2. ALL DIMENSIONS APPLY BEFORE PLATING OR COATING.
3. REMOVE ALL BURRS, BREAK SHARP EDGES 0.5 MM MAX.
4. ALL MACHINES SURFACES Ra 3.2 uM.
5. ALL APPLICABLE NAUTILUS STANDARDS AND
SPECIFICATIONS APPLY.
6. ALL DIMENSIONS ARE IN MILLIMETERS
7. ALL DUAL DIMENSIONS ARE IN INCH
UNLESS OTHERWISE SPECIFIED:
METRIC
THIRD ANGLE
PROJECTION
INTERPRET DIMENSIONS AND TOLERANCES
PER ASME Y14.5M - 1994
2.5
1.5
0.75
0.25
1°
X.
X.X
X.XX
X.XXX
ANGULAR
C
SIZE
This document is the property of Nautilus, Inc. It may not be reproduced in whole or part, provided to third parties, or used for any purposes other than the performance of work for Nautilus, Inc. without written authorization. All rights are reserved, including copyrights.
TOLERANCES.
DRAWN
DESIGNED
DATE
METRIC_C_REV G
NAUTILUS, INC.
16400 SE NAUTILUS DRIVE, VANCOUVER, WA 98683
LIFECYCLE
- -
APPROVALS
- -
- - - -
WARRANTY ITEM:
D.LOVELY
08 /13 / 2009
D.LOVELY
B
002-2353
TC PULL IN WARNING
MATERIAL.
COLOR.
DIE LINE
PMS 152
PMS 109
BLACK
WHITE
Labels must be created from an agency approved tamper proof labeling system
such as "UL Recognized component marking and labeling system (example: UL PGGU2) or equivalent.
Label and adhesive must be rated for surface it is applied to (painted metal or ABS plastic),
Label and adhesive must be rated for 60 degrees C minimum. Labels must meet UL 1647 Permanence of Marking Test.
A DRAWING RELEASE
B CHANGED SIZE 8/17/0912745
12247 DLOVELY
DLOVELY
120mm
30.5mm
-Moving parts can crush and
cut.
-Keep guards in place.
-Lock out power before
servicing.
REVISIONS
ECO REVISION REV DESCRIPTION APPROVED DATE
TITLE.
PART NO.
REV.
SHEET 1 OF 1 SCALE: 1:1
DO NOT SCALE DRAWING
1. ALL ITEMS MUST BE RoHS COMPLIANT
2. ALL DIMENSIONS APPLY BEFORE PLATING OR COATING.
3. REMOVE ALL BURRS, BREAK SHARP EDGES 0.5 MM MAX.
4. ALL MACHINES SURFACES Ra 3.2 uM.
5. ALL APPLICABLE NAUTILUS STANDARDS AND
SPECIFICATIONS APPLY.
6. ALL DIMENSIONS ARE IN MILLIMETERS
7. ALL DUAL DIMENSIONS ARE IN INCH
UNLESS OTHERWISE SPECIFIED:
METRIC
THIRD ANGLE
PROJECTION
INTERPRET DIMENSIONS AND TOLERANCES
PER ASME Y14.5M - 1994
2.5
1.5
0.75
0.25
1°
X.
X.X
X.XX
X.XXX
ANGULAR
C
SIZE
This document is the property of Nautilus, Inc. It may not be reproduced in whole or part, provided to third parties, or used for any purposes other than the performance of work for Nautilus, Inc. without written authorization. All rights are reserved, including copyrights.
TOLERANCES.
DRAWN
DESIGNED
DATE
METRIC_C_REV G
NAUTILUS, INC.
16400 SE NAUTILUS DRIVE, VANCOUVER, WA 98683
LIFECYCLE
- -
APPROVALS
- -
- - - -
WARRANTY ITEM:
D.LOVELY
08 /17 / 2009
D.LOVELY
B
002-2354
TC SHOCK WARNING
MATERIAL.
COLOR.
DIE LINE
PMS 152
PMS 109
BLACK
WHITE
Labels must be created from an agency approved tamper proof labeling system
such as "UL Recognized component marking and labeling system (example: UL PGGU2) or equivalent.
Label and adhesive must be rated for surface it is applied to (painted metal or ABS plastic),
Label and adhesive must be rated for 60 degrees C minimum. Labels must meet UL 1647 Permanence of Marking Test.
72mm
30.5mm
A DRAWING RELEASE
B CHANGED SIZE 8/17/0912745
12247 DLOVELY
DLOVELY

4
SPECIFICATIONS
Maximum User Weight: 375 lbs. (170 kg)
Maximum Inclined Deck Height: 16 inches (40.6 cm)
Machine Weight:   approx.280lbs(127kg)
Power Requirements:
Operational Voltage: 120V AC @60Hz
Operating Current: 15 A
Heart Rate Chest Strap: 1 CR2032 battery
This product, its packaging, and components contain chemicals
known to the State of California to cause cancer, birth defects, or
reproductive harm. This Notice is provided in accordance with
California’s Proposition 65. If you would like additional information,
please refer to our web site at www.nautilus.com/prop65.
55.2”
(140.1 cm)
36.3”
(92.3 cm)
84.6”
(214.8 cm)
67”
(170.2 cm)
52.5”
(133.4 cm)

5
Safety Warning Labels and Serial Number
Metal Screw
Tab for Grounding
Screw
Adapter
Grounded
OutletBox
Grounded
Outlet
Grounding Pin
Emergency Stop Procedure
The Treadmill machine is equipped with a Safety Key that can prevent serious injury, as well as prevent children from playing with and/or being
injured on the machine. If the Safety Key is not correctly inserted into the Safety Key Port, the belt will not operate.
!Always attach the Safety Key Clip to your clothing during your workout.
When you use the machine, only remove the Safety Key in an emergency. When the key is removed while the machine is in
operation, it will stop quickly, which could cause the loss of balance and possible injury.
For safe storage of the machine, and to prevent unsupervised operation of the machine, always remove the Safety Key and
disconnect the power cord from the wall outlet and the AC input. Place the power cord in a secure location.
The Console will display “ + SAFETY KEY ”, or add Safety Key, for a Safety Key fault. The Treadmill machine will not start a Workout, or will end and
clear an active Workout, when the Safety Key is removed. Inspect the Safety Key and be sure it is connected to the Console correctly.
Grounding Instructions
This product must be grounded. If it should malfunction or break down, grounding provides a path of least resistance for electric current to reduce
the risk of electric shock. This product is equipped with a cord having an equipment-grounding conductor and a grounding plug. The plug must be
plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.
Improper connection of the equipment-grounding conductor can result in a risk of electric shock. Check with a qualied
electrician or service person if you are in doubt as to whether the product is properly grounded. Do not modify the plug
provided with the product – if it will not t the outlet, have a proper outlet installed by a qualied electrician.
If you connect the machine to an outlet with GFI (ground fault interrupt) or AFI (arc fault interrupt), machine operation can cause the circuit to trip.
This machine is for use on a nominal 120-V circuit, and has a grounding plug that looks like the plug illustrated below. A temporary
adapter that looks like the adapter illustrated may be used to connect this plug to a 2-pole receptacle as shown if a properly
grounded outlet is not available.
Thetemporaryadaptershouldbeusedonlyuntilaproperlygroundedoutletcanbeinstalledbyaqualiedelectrician.Thetabforthegrounding
screwmustbeconnectedtoapermanentgroundsuchasaproperlygroundedoutletboxcover.Whenevertheadapterisused,itmustbeheldin
place by a metal screw.

6
Moving and Storing the Machine
The machine can be moved by one or more persons. Use caution when you move the machine. The treadmill is heavy and can be
awkward. Make sure that your own physical strength is capable of moving the machine. Use a second person if necessary.
1. Before the machine can be moved, inspect the Walking Deck to be sure the Incline setting is at “0”. If necessary, adjust the Incline setting to “0”.
Be sure the area below the machine is clear before adjusting the incline of the Deck. Fully lower the incline of the Deck after each
workout.
2. Remove the Safety Key and place it in a secure location.
When this machine is not in operation, remove the Safety Key and keep out of the reach of children.
3. Make sure that the power switch is turned Off, and the power cord is disconnected.
4. You must fold the treadmill before you move it. Never move the treadmill if it is not folded.
Never move the machine with the Walking Deck not folded. Rotating or moving parts can pinch, resulting in personal injury.
5. Make sure that there is safe clearance around, on and above your treadmill. Make sure there is no object to spill or cause blockage from the fully
folded position.
Be sure there is adequate height clearance for the raised deck.
6. With your right hand, push and hold down the Walking Deck Release Button. Using the lifting handle found below the rear of the walking belt, lift
the walking deck fully upward and engage the hydraulic lift. The Walking Deck Release Button can be released when the walking deck has moved
about 10 inches (25.4 cm). Be sure that the hydraulic lift is correctly locked in place.

7
Use proper safety precautions and lifting techniques. Bend your knees and elbows, keep your back straight and pull up equally with
both arms. Straighten your legs to lift. Make sure that your own physical strength is capable of lifting the walking deck until it
engages the locking mechanism. Use a second person if necessary.
Do not use the walking belt or rear roller to lift the treadmill. These parts do not lock in place and can abruptly move. Injury to you
or damage to the machine can occur.
7. Make sure that the locking mechanism is engaged. Carefully pull back on the walking deck and make sure that it does not move. When you do
this, keep clear of movement path in case the treadmill lock is not properly engaged.
Do not lean against the treadmill when it is folded. Do not put items on it that could cause it to become unstable or fall.
Do not connect the power cord or try to operate the treadmill in the folded position.
8. Carefully tilt the base frame of the folded treadmill a small distance back on the transport wheels while grasping the front support bar.
Do not use the Console, handlebars, or lifted walking deck to lift or move the treadmill. Damage to the treadmill can occur.
Keep clear of the movement path of the lifted walking deck.
9. Roll the machine on the transport wheels to its new location.
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 should be used below the machine to prevent the release of static electricity and protect your ooring.
Do not put objects in the path of the walking deck when lowered.
NOTICE: Move the machine carefully so that it does not hit other objects. This can damage the Console operation.
10. Prior to use, refer to the “Unfolding the Machine” procedure in this manual.

8
Unfolding the Machine
1.Makesurethereissufcientspacetolowerthewalkingdeck.
Keep a minimum clearance behind the machine of 79” (2 m) and 24” (0.6 m) on each side. This is the recommended safe distance
for access, movement and emergency dismounts from the machine.
Place the machine on a clean, hard, level surface, free from unwanted material or other objects that may hamper your ability to
move freely with a sufcient clear workout area. A rubber mat below the machine is recommended to prevent electrostatic dis-
charge and protect your oor.
Be sure that the workout space you are utilizing has adequate height clearance, taking into consideration the height of the user and
the maximum incline of the deck.
2. Make sure there is no object on or around the treadmill to spill or cause blockage from the fully unfolded position.
3. Slightly push the walking deck toward the console. With your right hand, push and hold down the Walking Deck Release Button and pull the walk-
ing deck away from the console. Once the end of the walking deck has moved about 10 inches (25.4 cm), release the button and move to the side of
the machine. Continue to pull the walking deck.
Keep clear of the movement path of the walking deck.
4.Thehydraulicliftissetuptodroplightly.Holdontothewalkingdeckuntilapproximately2/3ofthemovementdown.Makesurethatyouuse
proper lifting technique; bend your knees and keep your back straight. Lower the weight with your legs. The walking deck can possibly drop quickly
in the last part of the movement.

9
Leveling the Machine
The machine needs to be leveled if your workout area is uneven. To adjust:
1. Place the machine in your workout area.
2.Adjustthelevelersuntiltheyallcontact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. Adjust until the machine is level.
Makesurethemachineislevelandstablebeforeyouexercise.
Treadmill Belt
Your treadmill comes equipped with a durable, high quality walking belt designed to provide many hours of reliable service. The walking belt on a
treadmillthathasnotbeenoperatedforalengthoftime,eitherinfactorypackagingorafterassembly,canexhibita“thumping”noisewhenstarted.
This is due to the belt taking on the curve of the front and rear rollers. This is a common occurrence and does not indicate a problem with your ma-
chine. After the treadmill has been used for a short period of time the thumping noise will discontinue. The amount of time will vary depending on the
temperature and humidity of the environment where the treadmill is placed.

10
Bluetooth®Connectivity with the “Bowflex Results Series™” Fitness App
ThistnessmachineisequippedwithBluetooth®connectivityandcanwirelesslysyncwiththe“BowexResultsSeries™”FitnessApponsupported
devices.TheSoftwareAppsyncswithyourtnessmachinetotracktotalcaloriesburned,time,distance,andmore.Itrecordsandstoresevery
workout for quick reference. Plus, it automatically syncs your workout data with MyFitnessPal®, and Under Armour®Connected Fitness to make
hitting your daily calorie goal easier than ever! Track your results and share with friends and family.
1. DownloadthefreeSoftwareApp,namedBowexResultsSeries™.ThesoftwareappisavailableoniTunes®andGooglePlay™.
Note: For a complete list of supported devices, review the software app on iTunes®orGooglePlay™.
2. FollowtheinstructionsontheSoftwareApptosyncyourdevicetoyourexercisemachine.
3. To sync your workout data with MyFitnessPal®or Under Armour®Connected Fitness, click on the desired program and login with your
information.
Note: The “BowexResultsSeries™”FitnessAppwillautomaticallysyncyourworkoutsaftertheinitialsyncing.
USB Charging
If a USB Device is attached to the USB Port, the Port will attempt to charge the Device. The power supplied from the USB Port may not be enough to
operate the Device and charge it at the same time.
CONNECTIVITY