Bowflex Revolution Service manual

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Bowflex Revolution Service manual | Manualzz

P/N: 000-6911 Rev A (04/2007)

The Bowflex Revolution

®

,

Revolution

®

XP, and Revolution

®

FT

Home Gym

Service Manual

Table of Contents

Specifications / Approvals ............................... 3

Revolution Models ............................................ 4

Preventative Maintenance ............................... 5

Untangle Derailed Rope ................................... 6

Adjust Rope Tension ....................................... 15

Replace Cam Assembly .................................. 15

Replace Rope .................................................. 22

Specifications

Product Specifications

Product Weight Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Shipping Weight

Product Dimensions

Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Workout Area Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Number of Exercises

SpiralFlex ® Resistance

SpiralFlex ®

Upgradability

User Weight Limit

Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

Revolution®

Revolution® FT

Revolution® XP

XP with Lat Tower

336.2 lbs. (152.5 kg)

234.3 lbs. (106.1kg)

291.2 lbs. (131.4kg)

319.9 lbs. (144.4kg)

414.46 lbs (188.1kg)

253.9 lbs. (115.1kg)

316.6 lbs. (143.5kg)

350.8 lbs. (159kg)

112”L x 63” W x 73”H (284cm x 160cm x 185cm)

64.5” L x 37.8” W x 73” H (163.8cm x 98cm x 185.4cm)

64.5” L x 37.8” W x 73” H (163.8cm x 98cm x 185.4cm)

64.5” L x 37.8” W x 83.2” H (163.8cm x 98cm x 211.3cm)

112” x 63” (284cm x 160cm)

84” x 64” (213.4cm x 162.6cm)

84” x 64” (213.4cm x 162.6cm)

84” x 64” (213.4cm x 162.6cm)

220 lbs (99.8 kg)

200 lbs (90.7 kg)

200 lbs (90.7 kg)

200 lbs (90.7 kg)

300 lbs. (136 kg)

280 lbs (127 kg)

280 lbs (127 kg)

280 lbs (127 kg)

90+

80+

90+

90+

300 lbs (136 kg)

300 lbs (136 kg)

300 lbs (136 kg)

300 lbs (136 kg)

Bowflex Revolution ™ Service Manual

3

Revolution Models

4

Revolution ®

Revolution ® FT Revolution ® XP

Preventative Maintenance

Daily

Wipe down with a damp cloth. Pay special attention to areas where perspiration

could settle.

Monthly

Inspect the unit for loose parts, nuts, bolts, etc.. Inspect ropes and straps for

fraying or excessive wear.

Yearly

Remove the Top Cover and inspect the condition of the internal components.

look for fraying or excessive wear on straps, ropes, and moving parts and

replace as necessary.

Note:

Before adding or removing resistance packs, spray a light coating

of silicone lube on the shaft. This will allow the packs to slide easily

on and off the shaft.

Bowflex Revolution ™ Service Manual

5

Maintenance Procedures

Untangle Derailed Rope

Tools needed:

• 1/8” Allen Wrench • 6” Phillips Screwdriver • 7/32” Allen Wrench

Note: All instructions in this bulletin are given with the orientation of standing facing the engine with the bench behind you.

Instructions:

Before beginning this procedure, remove all resistance packs except for the attached pre-stretch pack.

Step 1: Remove Top Cover

1-1 Use a 1/8” allen wrench to remove the four allen bolts that secure the Top Cover. See

Figure 1. Set bolts aside for Step 14.

1-2 Remove Top Cover and set aside.

Top Cover

Pre-stretch

Pack

6

Figure 1

Step 2: Remove Shroud Clip.

2-1 If there is a Clip securing the shrouds under top inside, remove the Clip. (The clip may already have been removed after shipping.)

See Figure 2. Set Clip aside for Step 11.

If Clip is not present, go to Step 3.

Figure 2

Clip

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 3: Remove Tension Adjust Knob Cap

3-1 Use a phillips head screwdriver to remove the screw securing Tension Adjust Knob Cap (Figure

3a) and set aside for Step 13.

3-2 Once the Screw is removed, use the screwdiver to gently pry the cap out of the knob (Figure 3b).

Tension Adust Knob

Tension Adust

Knob Cap

Figure 3a

Step 4: Remove Tension Adjust Knob.

4-1 Use a phillips head screwdriver to remove the four screws securing the Tension Adust Knob.

See Figure 4. Set screws aside for Step 12.

4-2 Remove the Tension Adjust Knob and set aside.

Figure 3b

Tension Adust Knob

Figure 4

Bowflex Revolution ™ Service Manual

7

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 5: Remove Shroud

5-1 Use a phillips head screwdriver to remove the five screws securing the shroud (one longer screw and four shorter screws). Set screws safely aside for Step 10.

5-2 Remove the Shroud and set aside. See Figure 5.

Figure 5

Shroud

Step 6: Remove Lower Spool

6-1 Use a 7/32” allen wrench to remove the bolt securing the Lower Spool. See Figure 6a.

Set bolt aside for Step 9.

6-2 Remove the Spool (Figure 6a), unwrap the Strap (Figure 6b), and hook the Spool behind the frame (Figure 6c) to keep it out of your way.

8

Figure 6a

Lower Spool

Figure 6b Figure 6c

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 7: Remove Large Pulley.

7-1 Slide the Large Pulley (Figure 7a) and tangled Rope (Figure 7b) off of the axle.

Large Pulley

Tangled Rope

Figure 7a

Figure 7b

Bowflex Revolution ™ Service Manual

9

10

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 8: Re-wrap Rope

8-1 Begin to re-wrap the rope in the outer most channel on the Large Pulley (Figure 8a).

8-2 Slide the Large Pulley back onto the axle and finish wrapping the Rope by turning the

Large Pulley in a clockwise direction.

NOTE: Do not let go of the Large Pulley. (See Figure 8b.) Keep tension on the Rope to make sure it stays in the channel while performing the next step.

Figure 8a

Large Pulley

Figure 8b

Hold Pulley in place

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 9: Replace Lower Spool.

9-1 While still holding the Large Pulley in place, coil the Strap around the Spool in a counter clockwise dirction. (See Figure 9a).

9-2 Slide the Spool back onto the axle (Figure 9b) and secure the Lower Spool with allen bolt

(Figure 9c).

Strap

Figure 9a

Lower Spool

Figure 9b Figure 9c

Bowflex Revolution ™ Service Manual

11

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 10: Replace Shroud.

10-1 Make sure that the right Rope (Figure 10a) passes above the flat guide to the upper right side of the Pulley.

10-2 Replace the Shroud (Figure 10b) making sure the left Rope passes between the guides on the inside of the Shroud (Figure 10c) and beneath the “fender” on the left side of the Pulley (see

Figure 10a).

10-3 Secure the Shroud with five phillips head screws (one longer screw and four shorter screws) from Step 5. Note the location for the long screw in Figure 10d.

Right Rope

Right Guide

Strap

Fender

Figure 10a - Right rope and rope guide

(pulley not shown)

Left Rope

Guides

Figure 10b

Left Shroud

12

Figure 10c - Left rope and rope guides Figure 10d - Location of long screw to secure shroud

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 11: Replace Shroud Clip

11-1 Replace the Clip securing the shrouds under top inside. See Figure 11.

If there is no Clip, go to Step 12.

Figure 11

Step 12: Replace Tension Adjust Knob

12-1 Use a phillips head screwdriver and four screws to secure the Tension Adjust Knob.

See Figure 12.

Clip

Figure 12

Step 13: Replace Tension Adjust Knob Cap

13-1 Use a phillips head screwdriver and one screw to secure the Tension Adjust Knob

Cap. See Figure 13.

Figure 13

Bowflex Revolution ™ Service Manual

13

Maintenance Procedures

Untangle Derailed Rope (continued)

Step 14: Replace Top Cover

14-1 Use a 1/8” allen wrench and four allen bolts rom step 1 to secure the Top Cover.

See Figure 14.

Step 15: Adjust Rope Tension

15-1 Pull out Tension Adjust Knob and rotate

Large Pulley in a clockwise direction until it stops, then release the Tension Adjust

Knob to lock. See Figure 15.

Figure 14

Large Pulley Tension Adjust Knob

14

Step 16: Final Check

Please inspect your machine to ensure that all fasteners are tight and everything is properly assembled.

Figure 15

Maintenance Procedures

Adjust Rope Tension

Large Pulley

Pull out Tension Adjust Knob and rotate Large Pulley

in a clockwise direction until it stops then release the

Tension Adjust Knob to lock.

Tension Adjust Knob

Replace Cam Assembly

1. Remove Top Cover.

1-1. Use a 1/8” allen wrench to remove the four allen bolts that

secure the Top Cover.

1-2. Remove Top Cover and set aside.

2. Remove Shroud Clip.

2-1. Remove the Clip securing the shrounds under

top inside.

Bowflex Revolution ™ Service Manual

15

Maintenance Procedures

Replace Cam Assembly (continued)

3. Remove Tension Adjust Knob Cap.

3-1. Use a phillips head screwdriver to remove the screw securing Tension Adjust Knob Cap.

(Figure A)

3-2. Once the Screw is removed, use the screwdiver to gently pry the cap out of the knob.

(Figure B)

16

Tension Adust Knob

Tension Adust Knob Cap

Figure A

4. Remove Tension Adjust Knob.

4-1. Use a phillips head screwdriver to remove

the four screws securing the Tension Adust

Knob.

4-2. Remove the Tension Adjust Knob and set aside.

Tension Adust Knob

Figure B

Maintenance Procedures

Replace Cam Assembly (continued)

5. Remove Shroud.

5-1. Use a phillips head screwdriver to remove

the five screws securing the shroud

5-2. Remove the Shroud and set aside.

6. Remove Tension Shaft From Cam Assembly.

6-1. Use a 7/32”allen wrench to loosen the eight bolts

on the Tension Shaft Holder. ( Figure A)

6-2. Pull the Tension Shaft through ( Figure B ) until it

clears the Cam Assembly ( Figure C ) being replaced.

Tension Shaft Cam Assembly

Shroud

Tension Shaft Holder

Figure A

Figure B Figure C

Bowflex Revolution ™ Service Manual

17

Maintenance Procedures

Replace Cam Assembly (continued)

7. Remove Pre-Tension Pack.

7-1. Use a 3/32”allen wrench to remove the six allen bolts

from the Pre-Tension Pack. ( Figure A )

7-2. Remove the Pre-Tension Pack. ( Figure B )

Cam Assembly

Pre-Tension Pack

Figure A

8. Remove Lock Collar From Cam.

8-1. Use a flat head screwdriver to pry up the bottom

tab on the Lock Collar. ( Figure A / Detail A )

8-2. Remove the Lock Collar from Cam. ( Figure B )

Cam

Detail A

Figure B

Lock Collar

Figure B

18

Figure A

Maintenance Procedures

Replace Cam Assembly (continued)

9. Remove Cam.

9-1. Remove Cam from Cam Axle.

10. Remove Lower Spool.

10-1. Use a 7/32” allen wrench to remove the bolt securing

the Lower Spool.

10-2. Remove the Lower Spool.

Bowflex Revolution ™ Service Manual

19

20

Maintenance Procedures

Replace Cam Assembly (continued)

11. Install New Cam Assembly.

Reverse the disassembly procedure to install the new Cam Assembly with the

following notes.

1.When replacing the Lower Spool, make sure to wind the strap counter clockwise. ( Figure A )

Lower Spool

Figure A

2.When sliding the Tension Shaft back into position, slowly slide the shaft through until it clicks

into place. If you do not feel or hear a distinct click, make sure the shaft is centered by measuring

the amount of exposed shaft on each side of the main unit.

Maintenance Procedures

Replace Cam Assembly (continued)

2.When tightening the Tension Shaft Holder, tighten the screws in numerical

order shown on the tensioner. Tighten the two screws marked 1 then the

two marked 2 and so on.

Tension Screws

Tighten screws in order

1&1, 2&2, 3&3, then 4&4.

Tension Shaft Holder

Bowflex Revolution ™ Service Manual

21

22

Maintenance Procedures

Replace Rope

1. Follow Steps 1-5 of Replace Cam Assembly to Remove Shroud.

2. Remove Lower Spool

2-1. Use a 7/32” allen wrench to remove the bolt securing the Lower Spool.

2-2. Remove the Spool,(Figure A) unwrap the Strap (Figure B) and hook the Spool behind the frame

(Figure C) to keep it out of your way.

Lower Spool

Figure A

3. Remove Large Pulley.

3-1. Slide the Large Pulley off of the axle.

Figure B Figure C

Large Pulley

Maintenance Procedures

Replace Rope (continued)

4. Remove Rope From Pulley.

9-1. Remove Cam from Cam Axle.

5. Remove Old Rope.

5-1. Raise the Arm to fully upright position.

5-2. Tie a piece of string (about 6 feet long) to the end

of the old Rope. ( Figure A )

5-3. Gently pull the old Rope through the Arm and and

over the Upper Pulley leaving the string theaded

through the arm. ( Figure B )

Note: Do not pull the string through the arm. Leave enough

string exiting at the Lower Pulley to pull the new Rope

back through.

Arm

Upper Pulley

Rope

Rope

String

Figure A

Lower Pulley

Figure B

Bowflex Revolution ™ Service Manual

23

Maintenance Procedures

Replace Rope (continued)

6. Route New Rope.

6-1. Untie the old Rope from the string at the Upper Pulley and

tie the string to the new Rope.

6-2. Thread the new Rope through the Arm by gently pulling

the string from the Lower Pulley.

Rope

Lower Pulley

String

7. Clamp Rope In Large Pulley.

7-1. Feed the Rope through the hole in the Large Pulley and

clamp in place.

Note: To be sure Rope is securely clamped, leave about 1/4”

showing on the inside of the clamp.

24

8. Reverse Steps 3,2, and 1 to reassemble..

1/4” of Rope showing

©2005 Nautilus Inc. All rights reserved. 16400 S.E. Nautilus Drive, Vancouver, Washington, USA 98683.

Bowflex, Bowflex Revolution, Spiraflex, and the Bowflex and Nautilus logos are either registered trademarks or trademarks of Nautilus, Inc.

Bowflex Revolution ™ Service Manual

25

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