Service Bulletin. Premature Drive Belt Wear

Transcription

1 Premature Drive Belt Wear Applies to: E-TRx Tools Required Washers 120 grit sand paper Adjustable Wrench ¼ Hex key 4mm Hex key Steel Square 12 Steel Square 90 degree Symptom Drive belt is damaged (Fig. 1) or is tracking off the pulley. Latest Rev. Fig. 1 Page 1

2 Drive Belt Replacement Chart Please follow chart below to see if the drive belt (Part# ) would need to be replaced or not. Good, minimal wear on the belt Good, some wear Recommend belt replacement Recommend belt replacement immediately Page 2

3 Possible Cause 1. The idler pulley is not centered with the drive belt 2. The idler pulley has a sharp edge (Fig. 2) that is damaging the pulley. 3. The idler pulley arm is not straight and/or the hole for the bolt on the idler arm is oversized. 4. Drive motor pulley is not aligned with the head roller pulley Fig. 2 Resolution 1. Remove the shrouds (both top and back). 2. Release the tension on the idler pulley by pulling and turning the key Be careful when pulling and releasing the key (Fig. 3). The spring may pull the key out of your hands. Gently release the spring to pull the key into the frame (Fig. 3). Fig. 4 and Fig. 5 show the picture of the key after loosened. Fig. 3 Page 3

4 Fig. 4 Fig. 5 Aligning the Pulley Once the tension on the pulley is released, remove the nut on the idler shaft by using a hex key to stabilize the screw and turn wrench toward the opposite direction to extract the idler bracket. (Fig. 6). Fig. 6 Page 4

5 Take the drive belt off of the motor pulley and insert the steel square to the head roller pulley and run it to the idler tensioner pulley as shown in Fig 7. Make sure the poly-v spacing is even between the belt and steel square as it tracks around all of the pulleys, a closer look is shown in Fig 8 and Fig 9. This will ensure parallelism of the head roller and drive motor shafts, if not adjustments will need to be made. Fig 7 Fig 8 Page 5

6 Fig 9 If the drive motor is mounted askew, to re-align it loosen the four mount lock-nuts with a 5/16 wrench (Fig 10 and 11) and the alignment fixture in place. Once aligned tighten the lock-nuts to 48 ft lb. Fig 10 Fig 11 Page 6

7 If the motor pulley is not in aligned (in or out Fig 12) with the idler pulley and head roller, then the motor pulley will need to be moved in or out to correct this issue. Use the 4mm hex key to loosen the motor pulley set screws, and make the adjustment (Fig 13). Tighten set screws to 4 ft lb. Fig 12 Fig 13 If the idler is not straight or the hole is oversized, the idler pulley will travel to one side and fall off of the drive belt (Fig. 14). Should this happen, replace the idler pulley assembly (PN: KT). Page 7

8 Fig 14 If the idler is straight and the hole is not oversized, the idler pulley may travel towards (and even scrape) the flywheel or the frame but will not fall off the drive belt (Fig. 15). Page 8

9 Fig 15 Take the washers and the idler arm off the shroud. Remove the left washer and place it on the right side (where the nut is located). This will make it a total of two washers on the right side (Fig. 16) and should center the idler pulley on the drive belt. Install and tighten the nut. Fig. 16 Page 9

10 Once the tension on the pulley has been released, remove the cotter pin from the idler pulley shaft (Fig. 17) then pull the pulley shaft out (Fig. 18). Fig. 17 Fig. 18 Feel the edges of the pulley with your finger. If they feel sharp, use 120 grit sand paper to sand down the edges (Fig. 19). The edges should be rounded. Fig. 19 Before After Page 10

11 After performing these steps, apply tension to the pulley by tightening up the key and assemble the shroud back to its original form. To verify if the idler pulley arm is straight and/or to ensure the hole for the idler pulley arm is not oversized, perform the following test. Note: This is for testing purposes only. The belt should not be pushed in reverse as any part of an exercise routine. With the treadmill turned off, push the running belt in reverse for the full length of the deck (Fig. 20). Fig. 20 Page 11