8G Brake Assembly Alignment

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Jessie Simmons
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8G Brake Assembly Alignment 8G (9-5250) This document explains how to do the 8G (9-5250) brake assembly alignment in order to eliminate noise in the drive system coming from the mis-aligned brake

1 8G Brake Assembly Alignment 8G (9-5250) This document explains how to do the 8G (9-5250) brake assembly alignment in order to eliminate noise in the drive system coming from the mis-aligned brake plates. Tools Required 1/8 hex key #5 metric hex key 7/16 socket ½ socket Cable snips Phillips screwdriver Small crescent wrench Torque wrench Brake plate alignment tool. Lithium-based grease x3 (not needed if re-doing alignment) x3 (not needed if re-doing alignment) 3 small zip ties Alignment Procedure 1. Remove user left side shroud, be sure to remove the white polymer fastener from the inside, then use a 7/16 socket to remove the transmission-to-frame bracket CORE HEALTH & FITNESS LLC Page 1 of Rev: D

2. Use a 1/8 hex key to loosen the transmission sprocket

Pull the transmission sprocket off of the transmission,

2 2. Use a 1/8 hex key to loosen the transmission sprocket set screws 3. Push up on the idler sprocket to release tension on the chain, then walk the chain off of the idler sprocket 4. Pull the transmission sprocket off of the transmission, be careful not to lose the key for the sprocket CORE HEALTH & FITNESS LLC Page 2 of Rev: D

5. Use a ½ socket to remove the bolt connecting the transmission to

3 5. Use a ½ socket to remove the bolt connecting the transmission to the alternator via the alternator bracket then walk the alternator belt off of the alternator. 6. Cut any zip ties holding the black cable running from the brake to the lower board 7. Remove the two (2) screws securing the clear plastic shield that covers the lower board using a Phillips screwdriver CORE HEALTH & FITNESS LLC Page 3 of Rev: D

8. Unplug the black/white brake cable from the PCB 9.

act as pressure relief for the next step 10.

frame, remove the strap securing the transmission to the frame, then extract the

4 8. Unplug the black/white brake cable from the PCB 9. Wrap a belt or large zip tie around the middle of the transmission shaft and the frame to act as pressure relief for the next step 10. Use a 7/16 socket to remove the four (4) screws that hold in the transmission to the frame, remove the strap securing the transmission to the frame, then extract the brake/transmission assembly from the unit. Take care not to lose the rubber dampening pad located between the transmission and the frame. CORE HEALTH & FITNESS LLC Page 4 of Rev: D

Remove the clutch plate by pulling it off of the splined transmission pulley.

5 11. Using a #5 metric hex key, remove the three (3) screws securing the brake to the transmission bracket 12. Remove the brake 13. Remove the clutch plate by pulling it off of the splined transmission pulley. Be careful that the small o ring located in the clutch plate is not lost. CORE HEALTH & FITNESS LLC Page 5 of Rev: D

6 14. Optional - Only do this step if doing alignment from scratch, skip if you are not replacing hardware. Using a #5 metric hex key, remove the three (3) nuts and screws securing the inner brake plate to the transmission bracket Do not replace nuts if only solving for noise. 15. Insert the brake plate alignment tool onto the splined transmission shaft and make sure the end of the tool passes through the inner brake plate and seats fully up against the transmission bracket. Loosen hardware as necessary to insert tool/ 16. Using a torque wrench, tighten the three (3) sets of screws and nuts that secure the inner brake plate to the transmission bracket to 10 NM or 7.3 Ft-Lbs. Do not free-hand tighten. CORE HEALTH & FITNESS LLC Page 6 of Rev: D

Remove the brake plate alignment tool and grease the two o rings located on the splined

Be sure to remove any grease that gets on the inner brake plate.

move even with a user 150+ lbs (See photos below).

7 Remove the brake plate alignment tool and grease the two o rings located on the splined on the splined transmission pulley using a lithium-based grease. Be sure to remove any grease that gets on the inner brake plate. If a large amount of grease is on the clutch plate, you may find the steps difficult to move even with a user 150+ lbs (See photos below). Note: Excessive grease mixed with brake dust will prevent the brake from disengaging with some users 17. Push the clutch plate back onto the splined transmission pulley and ensure that the clutch plate is fully seated up against the inner brake plate, ensure there is no gap between the two plates. CORE HEALTH & FITNESS LLC Page 7 of Rev: D

18. Mount the brake back onto the transmission bracket using the same screws removed prior in step #11. 19.

The transmission/brake assembly is now ready to be re-installed back into the unit.

8 18. Mount the brake back onto the transmission bracket using the same screws removed prior in step # Use a torque wrench to tighten screws to 10 NM or 7.3 Ft-Lbs. Note the orientation of the manual release lever. Do not freehand tighten. 20. The transmission/brake assembly is now ready to be re-installed back into the unit. Align the holes in the rubber dampening pad with the holes in the frame, then tape the pad to the frame; this will make re-installation of the transmission/brake assembly much easier. CORE HEALTH & FITNESS LLC Page 8 of Rev: D

21. After reinstalling the transmission/brake assembly, be sure to re-zip tie any cables, including the brake cable, up and away from any moving parts. 22.

9 21. After reinstalling the transmission/brake assembly, be sure to re-zip tie any cables, including the brake cable, up and away from any moving parts. 22. Optional - Once the transmission/brake assembly is installed, the transmission pulley may need to be realigned. Please see doc. # Stepmill Alternator Belt Alignment for that process. CORE HEALTH & FITNESS LLC Page 9 of Rev: D

Drive Belts. Air Fit (160002)

Drive Belts. Air Fit (160002) Drive Belts Air Fit (160002) Parts Required: Crank to Transmission Belt (PN: 130-1812) Transmission to Fan Belt (PN: 130-1814) Tools Required: Screwdriver Set or Specific Drivers o Phillips Head Screwdriver