Troubleshooting Slow or No Treadle Movement

Troubleshooting
Slow or No Treadle Movement
TreadClimber®
When a user steps on the TreadClimber, the system recognizes someone is on the machine and resistance is applied to
treadles. This makes it more comfortable for the user to stand until they start a program. Once they start a program,
resistance level 1 will continue to have resistance so the treadles will be harder to move until they start increasing the level.
They can choose between level 1 – 5 (1 = max resistance and 5 = least resistance).
To eliminate any electronic resistance issues, turn off power to test.
Symptom
With the power turned off, the TreadClimber treadles move slowly or will not move at all with a user on them.
Possible Causes
Slow moving treadles are a symptom of mechanical binding in the system which may come from two sources:
• One or more of the belts are over tensioned.
• Mechanical binding in the clutch shaft assembly.
Resolution
A. Dumbbell Test
Using a dumbbell is an objective way to test if the treadle system has excess binding .
1. Be sure the power switch is in the off position.
2. With one treadle elevated to the maximum position, place a 45lbs (20kg) dumbbell near the headroller of the
elevated treadle (Fig. 1).
Fig. 1
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3. Us a stop watch to measure how long the treadle takes to go from a maximum elevated position to the bottom
position.
a.
b.
c.
d.
Less than 5 seconds indicates belts may be too loose.
Between 5 – 6 seconds = TreadClimber is operating properly.
Between 6 – 7 seconds = There is minor binding in the system. TreadClimber can be used.
More than 7 seconds = Diagnosis and adjustments to the treadle system should be made. Start with
checking belt tension.
B. Check Tension on Belts
There are 3 belts that should be checked:
• Clutch Shaft to Transmission
• Transmission to Alternator
• Alternator Belt
1. Use Fig. 2 to determine proper tension on the first 3 belts.
a. If belts need to be adjusted go to step 2.
b. Check the timing belt tension.
Fig. 2
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2. If adjustments are needed, follow instructions on step a and b.
.
a. To adjust the tension on the transmission to alternator belt and clutch shaft to transmission belt, loosen or
tighten (Fig. 3) until specs are correct as shown on Fig. 2.
NOTE: Before making adjustments, be sure the clutch shaft and the transmission shaft are parallel. Be sure to turn both bolts
equally. If not turned equally, it can misalign the shaft and causes the belts to track to one side
Fig. 3
b. To adjust the alternator belt, loosen the bolt and move the alternator to tighten or loosen. After the tension
desired is set, tighten bolt.
Fig. 4
3. Perform the dumbbell test. If the treadles still take longer than 7 seconds to drop, check tension on the timing belt.
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C. Checking Tension on Timing Belt
1. Check the tension on the timing belts. Follow instructions in document 637-1529 (at the end of this document)
a. If the timing belt does not need adjustment, check for mechanical binding in the clutch shaft assembly.
b. If adjustments were made, go to step 2.
2. Perform the dumbbell test. If the treadle still takes more than 7 seconds to fall, there is mechanical binding in the clutch
shaft assembly.
D. Check for Mechanical Binding in the Clutch Shaft Assembly
There are three areas for mechanical binding in the clutch shaft assembly:
•
•
•
Missing spacer between the clutch pulley and alternator belt pulley.
Timing belt misalignment.
Mechanical binding in the clutch shaft bearings.
1. Verify that there is a spacer between the clutch pulley and alternator belt pulley (Fig. 5). If the spacer is missing, order
part number 717-0379 (Fig. 6). This spacer can easily be clipped in place. No disassembly of the clutch shaft is
necessary.
Fig. 6
Fig. 5
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2. Check the timing belts (both left and right) to verify they are not tracking off to one side of the clutch pulleys (Fig. 7).
They should be completely on the clutch pulley and aligned with the treadle (Fig. 8). It does not need to be in the center
of the clutch pulley.
Fig. 7
Fig. 8
3. If the timing belt is tracking off (as in Fig. 5), it could be that the timing cable pulley is missing a bracket (Fig. 9). If
the timing cable pulley is missing the bracket, install part number 717-0087.
Fig. 9
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4. Once the timing belts are aligned, perform the dumbbell test. If the treadles still take more than 7 seconds to drop,
replace the clutch shaft assembly part number 717-0051 (Fig. 10).
Fig. 10
5. To replace the clutch shaft assembly follow instructions outlined on document 637-1528 (at the end of this
document)
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Part Replacement
Clutch Assembly Shaft
TreadClimber®
Parts Required:
•
Clutch Assembly Shaft (PN: 717-0051)
Tools Required:
•
•
•
•
Metric Hex Key Wrench Set
Screwdriver Set or Specific Drivers
o Flat Head Screwdriver
o Phillips Head Screwdriver # 2
12” Straight Edge
Tape Measure, Caliper, Ruler, or Other Measuring Device
Instructions:
1. Turn power off at the base of the machine.
Fig. 1
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2. Remove all the shrouds referenced (Fig. 2) to expose the internal workings of the machine.
Fig. 2
3. Remove tension from the rear cable tensioning system (Fig. 3) to loosen stress from the timing belts by extracting
the thimble and socket head cap bolt from the swivel pulley bracket assembly.
Fig. 3
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4. Loosen the alternator tension positioning socket head bolt (Fig. 4).
Fig. 4
5. Remove the tensioning washer and socket head cap bolts (Fig. 5) from the brackets that guide the transmission
shaft assembly.
Fig. 5
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6. Push the transmission shaft off the mounting brackets.
Fig. 7
7. Remove the socket head cap bolts securing the clutch shaft pillow blocks to the left (Fig. 5) and right (Fig. 6) side
of the frame.
8. Lift the clutch assembly shaft upwards and maneuver out through the belts.
Fig. 8
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9. To reinstall the new clutch assembly shaft; reverse all the previous instructions.
10. Stress all the following belts & cables (Fig. 9) to proper tensions.
Fig. 9
11. Power on the unit to process a speed calibration and test the unit to complete the reinstallation procedure.
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Technical Procedure
Timing Belt Tensioning
TreadClimber®
In case the tension on the timing belts is too loose or tight, please follow these instructions.
Tools Required
•
•
Phillips Screw Driver
6mm Allen Wrench
1. Remove all shrouds underneath the treadles to gain free access to the cable system.
2. Check the actual tension to determine if you have to loosen or tighten the cable. There is two ways to do that.
a. Utilizing a Frequency gauge, push one treadle
all the way down, so the other side is all the
way up. Plucking in the middle of the timing
belt (LIFTED treadle side, Fig. 1) to measure
the frequency in Hertz (Hz). The optimal value
should be between 65 to 69 Hz.
Fig. 1
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b. Utilizing a 20 lb free weight on the cable to deflect it to come in contact with the edge of the crossbeam (see
Fig.2 for exact location, also at the LIFTED treadle side). Repeat this again with a 15 lb free weight and the
cable should NOT come in contact with the crossbeam.
Fig. 2
3. The tension should be such that the timing belts do not skip when the unit is subjected to a 350lb user. An easy
way to test this is to step with both feet onto the front of ONE treadle when this is fully lifted and apply your full
force using the side rail to even increase this force. If you can hear a loud noise, this means the timing belt
jumped over a tooth on the pulley and it has to be re-tensioned.
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4. To re-tension the timing belts locate the tensioning fastener (Fig. 3). Using a 6mm Allen wrench to increase or
decrease the tension. Turning the Allen key clockwise will INCREASE the tension. To DECREASE the tension
turn the Allen key counter clockwise.
Fig. 3
5. Check the unit for proper function and put the shrouds on again.
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