Service Bulletin

Page 1637-1450 Rev. K

Latest Rev.Tools Required• Washers• 120 grit sand paper• Adjustable Wrench• ¼ Hex key• 4mm Hex key• Steel Square• 12” Steel Square 90 degree

SymptomDrive belt is damaged (Fig. 1) or is tracking off the pulley.

Fig. 1

Premature Drive Belt WearApplies to: E-TRx

Service Bulletin

Page 2637-1450 Rev. K

Drive Belt Replacement Chart

Please follow chart below to see if the drive belt (Part# 130-1695) would need to be replaced or not.

Good, minimal wear on the belt

Good, some wear

Recommend belt replacement

Recommend belt replacement immediately

Service Bulletin

Page 3637-1450 Rev. K

Possible Cause1. The idler pulley is not centered with the drive belt2. 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 over-

sized. 4. Drive motor pulley is not aligned with the head roller pulley

Fig. 2

Resolution1. 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

Service Bulletin

Page 4637-1450 Rev. K

Fig. 4 Fig. 5

Aligning the PulleyOnce 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

Service Bulletin

Page 5637-1450 Rev. K

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 be-tween 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

Service Bulletin

Page 6637-1450 Rev. K

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

Service Bulletin

Page 7637-1450 Rev. K

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: 715-3790-KT).

Service Bulletin

Page 8637-1450 Rev. K

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).

Service Bulletin

Page 9637-1450 Rev. K

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.

Fig. 16Install and tighten the nut.

Service Bulletin

Page 10637-1450 Rev. K

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

Service Bulletin

Page 11637-1450 Rev. K

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