Tectrix Climbmax 150 User manual

•
•
C/imbMax
MADE IN U.S.A.
Everyone Should Be This Well Built
THIS MANUAL, (INCLUDING PART NUMBERS), APPLIES TO THE 'INSTITUTIONAL STYLE' CUMBMAX,
SERIAL NUMBER 166190 AND Up, MANUFACTURED JULY 1993 OR LATER. FOR OPERATION AND PART
NUMBER INFORMATION FOR CUMBMAXMODEL 150 (SERIAL NUMBERS PRIOR TO 166190) REFER TO
THE CUMBMAX MODEL 150 OWNERS MANUAL (part number 03001) .
Page 1

Table of Contents
1. Assembly Instructions 4
2. Setup Mode 7
3. Test Mode 10
MAINTENANCE
4. Cleaning 11
5. Drive Cable / Clevis Bearing & Bolt Replacement 11
6. Pedal/Cable Clevis Lubrication 11
7. Clutch Bearing, Chain, Crank Arm & Parallel Shafts Lubrication 12
8. Friction Belt Replacement / Switch Ends 13
9. Pedal Bearing Inspection 13
TROUBLESHOOTING GUIDE
10. 'Can't Slow Down' or 'Control Lost 14
11. 'No Slack" 17
12. 'No Brake' 17
13. 'Memory Lost' 18
14. A Numeral Appears In The Interval Display 18
15. Some LED's (lights) Are Out On The Display And There Is No Beep When The Power Switch
Is Turned On 19
16. All LED's (lights) Are Out On The Display And There Is No Beep When The Power Switch
Is Turned On 19
17. Reset Problem 20
18. A Key On The Display Console Doesn't Work 21
19. Pedal Squeak 21
20. A Pedal Doesn't Return To The Top or A Pedal Won't Go Down 21
21. No Speed Control And No Error Message Is Displayed 22
22. Speed Control is Jerky or Varies Speed 22
23. The ClimbMax Won't Accelerate To Top Speed 23
24. Cannot Select Group Race 24
PART REPLACEMENT
25. Cover 26
26. Motor Assembly 27
27. Slack Switch Adjustment 28
28. Friction Belt Replacement 28
29. Power Board Assembly 28
30. Display Console 29
31. Display Cable 30
32. RPM Assembly :.: 31
33. Switch Plate Assembly 31
34. Spring / Drive Cable Replacement 32
35. Flywheel Assembly 33
36. Crank / Pedal Removal From Frame 34
37. Crank Arm Assembly 34
38. Parallel Arm Assembly 35
39. Pedal Assembly 36
40. Transmission Assembly 37
Page 2

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41. FIGURES 40
Description Paqe#
1
Attaching the Hand Rail Upright 40
2
Attaching the Hand Rails 41
3
Connecting the Display Cable
42
4 Power/Communications Connectors
43
5
Brake and Motor Assembly
44
6
Parallel Arm Assembly 45
7 Spring Cable Routing
46
8
Flywheel Assembly 47
9
Crank Arm Assembly 48
10 Pedal Assembly 49
11
Transmission Assembly
50
12
Display Overlay
51
13 Display Board Component Layout 52
14 Display Board Schematic (page 1 of 2)
53
15 Display Board Schematic (page 2 of 2)
54
•
16 Power Board Assembly
55
17 Power Board Schematic
56
•
Page 3

1. ASSEMBLY INSTRUCTIONS
The ClimbMax is quite easy to assemble and
should take around 30 minutes to complete. It
will require the following common tools:
1/4" Allen Wrench,
3/16" Allen Wrench,
Medium Phillips Screwdriver (#2)
7/16" socket and ratchet
1/2" socket and ratchet
Unpacking your new ClimbMaJC
Remove the Chassis base from the pallet by removing the clamps and screws (use the 7/16" socket and
ratchet). Remove all the parts from the box and check that they are all present. CAUTION: Do not at any
time lean the display console upright tube up on its end. The display ribbon cable could be damaged.
Parts List
#
Part Name Part #
atv
1
Main Chassis Base (WHT, BLK, GRAY)
Color
1
2
Hand Rail Upright 1
3
Hand Rails (WHT, BLt<, GRAY) Color 2
Ship Kit (Contains the Following) 1
4 Right Hand Rail Clamp
53003
1
5
Left Hand Rail Clamp
53006
1
6
5/16"-18 X 2" Socket Screws 41011 2
7 5/16" Flat Washers 53017 2
8
5/16" Lock Washer 53018 2
9
1/4"-20 X 1/14" Socket Screws 41012 4
10 1/4" Flat Washer
53019 4
11
#10-24 x 1/2" Self-Tapping Screw 41006
6
12 Hand Rail End Caps
40006
2
13
Telephone Cable
61033 1
14 Termination Plug
61026 1
15 Power Cord
14007
1
16 Owners Manual
13010
1
17 Reading Rack
61029
1
18 Maintenance Manual
03012 1
19 Friction Belt with Button Hole
61077
1
Page 4•

Attaching The Hand Rail Upright
2
/
11
~
Attaching the Hand Rails
Attach the hand rail upright (2) to the chas-
sis (1) using two 5/16" screws (6), flat wash-
ers (7) and lock washers (8) as' shown in
Fig. 1. Make sure that the display cable goes
through the slot and the display is facing to-
ward the chassis. Finger tighten screws,
wrench tighten after hand rails are installed.
Fig. 2
Fig. 1
Insert the clamps (5 & 6) into the upright so
that the threaded holes are facing up to check
the fit and to see how they insert, then re-
move the clamps (you may need a soft mal-
let to tap the clamps in). Slip the hand rails
(3) over the black nylon plugs on the rear
foot. Slip the right (4) and left (5) clamps
over the hand rails so that the threaded holes
-~~~ face up when pushed into the upright (2) as
.. ~-
shown in Fig. 3. The easiest way to insert
the clamps (5 & 6) into the upright (2) is to
check the alignment of the clamps with the
uprights. It may be necessary to twist the
handrail (4) towards the display then pull
the handrail away from the display without allowing it to twist to get the proper alignment. If this is
difficult, use a1/2" socket and loosen the 5/16" boh that holds the black nylon plug underneath the rear
foot. This allows easy alignment of the handrail. Screw in the 1/4" screws (9) with the flat washers
(10) but do not tighten. Move the up-
right forward or backward to locate
the hand rails 1/2" (inside) from the
edge ofthe clamp (see Fig. 2). If the
upright will not move, loosen the 5/
16" screws at the base of the up-
right. Tighten the 1/4" screw until
the edge of the clamp is flush with
the top surface of the upright.
Tighten the four #1 0 screws (11) as
shown. Now the 5/16" screws atthe
base of the upright can be tightened
and the hand rail end caps (12) can
be inserted.
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Page 5

Connecting The Display Cable
B
Fig. 3
< ~LPower
In
c
A
r--
/
/
/
/
Fig. 4
11
B
Power_lJ
Out
A
The Climb Max has both a power in (A) and power out (B)
connector (see Fig. 4). This allows you to string power from
one Climb Max to the next and eliminates the need for ex-
tension cords. One end of the power cord (15) plugs in to
the power in (A) and the other end plugs into either the power
out (B) of the next ClimbMax or the wall socket. (C) is the
power switch.
c
Move the ClimbMax to where it will be used. Check the
level of the Climb Max by pressing on both sides of the
front foot. If it rocks back and forth, lower or raise one of the
glides on the front foot by loosening the lock nut and screw- A
ing the glide in or out. Once it is level, tighten the glide lock-
nuts.
Power Connector
Leveling the ClimbMaJC
Lay the Climb Max on its right side and locate the display
cable. As shown in Fig. 3, fold the display cable (A), attach
the cable to the connector (B). Stand the ClimbMax up.
)
120r 13- _-oJ
E ---1~:::t:::~:::t:::~-D E---1~=i=~:±::t--D
~ 12 / ~
'------------- '---120r13
Communications Connectors
The Climb Max has a built-in serial port designed to interface to other ClimbMaxes or a host computer. A
maximum of eight ClimbMaxes can be linked together and races among 2 to 8ClimbMaxes are possible
with up to four different races occurring simultaneously. If you have more than one ClimbMax, plug in a
telephone type cable (13) from the Out Jack (D) of each climber to the In Jack (E) of the next Climb Max and
continue until all ClimbMaxes are connected (see Fig. 4). Then terminate the first In Jack (E) and the last
Out Jack (D) with the plugs (14) provided to complete the communication ring.
Page 6

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2. SETUP MODE
Setup Mode is used to adjust program times, to select various options, including Prompted or Step and Go
operation, and to set the jackpot count.
Enter Setup Mode by holding the DISPLAY SHIFT key (Model 150 climbers use the Shift key) while turning
the ClimbMaJC on. The readouts show SETUP MODE and the Interval display shows a moving pattern.
The keys have special functions in Setup Mode:
DISPLAY SHIFT
or ENTER KEY
G
o
HELP
CLEAR
Scroll Through Programmable Options
Increase value or change option
Decrease value or change option
Display a brief message about the current option
Clear the display or exit setup
CLEAR restores the SETUP MODE sign-on if a programmable time or option or the Jackpot count is being
displayed. If the sign-on is displayed, CLEAR exits Setup Mode and displays the normal TECTRIX ClimbMaJC
sign-on. If any changes were made, the new values are written to memory at this time.
• If you make a mistake in Setup Mode and you haven't used CLEAR to exit, you can restore the previous setup
values by turning the climber off and on again. In other words, no permanent changes are made until you
press CLEAR and TECTRIX ClimbMaJC is displayed.
Programmable Options
SHIFT displays the following options, one at a time:
Option Factory Setting Alternatives
1. Maximum Time
MAX TIME = 30 (5-60)
2. First Time FIRST TIME = 20 (5-60)
3. Time-out Period TIME OUT = 0:30 NONE, 30, 1 :00, 2:00
4. Prompting PROMPTED STEP AND GO
5. Measurement system FEET AND POUNDS
METRIC READOUT
6. Quick Race Access ANNOUNCE RACES
NO RACE ANNOUNCE
7. Speaker Control
BEEP ON
BEEP OFF
•
Press '0 or 0. to change the displayed value or switch between alternatives. Press ENTER to advance to
the next option. The HELP key provides a brief message about the current option. When all options have
been entered, SETUP MODE reappears.
Page 7

PROGRAMMABLE TIMES
1. MAXTIME
The length of the longest workout can be adjusted in 5-minute increments from 5 to 60.
2. FIRST TIME
The number of minutes first offered after weight has been entered also ranges from 5 to
60. It can't be longer than the maximum time.
3. TIME OUT
The length of time that the climber retains its settings before resetting and displaying the
sign-on message if the user quits stepping. The period can be set to thirty seconds, one
minute, two minutes, or NONE, which keeps it from timing out.
OPTIONS
4. PROMPTING
Prompted
Prompting begins when you press
a key or when you start climbing.
5. MEASUREMENT SYSTEM
Feet and Pounds
Distance is displayed in feet and
weight is entered in pounds.
6. QUICK RACE ACCESS
Announce Races
Idle climbers display a message
during a race countdown, and
anyone can join by just pressing
ENTER.
7. SPEAKER CONTROL
Beep On
The speaker operates.
Page 8
Step and Go
If you start climbing without press-
ing a key, the climber starts in
Manual. If you press a key first,
prompting begins. Pressing ENTER
in Manual always begins the prompt-
in sequence.
Metric Readouts
Distance is displayed in meters
and weight is entered in kilograms
No Race Announce
No special handling for races.
Beep Off
Turns the speaker off completely.

•
•
•

3. TEST MODE
Test Mode is used to test the climber's electronic hardware. You enter Test Mode by holding the ENTER key
down while turning the ClimbMaJlon. All the displays light up as long as you hold the key down. When you
release the key, the readouts show the version number of the microprocessor software and the state of the
slack switch (SLACK or TIGHT). The Interval and speedometer displays show moving patterns.
The keys have these special functions in Test Mode:
DISPLAY SHIFT
'0
00
ENTER
HELP
CLEAR
Display odometer and RPM sensor data
Loosen Belt
Tighten Belt
Test LED digit groups
Test LED Segments
Clear Function disolav or Exit
The indicators show the state of the various inpuVoutput signals:
Distance Smart Link Out off
Program/Level Smart Link In off
Calories Slack Switch on
Calories/Hr Heart Rate Sense off
Elapsed Time RPM sensor off -
Time Remaining RPM sensor on -
The G and 00 keys run the belt tensioning motor as long as you hold them down. Don't hold the G to
loosen the belt for too long, or you may tangle or unsnap the belt.
SHIFT displays the odometer reading (the total distance climbed). The Interval display shows a graphic
display of the output of the speed sensor. At high speeds only the bottom row is lit; at low speeds the entire
display lights. Except at very low speeds the columns ought to be nearly the same. Variations in height of
more than one LED may indicate a problem with the RPM sensor or its encoder disk.
SHIFT also begins and ends a simple test of the Smart Link electronics. The Distance indicator should flicker
when the test begins; if the climber's In and Out jacks are connected together, both the Distance and Pro-
gram/Level indicators should turn on steadily.
ENTER lights up each display grouping (a matrix column together with an alphanumeric digit or a group of
sixteen LED's in the bar graph) in turn to locate shorted display drive lines.
HELP lights up each display segment in order to locate segments that are shorted together.
CLEAR restores the version readout if the odometer reading or a display test pattern is displayed; otherwise
it exits Test Mode and displays the TECTRIX ClimbMaJl sign-on.
Page 10

MAINTENANCE
• This section covers maintenance that should be regularly performed to minimize wear and to keep the
Climb Max in top operating order. The following recommendations are for heavy institutional use (8 or more
hours daily, 20 thousand feet climbed) and can be scaled down accordingly.
Required Maintenance
4.
5.
6.
7.
8.
Maintenance Procedure
Cleaning
Drive Cable / Clevis Replacement
Pedal/Cable Clevis Lubrication
Clutch Bearing Lube,
Chain, Crank Arm & Parallel Shaft Lube
Friction Belt Replacement / Switch Ends
Period
Daily
8-10 Months
Weekly
Yearly
3-6 Months
3 Months
Feet Climbed
5 Million
7 Million
3 Million
2 Million
•
•
4. Cleaning
Keeping the Climb Max clean helps to prevent rust and dirt from getting into the moving parts. The
Climb Max should be wiped down at least once a day and club members should be encouraged to wipe off
the climber after they use it. Most household cleaners are fine to use on the ClimbMaxexceptforthose that
have abrasives. Solvents should not be used on any plastic parts. A stiff scrub brush works well for cleaning
dirt off the pedals. Scratches or chips in the paint should be touched up to prevent rust.
5. Drive Cable / Clevis Bearing & Bolt Replacement
Drive Cable - Fig. 9, Part #12 and Fig. 7, Part # 2.
Clevis Bearing & Bolt - Fig. 9, Part # 4&#10.
The drive cables and clevis bearing & bolt should be replaced every 8 to 10 months or 5 million feet
climbed. The cables wear internally, darkening with use. A black cable is a worn cable and will even-
tually break (see section 34 for replacement).
The clevis bearing & bolt should be inspected when replacing a drive cable. A corroded bolt will quickly
wear through the bearing. This will result in damage to the crank arm leading to an expensive repair
(see section 37 for replacement).
6. Pedal/Cable Clevis Lubrication
Pedal Parallel Arm Bearing (see Fig. 10, Part #4)
Cable Clevis Bearing (see Fig. 9, Part #4)
A few drops of light machine oil (example: 'TRI-FLO' or 3-in-1 oil) each week will improve wear life. Make
sure to wipe off excess oil as it will attract dirt. Inspect the clevis action. The clevis must swivel freely.
Page 11

7, Clutch Bearing,
Chain, Crank Arm &
Parallel Shafts
Lubrication
7,1 Clutch Bearing
Lubrication
Remove the cover. See
Fig, 11, item #7,
Apply a few drops of 90
weight gear oil only, in
the hole,
CRANK ARIi ASSEIiBLY
Fi,ure 9
CIANI All ASSY. ::~~~ :=:1
, -- -,.
I CRAll: MIl - LfFI 5«]1. 1
2
CRAll: MIl - R(()lT 5«]15 1
]1',I-I..,..a112"
_De; 44021 4
• ],111".15132",112" _De; _ 2
(I/(}Wf 10 ALIQI WIDI
IIITOI I. ORllIE CAIl.E,
mil U1IU1IC' COIPO/fIltTS
, -- -,
5 IlETADe; RIll; - ;zs.., 4l106
6l'a1-],III" uve lPR. WASIQ 401l'
7 PMIT lIW'T 51111l
8 l'a1I2" •. IO lKl. WASIQ 40031
9.48" •. lIr lI'Il.lJj WASIQ 4n!9
10 ],III"xlW Q..EY(S lIJIEl 5~16
II 5116'-18 NI'lII: lIlT Q]]]
12 DRive CAIl.E 51015
13 CRAll: ... I.IF8! 5Oal2
7.2 Chain Lubrication
Remove the cover (see section 25), Use a throwaway rag to wipe the sludge from the chain, Apply a roller
chain lubricant (example: CRC brand part number 03050) evenly and wipe the chain to remove the excess,
14
15
17
PEDAL ASSEMBLY - 61063
1 NIl.,. Nlrl
I PBlAl. - 1IAOt. , AICIlIZED 52011
231. I 718 I SIB IlEAl!II(j ~
3 112 I 1!lI32 I 112 IlEAl!II(j ...cI2S
• ltll I 15132 I 112 IlEAl!II(j "'4026
5 PEOAl llJf'EI! SllXl3
Page 12
<
......
.......
PEDAL ASSEMBLY
Fiture 10
OTHER UFERENCE COIPONENTS
1 NIl.,. Nlrl
6ltll-16 lEX FUICiE lIlT .2043 I
731. I 1-5116 I.lBl WASIO OJ31 2
831.
WAVE SI'l!II(j WASIO ~ I
931. E;/11(j .3201 I
10 SIB-18.Jo\1l lIlT .20~ I
II
SIB SEIlI!A TEll un WASIO Ol2ll 1
12 RIGHT CJ!N« Al!Il - IIAOtIIEll 54015 I
13 ltll-18 I1-118 lIl.T .1043 I
I. ltll QJMD SI'l!II(j wASIEl! ~ I
IS ltll DIll TE IIIDlZE wASIEl! 44027 I
16 PBlAl. SHoIFT 5I 048 I
J7 PAI!ALla. Al!Il 52021 I

•
•
•
PARALLEL ARM ASSEMBLY
Fi:ure 6
5
PARALLEL ARI ASSY. - 61032
I NIr lUll 1111 I trf.
I PARAlLEl ARM 5202\ 2
2 314. \51\6 • 314 lEAl/II(; 4400!1 2
OTHER REFERENCE CO.PONEIiTS
I,.,-
NIl I
3 314. 1111 NYLl)l W~
0)25
4
4
314 WAVE WAS!£R
4lXXJ5
\
5PARAllR ARM SHAFT 5\172
\
6 314 E-I1II(;
43201
2
7.3 Crank Arm (see Fig. 9) & Parallel (see Fig. 6) Shafts Lubrication
Apply a few drops of light machine oil (example: 'TRI-FLO' or 3-in-1 oil) on the pedal bearing surfaces. Wipe
off any excess so that it does not attract dirt.
At the base of each crank arm is a lubrication point. Apply three squirts of a polymer grease (example:
Clenesco Polylube') to each crank arm lubrication point. Apply one small squirt between the two parallel
arms.
8. Friction Belt Replacement / Switch Ends
The friction belt should be replaced when the speed control degrades (see sections 21 & 22). In many
cases the belt can be reversed to extend its life because the major wear is at the end that attaches to the
motor pulley. Inspect the flywheel surface and remove any flywheel deposits with Scotch Brite or sandpa-
per.
9. Pedal Bearing Inspection
Pedal/Parallel Arm Bearing - Fig. 10, Part #4&#3
The 3/8" bearings should be checked annually or after 7 million feet and replaced if needed (see section
39).
Page 13

TROUBLESHOOTING GUIDE
This guide will help to locate a problem in the ClimbAfax. Troubleshooting is much easier with spare parts.
We highly recommend the purchase of a Dealer Service Kit as this guide refers to spare parts in some
sections.
DISPLAY ERRORS
10. CAN'T SLOW DOWN or CONTROL LOST
11. NO SLACK
12. NO BRAKE
13. MEMORY LOST
14. A Numeral Appears in the Interval Display
OTHER PROBLEMS
15. Some LED's (lights) Are Out On The Display And There Is No Beep When The Power Is Turned On
16. All LED's (lights) Are Out On The Display And There Is No Beep When The Power Is Turned On
17. Reset Problem
18. A Key On The Display Console Doesn't Work
19. Pedal Squeak
20. A Pedal Doesn't Return To The Top or A Pedal Won't Go Down
21. Speed Control Is Jerky Or Varies Speed
22. No Speed Control And No Error Message Is Displayed
23. The ClimbAfax Won't Accelerate To Top Speed
24. Cannot Select Group Race
DISPLAY ERRORS
The first thing to do if you get a Display Error is to press CLEAR. Sometimes the errors 'CAN'T SLOW DOWN'
or 'CONTROL LOST' may be displayed in conjunction with other errors such as 'NO BRAKE' or ' NO SLACK.'
If this is the case, follow the 'CAN'T SLOW DOWN' or 'CONTROL LOST' error. The following is a list of things
to check which can cause 'CAN'T SLOW DOWN' or 'CONTROL LOST':
10. 'CAN'T SLOW DOWN' or 'CONTROL LOST'
10.1 Friction Belt
Disconnect the power cord from the Climb Max and remove the cover (see section 25). See if the friction
belt has worn through or is disconnected. If this has happened see section 28, Friction Belt Replacement.
Page 14

10.2 Electrical Cables
• If the belt is ok, look for any loose connections or wires around the power board or motor assemblies.
10.3 Test Motor
Put the climber in the Test Mode (see section 3) and run the motor in both directions by using the arrow keys.
If the motor is not running refer to section 10.5.
10.4 Motor Runs
If the motor runs, check that the motor shaft is not spinning inside the pulley on which the belt wraps and that
the motor does not have a stripped gearbox. If the motor shaft is spinning inside the pulley, remove the motor
assembly (see section 26) and tighten the set screws (see Fig. 5). Make sure that one of the set screws is on
the flat portion of the shaft. To verify that the motor does not have a stripped gearbox, look at the armature
shaft on the outside of the motor. If the armature shaft on the outside of the motor spins but the output shaft
and belt pulley do not, the gearbox is stripped. Replace the motor assembly.
10.5 Motor Doesn't Run
•
•
Unplug the motor cable from the power board assembly (see Fig. 16). Plug in the spare motor assembly and
see if it will run in both directions. If the spare motor assembly runs, replace the original motor assembly. If
you do not have a spare motor assembly, use an analog (not digital) meter (observe polarity!) to verify voltage
at connector J5 on the power board. (see Fig. 16). Place the climber in the Test Mode (see section 3) .
Measure the voltage across the two pins of J5 while an assistant presses the up & down arrow keys on the
console. J5 voltage with no load should read approximately 13 to 14 volts DC. If you do read the expected
voltage, replace the motor assy. If the voltage is incorrect replace each of these parts in the following order:
1. power board assembly (see section 29), 2. display ribbon cable (see section 31), 3. display board (see
section 30) .
Page 15

'NO SLACK' & 'NO BRAKE' ERRORS
'NO SLACK' & 'NO BRAKE' refers to the slack switch located on the motor assembly (see Fig. 5). The
purpose of the slack switch is to tell the microprocessor (located on the display board) whether the belt is
loose or tight on the flywheel. When the Climb Max is turned on or after someone stops climbing the
microprocessor uses the slack switch to initialize the belt position. The following is the initialization process:
MOTOR ASSEMBLY - 61015
,,mlUl ,m,
I GEAR I()TlR :JiOO5
2 I()T!R II1ACKET 51021
3 SLACl: SVJT(H 1ml
4 SLACl: SVJT(H AIlJJST SlOT -
5 I()TlR LEADS V/TlJ!llIO 14042
6 IB.T Pll.LEY (5116' tnE) 46012
7IB.T Pll.LEY SCREV STlfl 41lDi
8IB.T OCHlR 511155
9IB.T OCHlR SCREV STlfl 41lDi
'OTOR ASSY. - FRONT VI"
OTHER REFERENCE CO.PONENTS
, NIr.. ,lit 1
10 H1I(TJ~ IELl 610n
II FL YVtEEl 61005
12 DIS( 51018
13 IIPM SENSlJ/ ASSY. 61 ()4.4
14 SENSD1 INIllJT AIlJJST
15 SENSD1 FI1lJH 18ACl: AO.1JST -
14 16 SlACl: SVJT(H ARM 1m7
17 SlACl: SVJT(H CAELE 61021
BRAKE
fil'" 5
The microprocessor checks the status of the slack switch. If the belt is pressed upon the slack switch arm,
the motor will loosen the belt. If after 1.5 seconds the slack switch is not deactivated the display will show a
'NO SLACK' error. If the belt is not pressed upon the slack switch arm, the microprocessor then commands
the motor to run slowly in the belt tightening direction until the belt presses the slack switch arm. If after 12
seconds the slack switch is not activated the display will show a 'NO BRAKE' error. Once the microprocessor
gets the signal from the slack switch that the belt has pressed it (the belt is tight), the microprocessor runs
the motor fast in the belt loosening direction until the belt is off the slack switch (this is the loose point). If after
1.5 seconds the slack switch is not deactivated the display will show a 'NO SLACK' error. No error will occur
if you start climbing prior to initialization being completed.
Page 16

11. 'NO SLACK"
11.1 Test Motor
• Remove the cover (see section 25). Put the climber in the Test Mode (see section 3) and run the motor in both
directions by using the arrow keys. If the motor is not running refer to section 10.5.
11.2 Test Slack Switch
Place the Climb Max in Test Mode (see section 3). Watch the 'CALORIES' LED on the display board while pressing
the slack switch on the motor assembly. The 'CALORIES' LED should be ON when the slack switch is NOT pressed,
and the 'CALORIES' LED should go OFF when the slack switch is pressed. Pre-serial number 166190 ClimbMaxes
(Model 150) require an assistant to observe the 'CALORIES' LED while you press the slack switch. Current models emit
an audible tone in response to the slack switch. (A status indicator also displays 'SLACK' or 'TIGHT' on the readouts).
If the climber passes the slack switch test, but displays a 'NO SLACK' error, the slack switch may be out of adjustment.
Refer to section 27 for slack switch adjustment procedure.
11.3 Bad Slack Switch
If the 'CALORIES' LED (or audible tone) does not respond to the slack switch as described above, turn the climber off.
Disconnect the slack switch cable from the power board assembly (see Fig. 16). Plug the slack switch cable of the
spare motor assembly into the power board without mounting the spare motor assembly and repeat the test. If the
climber now passes the slack switch test, replace the slack switch and slack switch cable. Otherwise, plug the original
slack switch back in and replace the following parts in this order: 1. display ribbon cable (see section 31)
2. power board assembly (see section 29), 3. display board (see section 30).
• 12. 'NO BRAKE'
12.1 Belt
Remove the cover (see section 25). See if the friction belt has worn through or is disconnected. If this has happened
see section 28, Friction Belt Replacement.
12.2 Test Motor
Put the climber in the Test Mode (see section 3) and run the motor in both directions by using the arrow keys. If the
motor is not running refer to section 10.5.
12.3 Test Slack Switch
Test the slack switch as described in section 11.2. If the climber passes the slack switch test, but displays a 'NO
BRAKE' error, the slack switch may be out of adjustment. Refer to section 27 for slack switch adjustment procedure.
12.4 Slack Belt Test
•
If the motor is running and the slack switch is adjusted properly (see section 11.2) turn the Climb Max off and on.
Start climbing to 100 fVmin and stop. Watch the belt as the flywheel slows. If the motor assembly unwinds an exces-
sive amount of belt, check for friction belt wear and belt residue on the flywheel surface. If there is considerable wear
and residue, replace or flip the belt end for end and use Scotch Brite or sandpaper to remove the residue. If the motor
passes the motor test (see section 10.4 and 12.2) and all prior tests have been completed but the motor still gives a
poor response in operation, replace the motor assembly.
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,----------------- - - --------
13. 'MEMORY LOST'
13.1 The contents of the permanent memory have been lost. If this occurs, Setup mode is automatically
selected. The Odometer and Use Count are set to zero, the user/club program is cleared, and program time
defaults to twenty minutes.
13.2 The permanent memory in the Climb Max should be able to retain its contents for at least ten years. If
this error consistently occurs before that time, you may consider replacement of the display board.
14. A Numeral Appears in the Interval Display
14.1 This indicates a problem with the display electronics. Sometimes it can be generated by turning the
climber off and on too quickly; it may also occur in response to an irregularity in the electrical power (such as
a surge or a brownout). This can be considered normal, and the display can be reset by slowly turning the
power off then on again. Use your spare motor assembly to test the climber. The motor assembly may be
using too much power. If you do not have a spare motor assembly, put the climber in Test Mode (see section
3). Press and hold the down arrow key. Keep pressing the down arrow key even after the motor assembly has
tightened the belt as far as possible. If the display resets (all LEOs go off then on) at this time, the motor
assembly may be causing the problem and should be replaced. If the motor assembly does not resolve the
problem and the number persists or if it appears while the Climb Max is in operation, the display board may
need replacement (see section 30). If replacement of the display board does not resolve the problem, replace
and test the following parts in this order: 1. power board assembly (see section 29) 2. display ribbon cable
(see section 31) 3. display board (see section 30)
POWER BRACKET ASSY.
PART # 61130
Figure 16
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OTHER PROBLEMS
15. Some LED's (lights) Are Out On The Display And There Is A Beep When The Power
Is Turned On
Power up in the Test Mode (see section 3) to check for LED's out. Replace the display board (see section 30)
if there are some LED's out.
16. All LED's (lights) Are Out On The Display And There Is No Beep When The Power
Is Turned On
16.1 Blown Fuse
Remove the cover (see section 25) and check the fuse (11 OVAC - MOL 3/4A 250V, or 220V - MOL 1/2A
250V) located on the power board (see Fig. 16). Check the fuse for zero ohms (good) using a volt ohm meter
(a visual check is not reliable). Usually a fuse doesn't blow for no reason so it may blow again (because it is
a slow blow fuse it may take up to a minute to blow). If it does, replace the fuse and unplug all of the
connectors except J1 (see Fig. 16). If it blows again, replace the power board assembly. If it doesn't blow,
plug each connector back in one at a time to find the part that is causing the fuse to blow. Replace that part.
16.2 Power Switch Test
Check that all wires are intact on the switch plate and power board. Using the volt ohm meter, check that the
power switch is supplying 110 volts AC to the power board. Place the meter probes on the black and white
wires
on top of the power switch (switch on and power cord plugged in). CAUTION: Care is required when
reading high voltage. Do not touch the two leads of the volt ohm meter together during the test as this can
create a short. If no AC voltage is present at the power switch try a different power cord. Make sure that 110
VAC is present at the wall outlet. If there is still no power, replace the switch plate assembly (see section 33).
16.3 Power Board Test (see Fig. 16 & 17)
Check that there is 9.2 +/-.2 volts DC at the test points (labeled '9.2 VDC' and 'GND') located in the right
bottom corner of the board (older versions of the power board do not have the test points, voltage may be
tested at pin 14 on the display connector (J2) using pin 1 (or the square pad) as the ground reference). Ifthe
voltage reading is less than 9 volts, unplug the display ribbon cable at the power board (J2) and read the
voltage again. If it is still less than 9 volts, replace the power board assembly. If the voltage is correct, replace
and test each of these parts in the following order: 1. display ribbon cable (see section 31), 2. display board
(see section 30).
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17. Reset Problem
If the display doesn't light when you first switch power on, try switching power off and on slowly several
times. The microprocessor (located on the display board) may have had a bad reset and hung up. A bad
motor assembly may cause apparent display symptoms. Examples include:
1 Intermittent reset
2. Oscillating reset
3. Temporarily display LED's (lights) go out
Such motors may pass the motor power test and provide acceptable speed regulation. Use your spare motor
assembly to test the climber. If you do not have a spare motor assembly, put the climber in Test Mode (see
section 3). Press and hold the down arrow key. Keep pressing the down arrow key even after the motor
assembly has tightened the belt as far as possible. If the display resets (all LEOs go off and the sign-on
prompt is displayed) at this time, the motor assembly may be causing the problem and should be replaced.
Even though the motor assembly passes this test, it could be the source of the problem and should be
replaced. If the motor assembly does not resolve the problem replace and test the following parts in this
order: 1. power board assembly (see section 29) 2. display ribbon cable (see section 31) 3. display
board (see section 30)
Irvine, CaIIfomIa (BOO) 767-8082 Made In U.S.A. CAUTIO.: Stop climbing If you don't feel well!
• Adjust TIME & Enter
• Select PROGRAM & Enter
• Adjust LEVEL & Enter
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