Nautilus StairMaster ClubTrack 2100 Series Service manual

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ClubTrack

®

2100 Series

Treadmill

Service Manual

PN 000-6583 Rev AA (2/20/2006)

Important—Please Read

This manual is intended for authorized Nautilus or Nautilus certified service personnel and not for the consumer. There are no user serviceable parts. Servicing of the StairMaster ® ClubTrack ® 2100 by other than authorized Nautilus or Nautilus certified service personnel may result in voiding of the warranty.

If you are a consumer and require technical support to resolve a problem with your StairMaster ® call Nautilus Customer Service at 800-864-1270 (USA) or +41-26-460-77-77 (outside USA).

ClubTrack ® 2100, please

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DANGEROUS VOLTAGES ARE PRESENT INSIDE THE

TREADMILL. SERVICING BY OTHER THAN AUTHORIZED

NAUTILUS SERVICE PERSONNEL MAY RESULT IN ELECTRIC

SHOCK OR OTHER INJURY.

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© 2006. Nautilus, Inc. All Rights Reserved. Nautilus, the Nautilus logo, Changing the Game in Health and Fitness, StairMaster, the StairMaster logo and ClubTrack are either registered trademarks or trademarks of Nautilus, Inc.

Scotch-Brite is a registered trademark of 3M.

Loctite is a registered trademark of Henkel Technologies.

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Contents

Maintenance

Viewing Maintenance Information .........................................2

Routine Maintenance Schedules ...........................................2

Cleaning ................................................................................2

Adjusting Belt Tension ...........................................................3

Adjusting Belt Tracking ..........................................................5

Replacing the Walk Belt ........................................................5

Replacing the Contact Heart Rate (CHR) Sensors .............12

Replacing the Lens ..............................................................12

Updating the Console Firmware ..........................................13

Console Codes

Overview..............................................................................16

Cardio ..................................................................................16

Owner-Defined Custom .......................................................19

Machine Status ....................................................................22

Diagnostic ............................................................................25

Diagnostic 2 .........................................................................26

Magnetic Key Limit Access Control .....................................27

Troubleshooting Electrical Problems

Common Electrical and Electronic Problems ......................31

Error Reporting ....................................................................32

VSD .....................................................................................34

Troubleshooting Flowcharts ................................................35

Replacing the Grade Actuator Motor ...................................39

Problems with the Drive Motor ............................................41

Replacing the Drive Motor ...................................................42

Magnetic Key Problems ......................................................45

Wiring Schematics ..............................................................45

Troubleshooting Mechanical Problems

Common Mechanical Problems and Solutions ....................50

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2100 Series Treadmill Service Manual

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Contents

Assembly Illustrations

Assembly Parts Lists ...........................................................53

Assembly Drawings Overview .............................................55

Side Rails ............................................................................56

Headframe ...........................................................................57

Grade Weldment .................................................................58

Slider Bed ............................................................................59

Driver Motor .........................................................................60

Front Roller Assembly .........................................................61

VSD Board ..........................................................................62

Upright Weldment ................................................................63

Controller Support ...............................................................64

Hood Assembly and End Caps ............................................65

Hand Grips and Ergo Bar ....................................................66

Cabling ................................................................................67

PCBA ...................................................................................68

Controller Keypanel .............................................................69

Controller Bottom Housing ..................................................70

Appendixes

Appendix A—Required Tools ...............................................72

Appendix B—Differences Between 2100

and 510/612 Motor Wiring ..............................................73

Appendix C—Replaceable Parts Lists ................................74

Appendix D—Using a Multimeter ........................................80

Appendix E—International Power Plug Configurations .......83

Appendix F—Specifications ................................................84

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ART

1

Maintenance

Contents

Viewing Maintenance Information .........................................2

Routine Maintenance Schedules ...........................................2

Daily ...................................................................................2

Cleaning ................................................................................2

Daily ...................................................................................2

Weekly ...............................................................................3

Treadmill Interior ................................................................3

Adjusting Belt Tension ...........................................................3

Adjusting Belt Tracking ..........................................................5

Replacing the Walk Belt ........................................................5

Replacing the Contact Heart Rate (CHR) Sensors .............12

Replacing the Lens ..............................................................12

Updating the Console Firmware ..........................................13

Cleaning

2

Viewing Maintenance Information

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To view the treadmill’s run-time information:

1 Press CLEAR, 4, 0, and ENTER. The controller will display the machine run time in hours since last cleared.

2 Press CLEAR to exit.

To view the total distance the treadmill has been used:

1 Press CLEAR, 4, 2, and ENTER. The controller will display the total distance the machine has gone since last cleared.

2 Press CLEAR to exit.

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Routine Maintenance Schedules

Performing routine maintenance will help prevent unnecessary wear to the treadmill and/or injury to the user. The maintenance schedules are meant only to serve as a guide. Depending on where and how the treadmill is being used, more frequent routine maintenance may be required.

Daily

• Inspect the power cord and walking belt for wear.

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• Check the position of the walking belt. Verify it is not rubbing against the frame. The belt should be evenly spaced on the deck within 0.25 inches. Adjust the belt if necessary.

• Check the optional side handrails to ensure they are fastened securely.

• Remove potential hazards from the treadmill area.

Cleaning

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Keeping the StairMaster ® 2100 LC/LE treadmill clean on a regular basis will help to improve operation and increase the lifespan of the components.

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DRY MOP THE DECK UNDER THE BELT ONLY. DO NOT ADD

ANY LUBRICANTS—ADDING LUBRICANTS CAN RUIN THE

PROPRIETARY FRICTION-CONTROL SURFACE.

DO NOT USE DETERGENTS OR CLEANING AGENTS ON ANY PART

OF THE DECK.

DO NOT LET LIQUID ENTER THE TREADMILL OR CONTROLLER. IF

IT DOES, THE EQUIPMENT MUST BE INSPECTED AND TESTED

FOR SAFETY BY A STAIRMASTER

BEFORE IT CAN BE USED AGAIN.

® -APPROVED TECHNICIAN

Daily

• Keep the treadmill and controller free of dust and debris. Use a damp sponge to wipe the exteriors and walking belt; do not soak surfaces. Dry all surfaces thoroughly.

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Adjusting Belt Tension

Weekly

• Elevate the treadmill to maximum incline and vacuum the floor under it to prevent excess dust and dirt from interfering with operation.

• If the magnetic key is being used, check it for rust. If you detect rust, replace the magnet. Rust on the magnetic key will cause power-up problems.

Treadmill Interior

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DANGEROUS VOLTAGES ARE PRESENT UNDER THE TREADMILL HOOD.

EXERCISE CAUTION WHEN PERFORMING SERVICE TO THE ELECTRICAL

COMPONENTS UNDER THE HOOD.

Depending upon the treadmill environment, dust and or lint can accumulate under the hood. Clean the interior of the treadmill following the procedure below:

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1 Turn the treadmill circuit breaker off, and unplug the treadmill power cord.

2 Remove the six (6) screws on the treadmill hood.

3 Lift off the hood.

4 Clean inside the unit.

5 Reinstall the hood and the six (6) screws.

6 Plug in the treadmill power cord, and switch on the treadmill circuit breaker.

Adjusting Belt Tension

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SECURE LONG HAIR AND LOOSE CLOTHING BEFORE WORKING NEAR THE

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Adjusting Belt Tension

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DO NOT USE ALL YOUR WEIGHT TO RESIST THE BELT MOVEMENT.

TOO MUCH RESISTANCE APPLIED TOO LONG (MORE THAN TWO

SECONDS) MAY SHUT DOWN THE SYSTEM. (VARIOUS ERROR

MESSAGES WILL APPEAR IF THIS OCCURS. CYCLE POWER TO

RESUME NORMAL OPERATION.)

DO NOT OVERTIGHTEN THE WALKING BELT. DO NOT TORQUE

ADJUSTMENT SCREWS BEYOND 80 IN-LBS (9 N-M) MAXIMUM.

OVERTIGHTENING THE BELT WILL REDUCE BELT LIFE AND

DAMAGE THE ROLLER BEARINGS.

Adjust the belt tension whenever the belt slips or moves unsteadily during operation by following the steps below:

1 Start by loosening the two (2) adjustment bolts.

Adjustment Bolts

2 With the walking belt loose, place two marks 35 inches (889 mm) apart on each side of the belt near the edge.

The belt must be loose enough for you to move it from side to side on the front or rear roller.

35.0"

(889 mm)

(889 mm)

35.0"

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Replacing the Walk Belt

3 Turn the adjusting bolts clockwise by equal amounts until the marks are between 35-3/16 inches and 35-5/16 inches apart. Proper tension for the walking belt is between .5%–.6%. This should be about six full turns of each adjustment bolt from the point where the belt begins to stretch. Important: Do not exceed 35-5/16 inches.

4 Test the belt by running on the belt at about four mph. Hold the handrail lightly and resist the belt movement with your feet.

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Adjusting Belt Tracking

Perform this procedure whenever the belt moves to one side or the other. Stay off the belt when adjusting the tracking.

1 Start the treadmill at minimum speed and grade.

2 Increase speed to six mph, and make the following adjustment:

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2.2 If the belt moves to the left, turn the left adjustment bolt 1/4-turn clockwise.

3 After making an initial adjustment, run the treadmill for five minutes and observe how the belt tracks. If the belt continues to move away from the center, adjust the appropriate side until properly centered.

Replacing the Walk Belt

Perform this procedure whenever the walk belt is still too loose after adjusting the tension or when the belt is worn or frayed.

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DO NOT CUT THE BELT—DOING SO WILL CAUSE THE REAR

ROLLER TO FALL AND SNAP THE ALIGNMENT PINS ON THE END

CAP.

1.0 Remove the Treadmill Hood

1.1 Turn the treadmill circuit breaker off, and unplug the power.

1.2 Remove the six (6) screws on the treadmill hood.

1.3 Lift off the hood.

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2.0 Remove the Rollers

2.1 Remove the end cap by removing the adjustment bolts.

Adjustment Bolts

2.2 From the rear of the machine, slide the molding off the side rails.

2.3 Remove the rear roller by lifting up the roller and sliding it out from under the belt.

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2.4 Place a 9/16 wrench on the head of the bolt mounting the Tensioner and turn counter clockwise until

Tensioner loosens.

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b. Lift up on the Tension Wheel and slide the motor drive belt over pulley to remove.

2.5 Remove the two (2) front retainer bolts at each end of the front roller.

Retainer Bolts

2.6 Lift the front roller at its pulley end and pull it out of the opposite side rail. Important: The front roller is heavy; be sure to support both ends.

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2.7 Slip the motor drive belt off the front roller pulley.

2.8 Fully lift the front roller out from between the walk belt.

3.0 Removing the Deck

3.1 Remove the twelve (12) deck screws that secure the deck to the side rails. Important: Apply pressure on the deck next to the screw to keep the compression mount from turning with the screw; otherwise, you can strip the compression mount threads.

3.2 Lift the deck to one side.

3.3 Slide the deck out from between the belt.

4.0 Inspection and Cleaning

4.1 Check the compression mounts for any wear and cracking. Make sure they are tight.

4.2 Check the deck for signs of wear. Decks are waxed on both sides. If you are flipping the deck, wipe off loose debris with a dry cloth. Inspect the wax on the unused side for deterioration. If the wax appears crusty white and is not adhering to the deck surface, the deck should be replaced. To obtain optimum belt life, always begin with a waxed deck surface. (Refer to the photos below for what is a good deck surface—useable—and what is a bad surface—unuseable.)

Important: Do not apply any cleaners or petroleum products to the deck surfaces.

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Wax—Good Side No Wax—Bad Side

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4.3 Inspect the motor drive belt for wear and cracking. Cracking is prevalent between the grooves on the belt.

4.4 Inspect the rollers for wax build-up (black deposits on the rollers). Use #000 steel wool or a Scotch-

Brite

™

pad to clean the wax off the rollers.

4.5 Stand each roller on one end and rotate it. Listen for any squeaking sounds, and verify that the rollers spin smoothly.

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4.6 Vacuum the deck and inside the motor housing.

5.0 Installing the New Walk Belt

5.1 Slip the new belt over the deck. Make sure the deck’s waxed surface is on the up side and that the arrow on the inside surface of the walk belt points in the proper direction of belt travel.

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5.3 Lift and slide the belt until the arrow is visible on top of the deck. Verify that it points toward the back of the treadmill.

6.0 Attaching the Deck

6.1 Align the deck mounting holes with the compression mounts.

6.2 Install all twelve (12) deck screws and hand tighten.

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tightening. Important: Do not over-tighten the deck screws.

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DO NOT OVER-TIGHTEN THE DECK SCREWS. OVER-TIGHTENING

THE DECK SCREWS WILL DAMAGE THE COMPRESSION

MOUNTS

.

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7.0 Reinstalling the Front Roller

7.1 Slide the front roller inside the walking belt.

7.2 Insert the end of the roller opposite the pulley into the cut-out on the side rail.

Cut-Out

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7.3 With your free hand, slip the motor drive belt onto the pulley.

7.4 Install the two front roller retainer plates. Make sure the retainer plates seat in the grooves on the rollers. Tighten all the screws on the retainer plates.

Groove

7.5 After alignment of the Front Roller and Flywheel, place belt on the Front Roller and Flywheel.

7.6 Place 5/16 wrench on nut of Tensioner and turn counter clockwise creating tension on the bent and hold. The top two notches should line up.

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Replacing the Contact Heart Rate (CHR) Sensors

7.7 Place the 9/16 wrench back on the head of the mounting bolt and turn clockwise, until the bolt tightens.

8.0 Reinstalling the Rear Roller

8.1 Slide the rear roller inside the belt and let it hang loose.

8.2 Slide the molding onto the side rails.

8.3 Install the alignment bolts through their holes in the end cap and into the holes on the roller.

Hole

8.4 Install the end cap onto the rear of the treadmill, making sure the alignment pins go into the holes on the ends of the side rails.

8.5 Hand tighten the adjustment bolts.

8.6 Align the walk belt so that the edges of the belt are equal distance from the side rails.

8.7 Tighten the adjustment bolts to take the slack out of the walk belt.

8.8 Perform the belt tension and belt tracking procedures outlined on pages 4–6.

9.0 Reinstall the Treadmill Hood

9.1 Install the treadmill hood over the motor compartment.

9.2 Install the six (6) screws in the treadmill hood and tighten.

9.3 Plug the AC power cord into the treadmill, and turn on the treadmill circuit breaker switch.

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Replacing the Lens

Replacing the Contact Heart Rate (CHR) Sensors

1 Remove the old sensors.

2 Clean the old adhesive off the plastic contact point using rubbing alcohol.

3 Make sure that the wire connection tab is bent from a V-shape to a U-shape, and attach the wire to the tab.

4 Peel the paper off the sensor plate's adhesive tape.

5 Press the sensor plate firmly onto the plastic contact point.

6 Install one “zip tie” around each side of the sensor for both the left and right CHR sensors.

7 Using a knife or scissors, carefully remove the “zip ties” from the sensors after 24 hours. Important: The “zip ties” must remain on the sensors for at least 24 hours.

Replacing the Lens

1.0 Removing the Lens

1.1 Remove the three (3) T-15 torx screws from the bottom back of the controller.

1.2 Remove the seven (7) button head screws that hold the console onto the controller support weldment, and lift the controller off carefully.

1.3 Disconnect the contact heart rate wire from the contact heart rate (CHR) module.

1.4 Disconnect the ribbon cable from the power control board assembly (PCBA).

1.5 Disconnect the communication cable from the PCBA.

1.6 Remove the thirteen (13) T-15 torx screws from the back of the controller assembly.

1.7 Disconnect the three (3) keypad ribbon cables from the PCBA/processor assembly.

1.8 Remove the six (6) screws from the PCBA display/processor assembly and remove it.

1.9 Remove the nine (9) screws that hold the lens and remove it from the front controller assembly.

2.0 Reinstalling the Lens

2.1 Attach the lens to the front controller assembly with nine (9) screws.

2.2 Apply blue Loctite

®

to the six (6) screws

2.3 Attach the PCBA display/processor assembly with the six (6) screws.

2.4 Connect the three (3) keypad cables.

2.5 Reinstall the controller by repeating steps 1.1–1.6 under “1.0 Removing the Lens” in reverse order.

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Updating the Console Firmware

Updating the Console Firmware

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PLUG P7 and CONNECTOR J7 ARE KEYED. DO NOT CONNECT

P7 TO J7 BACKWARDS; OTHERWISE, THE PCBA/PROCESSOR

ASSEMBLY CAN BE DAMAGED.

1 Turn the power off.

2 Plug the data ribbon cable from the AVR FISP onto J7. J7 is accessible through the small hole on the left side next to the louvers on the rear of the console. The red line on the ribbon cable will be on the right if the cable is installed properly.

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J7

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3 Turn power back on.

• The LED on the AVR FISP will flash yellow as data is downloaded to the console.

• The download takes one minute.

4 Unplug the AVR FISP ribbon cable from J7.

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P

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Console Codes

Contents

Overview..............................................................................16

Cardio ..................................................................................16

Defaults ............................................................................16

User Weight .....................................................................17

Exercise Time ..................................................................17

User Age ..........................................................................17

Target Heart Rate ............................................................18

Treadmill Speed ...............................................................18

Cool-Down Time ..............................................................18

Quick Start .......................................................................18

Decline .............................................................................19

Owner-Defined Custom .......................................................19

Customize ........................................................................19

Max Time .........................................................................20

Change Units ...................................................................20

HR Inputs .........................................................................20

Language .........................................................................21

Contrast (2100 LC only) ...................................................21

Max Speed .......................................................................21

Side Lights .......................................................................22

Enable Mag Key ..............................................................22

Set Defaults .....................................................................22

Machine Status ....................................................................22

Machine Status ................................................................23

Run-Time Hours ...............................................................23

Number of Workouts ........................................................23

Distance Traveled ............................................................23

Software Revision ............................................................24

Configuration ...................................................................24

TM Drive ..........................................................................24

Maintenance Hours ..........................................................24

Program Selection ...........................................................24

Diagnostic ............................................................................25

Diagnostic ........................................................................25

Display Test ......................................................................25

Key Test ...........................................................................25

Serial Tests ......................................................................26

Bus Volts ..........................................................................26

Grade Act .........................................................................26

Diagnostic 2 .........................................................................26

Diagnostic 2 .....................................................................26

Error Log ..........................................................................27

Maintenance Hours ..........................................................27

Magnetic Key Limit Access Control .....................................27

Overview ..........................................................................27

Activation ........................................................................27

Deactivation .....................................................................28

Magnetic Key as an Emergency Stop .............................28

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Contents

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Cardio

Overview

There are five groups of console codes as follows: Cardio (codes starting with 2), Owner-Defined Custom (codes starting with 3), Machine Status (codes starting with 4), Diagnostic (codes starting with 6), and Diagnostic 2 (codes starting with 7). Each group of codes is defined below. To access these console codes and the options within each group, follow the instructions for each section.

Cardio

You can customize several default settings on the ClubTrack 2100 to conform to your individual requirements, including changing the:

• default weight,

• workout time,

• age,

• percentage of Maxmum Heart Rate for Target HR in HR Zone Trainer,

• treadmill speed,

• default cool-down time,

• initial speed for Quick Start, and

• incline minimum.

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6

3

4

7

1

2

Refer to the following table to scan through and change the cardio settings:

Table 2–1. Defaults

Step No. Press Keys On Console

CLEAR, 2, ENTER

Display (What you will see)

DEFAULTS

INCLINE UP or INCLINE DOWN

ENTER WT, RESERVED,

ENTER TIME, ENTER AGE, THR

PERCENT, SPEED, RESERVED,

COOLDOWN TIME, QUICK

START, DECLINE

ENTER

SPEED + or SPEED -

ENTER

CLEAR

CLEAR

Selected choice

Default value changes

UPDATING

DEFAULTS

THE RESULTS YOU WANT

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Refer to the following tables to change individual default workout settings without scanning through all the selections:

Table 2–2. User Weight

Step No. Press Keys On Console Display (What you will see)

3

4

1

2

CLEAR, 2, 0

ENTER


ENTER

ENTER WT

ENTER WT 175*

Weight changes from 50–400 lbs

UPDATING

5 CLEAR


* Default setting. Setting could be different if the treadmill was customized.

Table 2–3. Exercise Time


3

4

1

2

CLEAR, 2, 2

ENTER


ENTER


ENTER TIME

ENTER TIME 20*

Time changes from 5–99 min

UPDATING

5 CLEAR



Table 2–4. User Age


3

4

1

2

CLEAR, 2, 3

ENTER


ENTER


ENTER AGE

ENTER AGE 40*

Age changes from 10–99

UPDATING

5 CLEAR



Cardio

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Cardio

Table 2–5. Target Heart Rate


1

2

3

CLEAR, 2, 4

ENTER



THR PERCENT

THR PERCENT 70*

THR percentage changes from

50–85%

4

5

ENTER

CLEAR

UPDATING



Table 2–6. Treadmill Speed


1

2

CLEAR, 2, 5

ENTER


SPEED

SPEED MPH 2.0*

3 SPEED + or SPEED -

Adjust Speed to acceptable level

4

5

ENTER

CLEAR

UPDATING



Table 2–7. Cool-Down Time


1

2

3

CLEAR, 2, 7

ENTER



COOLDOWN TIME

COOLDOWN TIME 2*

Cool-down time changes from 2–10 min

4

5

ENTER

CLEAR

UPDATING



Table 2–8. Quick Start


1

2

3

CLEAR, 2, 8

ENTER



QUICK START

QUICK START 1*

Starting speed changes from 1–.5 mph

4 ENTER

UPDATING

5 CLEAR



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Owner-Defined Custom

Table 2–9. Decline


1

2

CLEAR, 2, 9

ENTER


DECLINE

OFF


Toggles between OFF and ON

4

5

ENTER

CLEAR

UPDATING



Owner-Defined Custom

You can customize several owner-defined parameters to conform to your individual requirements, including:

• changing the workout time limit,

• changing the units between English and metric,

• choosing the type of heart rate input,

• choosing the console language,

• changing the contrast,

• changing the treadmill’s maximum speed,

• enabling or disabling the sidelight during Intro Mode,

• enabling the magnetic key, and

• resetting the factory defaults.

1

2

Table 2–11. Customize


CLEAR, 3, ENTER


5

6

3

4

ENTER


ENTER

CLEAR

7 CLEAR

*Only available on the 2100 LC model.


CUSTOMIZE

MAX TIME, CHANGE UNITS,

HR INPUTS, RESERVED,

LANGUAGE, CONTRAST*, MAX

SPEED, SIDE LIGHTS, ENABLE

MAGKEY, SET DEFAULTS

Selected choice

Default value changes

UPDATING

CUSTOMIZE


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To customize the owner-defined parameters without scanning through all the selections, perform the following steps for that listed option:

Table 2–12. Max Time


MAX TIME

3

4

1

2

CLEAR, 3, 0

ENTER


ENTER

5 CLEAR

* Default setting. Setting could be different.

99*

Time limit of your choosing

UPDATING


2

3

Table 2–13. Change Units


1 CLEAR, 3, 1

ENTER


4 ENTER

5 CLEAR



CHANGE UNITS

USA UNITS*

Toggles between USA UNITS and

METRIC UNITS

UPDATING


1

2

3

Table 2–14. HR Inputs


CLEAR, 3, 2

ENTER


4 ENTER

5 CLEAR



HR INPUTS

EITHER INPUT

LOCKED INPUTS, EITHER INPUT,

TELEMETRY ONLY, HAND ONLY,

BOTH HR OFF

UPDATING


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Table 2–15. Language


1

2

3

CLEAR, 3, 4

ENTER



LANGUAGE

ENGLISH*

ENGLISH, GERMAN, SPAN-

ISH, FRENCH, ITALIAN, DUTCH,

SWEDISH, JAPANESE

UPDATING


4

5

ENTER

CLEAR


1

2

Table 2–16. Contrast (2100 LC only)


CLEAR, 3, 5

ENTER

3 SPEED + or SPEED - (press and hold)

4

5


(press and hold)

ENTER

6 CLEAR



CONTRAST

CONTRAST

2.2% 27:45 2.5 MPH*

Changes contrast in the upper LCD screen

Changes contrast in the lower LCD screen

UPDATING


1

2

3

Table 2–17. Max Speed


CLEAR, 3, 6

ENTER


4 ENTER

5 CLEAR



MAX SPEED

MAX SPEED 12*

Maximum treadmill speed of your choosing

UPDATING



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Machine Status

Table 2–18. Side Lights


1

2

CLEAR, 3, 7

ENTER


4

5

ENTER

CLEAR


Table 2–19. Enable Mag Key


1

2

CLEAR, 3, 8

ENTER


4

5

ENTER

CLEAR


1

2

5

Table 2–20. Set Defaults


CLEAR, 3, 9

ENTER

CLEAR


SIDE LIGHTS

SIDE LIGHTS ON*


UPDATING



ENABLE MAGKEY

ENABLE MAGKEY OFF*


UPDATING



SET DEFAULTS

UPDATING, then DONE


Machine Status

Use the machine status codes to view maintenance information such as the:

• machine run-time hours,

• number of workouts,

• distance traveled,

• console version,

• configuration setting,

• motor drive version,

• machine run-time hours since last cleared (for servicing purposes), and

• the individual program selection count.

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Machine Status

3

4

5

1

2

To scan through and change the owner-defined codes, perform the following steps:

Table 2–21. Machine Status


CLEAR, 4, ENTER


MACHINE STATUS


RUN HOURS, WORKOUTS,

DISTANCE -, CONSOLE

VERSION, CONFIGURATION, TM

DRIVE VERSION, MAINT HOURS,

PROGRAM SELECTION

ENTER

CLEAR

CLEAR

Value for selected choice

MACHINE STATUS


To view a particular machine status without having to scan through all the choices, perform the following steps for that listed option:

Table 2–22. Run-Time Hours


1 CLEAR, 4, 0


RUN HOURS

2 ENTER

Total run-time hours since last servicing

3 CLEAR


1

2

3

Table 2–23. Number of Workouts


CLEAR, 4, 1

ENTER

CLEAR


WORKOUTS

Total number of workouts


1

2

Table 2–24. Distance Traveled


CLEAR, 4, 2

ENTER

3 CLEAR


DISTANCE -

Total distance users have traveled using the treadmill


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3

4

5

Machine Status

1

2

Table 2–25. Software Revision


CLEAR, 4, 3

ENTER

3 CLEAR

1

2

3

Table 2–26. Configuration


CLEAR, 4, 4

ENTER

CLEAR

Table 2–27. TM Drive


1 CLEAR, 4, 5

2 ENTER

3 CLEAR

1

2

Table 2–28. Maint Hours


CLEAR, 4, 6

ENTER

3 CLEAR

1

2

Table 2–29. Program Selection


CLEAR, 4, 7

ENTER

INCLINE ↓ or INCLINE ↑

CLEAR

CLEAR


CONSOLE VERSION

CBD2G2 Vxx xxxx (where “x” is the version number)



CONFIGURATION

0.5–12 MPH 0–15%



TM DRIVE VERSION

TM DRIVE VERSION xx (where “x” is the version number)



MAINT HOURS

MAINT HOURS xxx.x (where “x” is the total number of hours since the machine was last serviced)



PROGRAM SELECTION

Program name, followed by the total number of times that program was used)

Cycles through program names

MACHINE STATUS


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Diagnostic

Use the diagnostic codes to test various components of the machine such as the:

• display,

• keyboard, and

• serial port.

The diagnostic codes also allow you to get a report on the treadmill’s:

• drive bus voltage and

• actual grade setting.

1

2

3

4

5

Table 2–30. Diagnostic


CLEAR, 6, ENTER


ENTER

CLEAR

CLEAR


DIAGNOSTIC

DISPLAY TEST, KEY TEST,

SERIAL TEST, RESERVED,

RESERVED, RESERVED,

RESERVED, RESERVED, BUS

VOLTS, GRADE ACT

Selected choice

DIAGNOSTIC


1

2

To scan through the list of diagnostic tests and view diagnostic information:

Table 2–31. Display Test


CLEAR, 6, 0

ENTER

DISPLAY TEST

Display LEDs or LCD pixels in alternating fashion

3 CLEAR TWICE


1

2

3

Table 2–32. Key Test


CLEAR, 6, 1

ENTER


KEY TEST

PRESS KEY

KEY PANEL KEY (press and hold) The name of the key you are pressing

4 CLEAR TWICE


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Diagnostic

25

Diagnostic 2

3

4

1

2

Table 2–33. Serial Tests


CLEAR, 6, 2

ENTER

CLEAR

CLEAR

1

2

Table 2–34. Bus Volts


CLEAR, 6, 8

ENTER

3 CLEAR TWICE

Table 2–35. Grade Act


1 CLEAR, 6, 9

2 ENTER

3 CLEAR TWICE


SERIAL TESTS

RUNNING, PASS, or FAIL

DIAGNOSTIC



BUS VOLTS

BUS VOLTS xxx (where “x” is the drive board bus voltage reading)



GRADE ACT

GRADE ACT x.x (where “x” is the actual grade setting)


Diagnostic 2

The DIAGNOSTIC 2 settings allow you to view the machine’s error log and reset or change the maintenance hours between service calls.

To scan through and change the owner-defined codes, perform the following steps:

5

6

1

2

Table 2–36. Diagnostic 2


CLEAR, 7, ENTER

3


DIAGNOSTIC 2


ERROR LOG, MAINT HOURS

ENTER (not necessary for maintenance hours)

Selects the option you want and displays the results

4


Error codes

CLEAR

DIAGNOSTIC 2

CLEAR


To view a particular machine status without having to scan through all the choices, perform the following steps for that listed option:

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Magnetic Key Limit Access Control

2

3

4

1

2

3

Table 2–37. Error Log


4

CLEAR, 7, 0

ENTER


ERROR LOG

ERROR (if any) or NO ERROR

INCLINE UP� or INCLINE DOWN

A list of errors

CLEAR


Table 2–38. Maintenance Hours


1 CLEAR, 7, 1


ENTER

CLEAR


MAINT HOURS xxx (where “x” is the current maintenance hours setting)

Zero or a setting of your choosing

UPDATING


Magnetic Key Limit Access Control

Overview

Limited-access control lets you restrict treadmill use to authorized personnel. It also lets you stop the treadmill in an emergency. The magnetically-activated control is located on the front of the handrail just below the STOP key. The limited-access control is deactivated on machines shipped from the factory.

Activation

Activate the limited-access control and restrict access by placing the magnetic key supplied with the treadmill in the designated area in the front handrail so that the StairMaster magnet will activate the control.

®

trademark “S” logo on the key faces the user. The

Magnetic Key

®

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Magnetic Key Limit Access Control

1 Place the magnetic key in its location on the Ergo bar.

2 On the keypad, press CLEAR, 3, 8, and ENTER.

3 Press the SPEED � or SPEED � to select “ON.”

4 Press ENTER.

5 Cycle the power.

The magnetic key feature for the treadmill is now active. If you remove the key, the treadmill belt will stop, and the controller will not respond to any key presses. The console will display a message “REPLACE MAGNET” when you remove the magnetic key from its designated area. You must replace the key or deactivate the control to start the treadmill belt.

Deactivation

1 With the magnet key in place and the display at the opening message “SELECT WORKOUT,” press CLEAR, 3, and 8. The console will display “ENABLE MAGKEY.”

2 Press ENTER, and the display will either read “ON” or “OFF.”

3 Press the SPEED � or SPEED � key to toggle between “ON” and “OFF.”

4 Select “OFF,” and press ENTER. The display will show “UPDATING” for a few seconds, then display the off setting.

5 Turn off power to the treadmill at the circuit breaker switch. The circuit breaker switch is located on the bottom front panel of the treadmill.

6 Remove the magnet key.

7 Turn power to the treadmill back on at the circuit breaker switch. The display will show the “SELECT

WORKOUT” screen. The limited-access control remains inactive, granting unrestricted access until you turn the magnetic key option back on or place the magnet back in its designated area.

Magnetic Key as an Emergency Stop

The magnetic key has a string with a clip that attaches to your wrist or belt during exercise. If you move too far from the front handrail, the cord will pull the key off and stop the treadmill walk belt.

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P

ART

3

Troubleshooting Electrical

Problems

Contents

Common Electrical and Electronic Problems ......................31

Table 3–1. Electrical Issues .............................................31

Table 3–2. Electronic Issues ............................................31

Error Reporting ....................................................................32

Error List ..........................................................................32

Future Errors ....................................................................33

Error Resolution ...............................................................34

VSD .....................................................................................34

LED Patterns ...................................................................34

Troubleshooting Flowcharts ................................................35

Replacing the Grade Actuator Motor ...................................39

Problems with the Drive Motor ............................................41

Contents

Replacing the Drive Motor ...................................................42

Magnetic Key Problems ......................................................45

Wiring Schematics ..............................................................45

120V Wiring Schematic ...................................................46

230V European Wiring Schematic ...................................47

230V Non-European Wiring Schematic ...........................48

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Common Electrical and Electronic Problems

Common Electrical and Electronic Problems

The following tables provide possible causes and solutions to the most common types of electrical and electronic problems. While the information in these tables may not resolve all problems, they should help you isolate the area affected by the problem.

Table 3–1. Electrical Issues

Problem Possible Causes Remedy

There is no display.

Circuit breaker on the treadmill hood is off.

Treadmill power cord is not plugged in.

• Set the treadmill circuit breaker to ON.

• Plug in the power cord, then set the treadmill circuit breaker to

ON.

Circuit breaker trips during normal operation.

Treadmill will not change grade.

Grade actuator motor runs, but grade never changes.

There is no power at the wall outlet.

• Check the building circuit breaker.

There is an internal electrical problem.

• Refer to the wiring schematics located in this section of the manual.

There is a blown fuse

There is a power fault.

There is an insufficient power source.

• Replace F1, F3, or F4.

• Inspect walk belt for wear.

• Make sure the outlet voltage is 115VAC (USA) or 230VAC

(International)

The treadmill is not on its own dedicated circuit.

Fuse is blown.

There is an internal problem.

Grade actuator motor is bad.

• Plug the treadmill into its own

20-amp dedicated electrical outlet.

• Replace blown fuse F2.

• Cycle the circuit breaker switch on the treadmill.

• Replace the grade actuator motor.

• Replace the grade actuator motor.

Table 3–2. Electronic Issues

Problem

TM COM ERROR appears on the display at power-up.

Treadmill will not change grade.

Treadmill will not reach maximum speed.

Treadmill will not reach maximum time.

Possible Causes

Main cable is possibly crimped.

Upper display board is bad.

VSD board is bad.

Remedy

• Replace the main cable.

• Replace the console.

• Replace the VSD.

Old firmware is installed.

• Upgrade the firmware.

Speed limit control may be activated

• Refer to Part 2 for adjusting treadmill maximum speed.

Time limit control may be activated.

• Refer to Part 2 for adjusting treadmill maximum time.

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Error Reporting

Table 3–2. Electronic Issues

Problem

Walking belt stops, and no error message appears.

Possible Causes

User hit the Ergo stop button.

CHR does not work.

Ergo PCB is not grounded.

Contact plates have excessive moisture under them.

Remedy

• Press START to resume workout.

• Ground the Ergo PCB.

• Replace the contact plates if cleaning them first does not resolve the problem.

• Replace the CHR PCB.

Error Reporting

The current lists of errors are for the firmware version LED 1.0 and LCD 5.0. The system reports various problems to the user via the display. The format includes the text line reporting the error.

Definitions

Warning—A message that appears on the console display that informs you of a condition that requires attention but does not stop treadmill operation.

Error—A message that appears on the console display that informs you of a condition that halts the operation of the treadmill and which requires immediate attention.

Table 3–3. Error List

Label Type

NO ERROR N/A

PROGRAM

ERROR

Error

Response

Displayed in the Error Log if no events.

Start-up—Stops operation.

Description

Placeholder label.

STATIC RAM

ERROR

Error

EEPROM ERROR Error



ALL—Microprocessor fails self-test program memory check sum error.

Display will be blank and the console will beep twice.

ALL—Microprocessor fails self-test

RAM check sum error. Display will be blank, and the console will beep. It will beep three times for an Internal

RAM error. It will beep four times for an external RAM error.

ALL—Microprocessor fails self-test

EEPROM chksum error. All of the

EPROM values will be loaded with the defaults. No error message appears.

Treadmill UART hardware link failure.

TM HW COM

ERROR

Error

TM COM ERROR Error

DRIVE ERROR Error

Anytime—Goes to idle. Treadmill slowly stops.


Program operation—Goes to idle.

Treadmill stops quickly.

Treadmill E204 drive communication failure low.

Treadmill E209 output switching fault low.

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Error Reporting

Table 3–3. Error List

Label Type

OUT CUR ERROR Error

BELT OVRLD

ERROR

Warning

SYS OVRLD

ERROR

Error

DRV MON ERROR Error

CONFIG RQRD

GRD LIMIT

ERROR

GRD MOVE

ERROR

SPD CHANGE

ERROR

STUCK KEY

Error

Error

Error

Error

Error

Response


Treadmill slowly stops.

During movement—Displays message until the user presses

CLEAR.






During change—Goes to idle.


During change—Goes to idle.





Description

Treadmill E208 output current too low.

Treadmill E207 moderate drive overload.

Designed to inform the user that the belt or deck will need to be replaced soon.

Treadmill E203 high drive overload.

Treadmill E210 current monitoring circuit failure.

Treadmill E212 configuration not allowed.

Treadmill E201 grade position outside limits.

Treadmill E211 grade system detected an non-requested response.

TM E(new) drive is commanded to change speed but doesn’t.

One of the keypad keys are stuck in an active state. Reports only “Stuck key.”

Table 3–4. Future Errors

Label Type

CS HW COM

ERROR

Warning

CS COM ERROR Warning

STUCK KEY

POWER LOSS

Error

Warning

Response

Start-up—Stops CSAFE but continues user selection.

Anytime—Stops CSAFE but continues program.

Start-up—Locks out key.


Description

ALL—CSAFE UART hardware link failure.

ALL—CSAFE communication failure.

Reports which key is stuck.

Loss of power to the motor drive electronics.

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33

VSD

Table 3–5. Error Resolution

Error Code Action

E204 Verify the cable connections at both ends. Check for bent or broken pins, and replace if required. If error persists, replace the VSD or controller as necessary.

E209

E208

E207

E203

E210

E212

E211

Replace the VSD.

Replace the VSD.

Replace the belt or deck if worn; otherwise, press CLEAR.

High Motor overload caused by one of the following:

1 Runner heavier than weight / speed envelope in conjunction with significant deck wear.

Solution: Restrict use to people within the weight/speed specifications, and check deck wear. Replace if necessary.

2 Motor lead disconnected or loose.

Solution: Check the motor leads to ensure all leads are connected. One loose or disconnected lead will cause the overload.

3 Electrical failure on the drive electronics.

Solution: Replace the VSD.

4 Motor blocked by obstruction.

Solution: Remove the obstruction.

Replace the VSD.

Verify that the 3 jumpers are attached correctly on the VSD board. If problem persists, replace

VSD board.

Replace the VSD or grade motor.

VSD

Table 3–6A. LED Patterns for PC Boards P/N - 27920 & 27115.

LED On Off

DS1 Only when belt is running When belt is stopped

DS2 Overload

DS3 Power to the console

DS4 Normal

Normal

No power to the console

VSD problem

Note: If the VSD detects an error, DS1 and DS2 will blink.

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VSD

Table 3–6B. LED Patterns for PC Board P/N - 41387.

LED On Flashing

DS1 Belt is running *

DS2 Motor Overload * or once per second for proper console communication n/a DS3 Power to the console and Drive

Processor

DS4 Power to Drive Motor Control Circuits n/a

Off

Belt is stopped

No console communication

No power present

No power to P20 or VSD problem

* DS1 and DS2 flashing together indicates an error condition and shows automatic resets of the system.

Troubleshooting Flowcharts

Use the flowcharts on the pages 36–40 to help you localize and correct electrical and electronic problems.

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35

Troubleshooting Flowcharts

No Display

There is no

Console display.

Is DS3 lit?

No

Yes

Check that voltages between

TP7 (GND) and pin 1 of P1 and

TP7 and pin 8 of

P1 on VSD Board are 18VDC.

Is the voltage good?

Yes

Remove Console, and disconnect J4 harness on

Console

Processor PCB.

No

Replace the VSD

Board

End

Check that the voltage between pins 1 (black) and

2 (brown) and pins

2 and 8 (purple) of the wire harness reads 18VDC.


Yes

Replace the

Processor PCB.

No Replace the Main

Cable.

End

36

Check fuses F1,

F3, and F4 on

Configuration

Plate Assembly.

Are the fuses good?

No

Replace the blown fuse.

Yes

Remove P14 on the VSD Board.

End

Check that the voltage between the red and black wires reads

14VAC.


Yes

Replace the VSD

Board.

No

Replace the

Configuration

Plate Assembly.

End

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No Elevation Movement

Treadmill will not elevate.

Is a

“Grade Move

Error” present?

No

Yes

Unplug P18, and check for 118VAC between the blue and brown wires.


Yes

No

Replace fuse F2 on the

Configuration

Plate Assembly.

Turn off power.

Short pins 1 and 2 of Q8 on the VSD

Board.

Turn power back on.

Does the

Actuator Motor run?

No

Replace the

Actuator Motor.

Yes

Replace the VSD

Board.

End

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Cycle the power.

Does the treadmill elevate?

Yes

No

Upgrade the firmware.

Perform keypad test: CLEAR, 6, 1.

End

Does

GRADE ? and

GRADE ?

work?

No

Yes

Replace the

Controller/

Processor PCB.

Replace the

Keypad Assembly.

End

37


Non-Functional CHR

CHR does not function.

Check for 2VDC between the top and bottom contact plates on each handgrip


Yes

No

Cycle the power.

Remove the contact plates from handgrips and recheck voltage.

Is the CHR working?

No

Yes

Replace the

Controller/

Processor PCB.

End

Is the voltage is good?

No Replace the CHR

PCB.

Yes

Replace the CHR, making sure the wire tabs do not contact each other inside the Ergo

Bar Assembly.

End

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Non-Functional Ergo Bar

Ergo Bar does not function.

Cycle the power.

“STUCK

KEY ERROR” present?

No

Yes

Replace the Ergo

Keypad and/or the

Ergo PCB.

Is the

Magnet Key in use?

No

Yes

Remove the

Magnetic Key and inspect for rust.

End

Is the

Magnetic

Key rusted?

Yes

No

Remove and inspect the Ergo

PCB for corrosion.

Replace the

Magnetic Key.

Is the

Ergo PCB corroded?

Yes

No

Inspect Ergo PCB ribbon cable from pod cover for crimped wire.

Replace the Ergo

PCB.

Is the cable crimped?

Yes

No

Replace the Ergo

PCB.

End

Replace the cable.

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End

39

� � � � � � �

� � � � � �

Replacing the Grade Actuator Motor

� � � � � � � � �

� � � � � � �

DANGEROUS VOLTAGES ARE PRESENT UNDER

THE TREADMILL HOOD. EXERCISE CAUTION WHEN

��

UNDER THE HOOD.

BEFORE REMOVING THE GRADE ACTUATOR MOTOR, PLACE

TWO 5-INCH BLOCKS UNDER THE FRONT OF THE TREADMILL

TO PREVENT IT FROM DROPPING WHEN YOU REMOVE THE

MOTOR.

1.1 Place two (2) 5-inch (13 cm) blocks securely under the treadmill headframe.

1.2 Turn the treadmill circuit breaker off, and unplug the treadmill power cord.

1.3 Remove the six (6) screws on the treadmill hood.

1.4 Lift off the hood.

2.0 Remove the Grade Actuator Motor

Unplug

� � � � � � �

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40

Replacing the Grade Actuator Motor

2.2 Remove the grade actuator ground wire using a 10-millimeter socket wrench.

2.3 Remove the two (2) 8-millimeter hex bolts and shoulder bushings that secure the swing arm to the grade nut block.

Bolts

2.4 Remove the 3/8-inch hex bolt, washer, lock washer, and nut from the headframe mounting bracket, and remove the grade actuator motor. The bolt is located underneath the motor.

2.5 Withdraw the steel cylinder bushing from the bronze bearing.

2.6 Unscrew the grade block containing the actuator nut from the actuator drive screw.

2.7 Remove the two (2) 4-millimeter hex screws and lock washers securing the grade nut.

3.0 Install the Replacement Grade Actuator Motor

3.1 Lubricate and insert the steel cylinder bushing on the new actuator bronze bearing.

3.2 Mount the actuator grade motor onto the headframe bracket, and secure the motor with the 3/8-inch hex bolt, flat washer, lock washer, and nut.

3.3 Reinstall the ground wire using screw and star washer previously remoeved in Step 2.2.

3.4 Insert the black wire into pin 4 on P17, as shown below, and plug P17 onto the VSD board, lip-side up.

� � � � � �

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41

Problems with the Drive Motor

4.0 Zero the Grade Actuator Motor

4.1 Plug the Actuator cable into the VSD.

4.2 Plug the Power Cord into the outlet and turn the machine on.

4.3 On the console press the “INCLINE UP” key to 4% incline. The shaft on the Actuator will rotate for a short period of time. Wait until it stops.

NOTE: If console displays “Grade Limit Error”, turn power off, then back on and repeat Step 4.3.

4.4 On the console press the “DECLINE DOWN” key to 0%. The shaft of the Actuator will rotate in the opposite direction. Wait until it stops.

4.5 Insert a new grade nut into the grade block, and secure it with the two (2) lock washers and 4millimeter screws.

4.6 Thread the Grade Block Nut onto the Actuator shaft, until the tip of the shaft can barely be seen (two or three threads inside the block).

4.7 Lubricate the grade block, and secure it to the swing arm using the two (2) shoulder bushings and 8millimeter screws. Tighten the screws until the bushings are flush.

Note: When installing the shoulder bushing, turn the bushings until the flat side of the bushings match the flat side of the mounting holes on the swing arm.

4.8 Press the “QUICK START” key, then “INCLINE INCREASE/DECREASE” keys to verify operation.

5.0 Reinstall the Treadmill Hood

5.1 Install the treadmill hood over the motor compartment.

5.2 Install the six (6) screws in the treadmill hood and tighten.

5.3 Plug the AC power cord into the treadmill, and turn on the treadmill circuit breaker switch.

Problems with the Drive Motor

The 3-phase AC drive motor is equipped with thermal protection circuitry. If you receive a “POWER LOSS” error that consistently reoccurs when the power is cycled to the treadmill, perform the steps below.

To verify if the thermal switch has opened:

1 Unplug P5 and P6 from the VSD board.

2 Ohm between the two wires and verify there is a short. If your reading shows an open circuit, the motor has overheated. Let the motor cool down for 60 minutes to allow the thermal switch to close. If the problem persists, replace the deck and walk belt.

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Replacing the Drive Motor

3 If you receive a “POWER LOSS” error after allowing the motor to cool down for 60 minutes; re-check the thermal switch wires as described in step 2. If the continuity test fails (your multimeter reads an “open”), replace the drive motor. If you have continuity between the two thermal switch wires and you receive a

“POWER LOSS” error at power-up, replace the VSD.

Important: When replacing the main motor, be sure to install the rubber insulators under the washers. If after replacing the motor the belt runs backwards, swap any two adjacent motor phase wires P7 and P8, or P8 and P9.

Replacing the Drive Motor

� � � � � � �

DANGEROUS VOLTAGES ARE PRESENT UNDER THE

TREADMILL HOOD. EXERCISE CAUTION WHEN PERFORMING

SERVICE TO THE ELECTRICAL COMPONENTS UNDER THE

HOOD.

1.0 Remove the Treadmill Hood

1.2 Remove the six (6) screws on the treadmill hood.

1.3 Lift off the hood.

2.0 Remove the Motor

2.1 Disconnect P5, P6, P7, P8, and P9 from the VSD board. (See appropriate wiring schematic on pages 46-

48 for the location of where the plugs connect to the VSD board.)

� � � � � � � � �

Unplug

��

� � � � � � �

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43


2.2 Place a 9/16 wrench on the head of the bolt mounting the Tensioner and turn counter clockwise until

Tensioner loosens. b. Lift up on the Tension Wheel and slide the motor drive belt over pulley to remove.

2.3 Use a 13-millimeter open-end or socket wrench to remove the four (4) hex nuts securing the motor to the headframe, and pull the motor off of the headframe.

Other nut hidden below housing

Nut

Nuts

44

2.4 Remove the four (4) washers and rubber isolators from the motor mount studs. Note the arrangement of the isolator mounts.

2.5 Loosen the two (2) set screws fastening the flywheel/drive pulley to the motor shaft, and then remove the flywheel/drive pulley.

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3.0 Install Motor

3.1 Install the new flywheel on the new motor shaft.

3.2 Inspect the rubber isolators for wear. If they are bad, replace them.

3.3 Slide the replacement motor onto the headframe motor mount studs.

3.4 Install the rubber isolators and washers onto the studs

3.5 Apply Loctite

®

to the motor mount studs.

3.6 Install the nuts on the motor mount studs and tighten. Important: Tighten the nuts until the lock washers flatten, then turn the nuts 1/2 turn further. Do not over-tighten the nuts.

3.7 Connect the five (5) wires from the motor to P5, P6, P7, P8, and P9 on the VSD board.

4.0 Align the Drive Belt

The new motor and flywheel must be aligned with the front roller pulley.

4.1 Use a straight-edged ruler placed on the outside of the front roller pulley to align the outside face of the motor drive pulley to within 0.020 inches (0.5mm) of the straight-edged ruler.

4.2 Tighten the two (2) set screws on the flywheel/drive pulley and tighten.

After alignment of the Front Roller and Flywheel, place belt on the Front Roller and Flywheel.

4.3 Place 5/16 wrench on nut of Tensioner and turn counter clockwise creating tension on the bent and hold. The top two notches should line-up.

4.4 Place the 9/16 wrench back on the head of the mounting bolt and turn clockwise, until the bolt tightens.

4.5 Replace the poly-V drive belt back onto the flywheel/drive pulley.

4.6 Slide the poly-V drive belt back under the tensioner.

5.0 Reinstall the Treadmill Hood

5.1 Install the treadmill hood over the motor compartment.

5.2 Install the six (6) screws in the treadmill hood and tighten.

5.3 Plug the AC power cord into the treadmill, and turn on the treadmill circuit breaker switch.

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45

Wiring Schematics

Magnetic Key Problems

Ergo bar problems include the Ergo bar itself and the magnetic key.

Rust on the magnetic key can cause intermittent “POWER LOSS” and “DRIVE ERROR” messages to appear on the console. The magnetic key should be inspected weekly for signs of rust forming on the magnet. Replace the magnet if it looks anything like the rusted magnet in the picture.

The magnetic’s logo “S” should be over the Ergo bar magnetic pick-up bracket.

If the magnetic key is not being used, the Ergo PCB and CHR PCB must be grounded.

Wiring Schematics

Use the schematics on the following pages to assist you in isolating and correcting electrical and electronic problems.

46

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120V Wiring Schematic

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47

230V European Wiring Schematic

48

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230V Non-European Wiring Schematic

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49

P

ART

4

Troubleshooting Mechanical

Problems

Contents

Common Mechanical Problems and Solutions ....................50

Walking Belt .....................................................................50

Noises ..............................................................................50

Common Mechanical Problems and Potential Causes

Common Mechanical Problems and Solutions

Table 4–1. Walking Belt

Problem

1 Walking belt is too far to the left or right.

Potential Causes

• The belt is tracking improperly.

2 Walking belt slips, but the front roller turns.

3 Walking belt hesitates. Adjusting the walking belt tension is ineffective.

• The walk belt tension is improperly set.

• The motor drive belt is slipping.

• The VSD is bad.

Solutions

• Adjust the tracking. (Refer to Part 1 to correct the problem.)

• Adjust the belt tension.

(Refer to Part 1 to correct the problem.)

• Replace the motor drive belt.

• Adjust the motor drive belt tension.

• Replace the VSD.

Table 4–2. Noises

Problem

1 There is a grinding sound.

2 Banging noise when the person is running.

3 There is a squeaking noise when you walk on the deck.

4 There is a squeaking noise all the time when the belt is running.

Potential Causes Solutions

• There is a bad roller bearing.

• Replace the roller.

• The motor has a bad bearing. • Replace the motor.

• One or more compression mounts are worn (normally the ones in the front).

• The unit may not be level.

• The deck is contacting the side rails.

• Replace the compression mounts.

• Check the leveling feet.

• Replace the deck.

• The motor drive belt is worn.

• Relace the motor drive belt.

• The motor drive belt is misaligned.

• Make sure the grooves on the belt are seated correctly in the grooves on the front roller pulley and the motor flywheel.

• The motor flywheel is misaligned.

• Realign the motor flywheel with respect to the front roller pulley.

Note: Remove the motor drive belt to isolate if the problem to a roller or the drive motor.

ClubTrack

®


50

P

ART

5

Assembly Illustrations

Contents

Assembly Parts List .............................................................53

Assembly Drawings Overview .............................................55

Side Rails ............................................................................56

Headframe ...........................................................................57

Grade Weldment .................................................................58

Slider Bed ............................................................................59

Drive Motor ..........................................................................60

Front Roller ..........................................................................61

VSD Board ..........................................................................62

Upright Weldment ................................................................63

Controller Support ...............................................................64

Hood Assembly and End Caps ............................................65

Hand Grips and Ergo Bar ....................................................66

Cabling ................................................................................67

PCBA ...................................................................................68

Controller Keypanel .............................................................69

Controller Bottom Housing ..................................................70

Contents

ClubTrack

®


52

Assembly Parts Lists

Assembly Parts Lists

Part number information in the following table is meant to help you identify the parts in the drawings. They are not intended for use in ordering replacement parts. To order replacement parts, refer to Appendix C.

Table 5-1. Part Identifier List

Part #:

10011-070 Decal, Ground

Description:

27069

27300

27350

27351

27377

27378

27379

27386

27388

12497

12506

22016

22027

22077

22160

22845

22878

23729

27068

27441

27443

27444

27458

27467

27469

27477

27410

27415

27417

27424

27425

27426

27430

27436

Contact Plate, CHR

Adhesive Transfer Tape, 5 MIL

Screw, .375-16x2.50 Hex Hd Cap

Washer, Split Lock .250

.375 Nut, Hex

Screw, #6 x.38 Thread Forming Phillips

Washer, 1 1/4 x 17/32

Screw, Set 0.25-28x0.375

Washer, Split Lock 3/8

Bracket, Actuator

Assembly, Bracket, Actuator

Felt, Adhesive-Backed

Decal, StairMaster Right, 2100

Decal, StairMaster Left, 2100

Washer, M8, Flat Stainless


M8 x 1.25 x 16 Button Head

Assemly, Cable C50 ErgoBar

Flywheel, Cast

Plate, Motor Mounting

Plug, Hole, Rib-Lock

Roller Assembly, Drive

Block, Grade Nut

Support, Grade Weldment, Machined

Assembly, Nutplate, Foot

Bracket Assembly, Tensioner

Guard, Foot

Washer, Shoulder Isolation

Bushing Spanner

Bushing Shoulder

Drive Belt, Poly-V

Pulley Assembly, Rear

Retainer Cover

Hood

53

16

4

10

1

1

1

1

1

6

4

2

3

1

2

1

3

8

4

4

1

14

1

2

1

4

2

2

2

1

1

1

1

1

2

1

Qty: Part #:

27478

27542

27543

27544

27551

27552

27556

27559

27561

27562

27485

27487

27488

27489

27490

27535

27536

27537

27540

27541

27571

27573

27574

27575

27576

27577

27578

27563

27564

27565

27566

27567

27568

27569

27570

Description:

Cover Trim, Front

Weldment, Grade

Drive Motor, AC Variable

Assembly, VSD, 2100

Plug, 1.50 Sheet Metal

Weldment, Upright

Bed, Slider, 612/2100

Extrusion, Sidewall Cover

M3 x .50 x 12 Screw, Sem, PHP, Ext Star

Washer, M3, Flat, Zinc Plated

Bushing, Bronze

M6 x1.0 x 16 Button Head

Compression Mount, Long

Compression Mount, Deck

Wheel, Polyoefin

Rotary Tensioner

Bushing, Grade Adjust

M8 x 1.25 x 70 Button Head

M8 x 1.25 Hex Nut

Washer, .490 x 1.063 x .093, Neoprene

M8 x 1.25 x 60 Hex Head Cap

Washer, M8, Flat Fender, Zinc Plated

Washer, M6, Flat, Black Oxide

Washer, M6, Split Lock Black

M6 x 1.0 x 16, Button Head Black

Washer, M8, Flat, Black Oxide

M8 x 1.25 .90 Hex Head Cap, Black

Clamp, VSD Board

Pad, VSD Clamp

Nut, M5 x 0.8 Hex


Washer, M6 Flat, Wide Zinc Plated


M6 x 1.00 x16 Hex Head Cap

Washer, M6 Split Lock

8

6

8

1

2

8

2

10

10

6

2

1

1

2

12

1

2

1

1

14

4

8

1

2

2

16

2

2

2

1

2

2

8

18

1

Qty:

ClubTrack

®


Assembly Parts Lists

27631

27632

27633

27634

27640

27641

27646

27647

27648

Part #:

27579

27591

27592

27593

27594

27595

27601

27602

27605

27612

27582

27583

27585

27586

27587

27588

27590

Description:

Washer, M6, Flat Zinc Plated

Rivet, .1875 Dia x .375 Grip, Black

Guide Wire .500

Washer, .406 x 1.25 x .047 Steel Zinc

Spacer Nylon

Washer, M10 Flat Zinc Plated

Washer, M10 Split Lock


Washer, M8, Flat Zinc Plated

Washer m8 Split Lock

36

64

M8 x 1.25 .25 Hex Head Cap 10

.25-20 x .75 Thread Cutting, Hex Washer Hd 8

Plate, Grade Nut Block, Mounting

Insert, Threaded, Metric 6MM

Insert, Treaded, Metric 8MM


Screw M3 x 0.5 x 10, Self Tapping Pan Hd

Torx

6

4

6

1

18

5

4

14

10

4

4

28

Housing ErgoBar, Left Upper

Housing ErgoBar, Left Lower

Housing ErgoBar, Right Upper

Housing ErgoBar, Right Lower

Belt, Walking

Wire Harness, Contact Heart Rate

Machined Extrusion Right Hand

Machined Extrusion Left Hand

Assembly, Endcap, Siderail Left

1

1

1

1

1

1

1

1

1

2

Qty:

27666

27675

27676

27677

27678

27679

27680

27681

27682

27684

27689

27764

Part #:

27649

27650

27654

27660

Description:

Assmebly, EndCap, Siderail Right

Weldment, Rear Frame Support 1

Leveling Pad (.500-13 UNC-2A x 1.88 BASE) 2

Assembly, Upright Support RH

PCBA, ErgoBar

1

1

Grill, Front Cover

Assembly, Retainer, Front Roller Shaft

Spacer, Soft Deck

1

2

2

Siderail, Stiffner Assembly LH

Siderail, Stiffner Assembly RH

Assembly, Upright Support LH

Housing ErgoBar Mid Upper

Housing ErgoBar Mid Lower

Logo, StairMaster

Weldment, Controller Support

Steel Headframe Assembly

Screw, Thread Forming #6-32 x .375

1

1

4

1

1

1

1

1

1

1

Qty:

27903

27912

27951

27952

27959

28390

Decal, Magnetic Switch 2100

Keypanel, ErgoBar

Assembly Cable, Lower C50 Comm

Assembly Cable, Upper C50 Comm

Assembly Config Cable

EndCap, Round 2”

35901-033 M6 x 1.00 x 16 Hex Head Cap

36209 Insert, Threaded, Metric, 6MM

SM27664 |

Keypanel W/Ergo Bar housing |

2

4

1

1

1

1

1

2

ClubTrack

®


54

Assembly Drawings Overview

Assembly Drawings Overview

1.

section. Refer to these notes when replacing parts because they mention critical torque specs.

The symbol

B throughout the drawings refers to the assembly revision.

Table 5–2. Notes Pertaining to Assembly Drawings

Note No. Note

1.

Torque fastener to 70 inch pounds (8 Nm).

8.

9.

6.

7.

4.

5.

2.

3.

10.

11.

12.

13.

14.







Apply grease to the surface before assembly.

Apply Hernon 423 to the threads before assembly.



Cut to 2 inch (5 cm). Apply to top center EndCap rib

Apply Silicone sealant Part Number 62998 at cable slot on Part Number 27680.

Seal cable on Part Number 27912 at opening in Part

Number 27680 with Silicone sealant Part Number

62998.

55

ClubTrack

®


SIde Rails

ClubTrack

®


56

Headframe

57

ClubTrack

®


Grade Weldment

ClubTrack

®


58

Slider Bed

59

ClubTrack

®


Drive Motor

ClubTrack

®


60

Front Roller Assembly

61

ClubTrack

®


VSD Board

ClubTrack

®


62

Upright Weldment

63

ClubTrack

®


Controller Support

ClubTrack

®


64

Hood Assembly and End Caps

65

ClubTrack

®


Hand Grips and Ergo Bar

ClubTrack

®


66

Cabling

67

ClubTrack

®


27471 PCBA Conf. LED 27472 PCBA Conf. LCD

Confirm the placement of 3 jumpers across PC0, PC3 and PC5 located in the upper right hand corner of the PCBA.

PCBA

ClubTrack

®


68

Controller Keypanel

69

ClubTrack

®


Controller Bottom Housing

ClubTrack

®


70

P

ART

6

Appendixes

Contents

Appendix A—Required Tools ...............................................72

Appendix B—Differences Between the 2100 and

510/612 Motor Wiring .....................................................73

Appendix C—Replaceable Parts Lists ................................74

Appendix D—Using a Multimeter ........................................80

Appendix E—International Power Plug Configurations .......83

Appendix F—Specifications ................................................84

Appendix A

Required Tools

This is a list of the most common tools you will need to service the treadmill.

Table 6–1. Required Tools and Uses

Tool Purposes

Socket wrench General

13-mm socket

10-mm socket

9/16" socket

9/16" open-end box wrench

3/4" wrench

15/16" open-end box wrench

5-mm Allen wrench

M-4 Allen wrench

M-4 Allen wrench

T-10 Torx screwdriver

T-15 Torx screwdriver

#1 Philips screwdriver

Tape Measure

Pliers

Diagonal cutters

Multimeter

Vacuum

#000 Steel Wool or Scotch-Brite™ pad

Removing and installing tracking bolts, front roller retainers, motor hardware, and grade block hardware

Removing and installing deck screws, VSD mounts, configuration mounts, and grounding screws

Removing and installing upper grade actuator mount; adjusting motor drive belt tension

Removing and installing upper grade actuator mount

Adjusting feet

Adjusting motor drive belt tension

Removing and installing console and uprights

Removing and installing hood screws

Front cosmetic cover

Ergo PCB

Removing and installing three (3) screws underneath the console

Removing and installing Ergo and CHR housings

Adjusting belt tension

General

General

Electrical troubleshooting

Cleaning the motor housing and side rails

Cleaning the wax from front and rear rollers

ClubTrack

®


72

Appendix B

Differences Between 2100 and 510/612 Motor Wiring

ClubTrack 2100

Config Plate:

 Transformer output is 12VAC.

Not the same transformer as on 510/612.

 Line filter is Corcom F7585B for all models.

 Uses same circuit breaker as Club 510/612.

 Uses same Config PCBA as Club 510/612.

Grade Motor:

 Black wire is moved one pin toward the red wire compared to 510/612. This was required to meet commercial safety standards.

WHITE x

RED

BLACK

ORANGE

BLUE x x

BROWN

Config Plate:

 Transformer output is 20VAC.

 Line filter is Corcom F7585B for 230V models, F7585A for 120V.

Grade Motor:

WHITE x

RED x

BLACK x

ORANGE

BLUE

BROWN

Main Motor:

 Leeson 230V 3-phase AC induction.

 Has 3 wires for connecting to 3-phase power input.

 Has 2 more wires that are thermal switch outputs. These are normally closed but will open if motor overheats.

Console:

 C50 with LED or LCD display.

 Commercial contact heart rate (CHR) system has higher performance than 510/612.

 Separate Ergo Board contains telemetry heart rate and magnetic stop key inputs.

Cables (Drive Board):

 Config cable: From Config PCBA to Drive

Board (P20). Has new connector on Drive

Board side– prevents “off by one pin” problems.

 Main VBUS wires (heavy blue/brown wires from Config Plate to Drive Board): For 120V, individual wires plug into P11, P15 on Drive

Board. For 230V, a single connector plugs into P19.

 Communications cable to Console: Plugs into

P1 on Drive Board using a single in-line latching header. Second half of cable plugs into corresponding Console connector. The two half-cables are mated together when the

Console is first installed.

Main Motor:





Baldor 200V 3-phase AC induction.

Has 3 wires for connecting to 3-phase power input.

Console:

 C40 LCD or Plus graphics LCD.

 Isolated contact heart rate (CHR) system.

 Telemetry heart rate and magnetic stop key are part of the main Console Board.

73

ClubTrack

®


Appendix C

Replaceable Parts Lists

Use the following parts list to order parts for the repair of the 2100 treadmills.

Warranty Terms:

Please note that warranty terms may differ outside the U.S.A. Contact your local dealer or distributor in your country to receive the warranty terms for your area.

Code 1 - 3 Year standard coverage on parts.

Code 2 - 1 Year standard coverage on wearable parts.

Code 3 - 15 Year standard coverage on frame and motor.

Table 6–2. Documentation Part Numbers

Owners Manual 2100 LE 2100 LC

Portugese SM27143 SM27143

Dutch

French

German

Italian

Spanish

English

User Guide

SM27144

SM27145

SM27146

SM27147

SM27148

SM27149

SM27483

SM27144

SM27145

SM27146

SM27147

SM27148

SM27149

SM27483

Table 6–3. Accessories

Part Number Description

SM27328 ClubTrack 2100 Decline Opt Kit

SM27331

SM27332

SM27333

ClubTrack 2100 Rail Ext Kit

ClubTrack 2100 Right Rail Kit

ClubTrack 2100 Left Rail Ext

Notes

Weldment Only

Table 6-4. Common Parts 110V, 220V and 240V Versions

Part Number Level 1 Level 2 Level 3 Description

SM20423

SM20473

SM21135

SM22077

SM24309

SM27122

SM27353

SM27354

20423

20473

21135

22077

24309

27122

27353

27354

ClubTrack

®


Tyrap, 1/8 x 7.515

Tyrap, 1/8 x 4

Loom, Flexible .350 ID

Nut, 3/8-16 NC Finish Hex

Screw, .375-16 x 5.50, Hex Hd Cap

Assy., Harness, Jumper, Male QD

Decal, ClubTrack 2100-LC Left

Decal, ClubTrack 2100-LC Right

1

2

1

1

2

1

1

Warranty

Code

1

74

Appendix C



SM27909

SM27911

SM27955

SM27671

SM12497

SM22016

SM22027

SM22077

SM22160

SM22845

SM27955

SM27470

SM27471

SM27474

SM27475

SM27627

SM27656

SM27908

SM27377

SM27379

SM27482

SM27483

SM27591

SM27606

SM27325

SM27472

SM27474

SM27475

SM27627

SM27656

SM27908

SM27909

SM27911

27377

27379

27482

27483

27591

27606

27325

27470

27671

12497

22016

22027

22077

22106

22845

27472

S27474

S27475

S27627

27656

27908

27909

27911

27955

27471

S27474

S27475

S27627

27656

27908

27909

27911

27955


Screw, M8 x 1.25 x 20 BHC

Unpacking Instructions

User Guide, 2100 Treadmill

Washer, M8, Flat

Kit, Hardware, 2100

Assy., Controller, C50-LCD

PCBA, Display/Processor, C50-LCD

Assy, Frt Controller Housing, 2100

Assy., Display Lens

Kit, C50, Key Panel, RH

Controller Housing, Bottom

C50 Keypanel, LH, English

C50, Keypanel, RH, English

C50, Keypanel, Mid, English

PCBA, Contact, HR, 2100 Treadmill

Assy., Controller, C50-LED

PCBA, Display/processor, C50-LED

Assy., Front Controller Housing 2100

Assy., Display Lens

Kit, C50 Key Panel RH

Controller, Housing Bottom

C50 Keypanel LH English

C50 Keypanel RH English

C50 Keypanel Mid English

PCBA, Contact HR 2100 Treadmill

Mechanical, Assy.-2100 Treadmill

Contact with adhesive

Screw, .375-16 x 2.50 Hex Hd Cap

Washer, .250 Split Lock

Nut 3/8-16 NC Finish Hex

Screw, #6 x .38 Thread Form Phil

Washer, 1 1/4 x 17/32 x .010T

75

2

2

1 n/a

2

1

1

1

1

1

1

2

1

1

1

1

1 n/a

1

1

1

1

2

2

2

1

1 n/a

1

1

1

Warranty

Code

n/a n/a

ClubTrack

®


SM27467

SM27477

SM27478

SM27485

SM27487

SM27490

SM27535

SM27536

SM27537

SM27540

SM27541

SM27542

SM27552



SM22878

SM23729

SM27000

SM27068

SM27069

SM27300

SM27350

SM27351

SM27388

SM27410

SM27415

SM27417

SM27424

SM27425

SM27426

SM27430

SM27436

SM27441

SM27444

S27477

S27478

27485

27487

27490

27535

27536

27537

27540

27541

27542

27552

27425

27426

27430

27436

27441

27444

27458

27467

22878

23729

27000

27068

27069

27300

27350

27351

27388

27410

27415

27417

27424

Screw, Set, Socket, .250-28 x .38

Washer, 3/8 Split Lock

Fast Tab, .250



Felt, Adhesive-backed

Decal, Stairmaster Right, 2100

Decal, Stairmaster Left, 2100

Flywheel, Cast

Motor Mount, Molded

Plug, Hole, Rib-Lock

510/612 Front Roller Assy.,

Block, Grade Nut

Support, Grade Weldment Mach.

Assy., Nutplate Foot

Bracket Assembly, Tensioner

Guard Foot

Washer, Shoulder Isolation

Bushing, Shoulder

Poly-V Drive Belt, 280J10

Pulley Assy, Rear

Assy., Hood, 2100

Assy., Front Cover

Weldment, Grade

Drive Motor, AC Variable

Weldment, Upright

Bed, Slider 612/2100

Extrusion, Sidewall Cover

Screw, M3 x 0.50 x 12 Pan Head, Ext.

Washer, M3, Flat

Bushing, Bronze, 0.313 x .501 x .500

Screw, M6 x 1.0 x 16, Button Head

Rotary Tensioner

ClubTrack

®


Appendix C

2

1

1

3

2

1

1

1

3

3

2

2

1

1

1

1

1

1

1

3

1

1

1

1

2

1

1

2

1

1

1

1

Warranty

Code

1

76

Appendix C



SM27578

SM27579

SM27583

SM27585

SM27586

SM27590

SM27592

SM27593

SM27594

SM27631

SM27632

SM27640

SM27646

SM27647

SM27569

SM27570

SM27571

SM27573

SM27574

SM27575

SM27576

SM27577

SM27556

SM27559

SM27561

SM27562

SM27563

SM27564

SM27565

SM27566

SM27567

SM27568

27578

27579

27583

27585

27586

27590

27592

27593

27594

27631

27632

27640

S27646

S27647

27569

27570

27571

27573

27574

27575

27576

27577

27556

27559

27561

27562

27563

27564

27565

27566

27567

27568

Bushing, Grade Adjustment

Screw, M8 x 1.25 x 70, Button Hd

Nut, M8, Hex, Zinc Plated

Washer, Neoprene, .490 x 1.063 x .09

Screw, M8 x 1.25 x 70, Button Head

Washer, M8, Flat, Ender

Washer, M6, Flat, Black

Washer, M6, Split Lock Black

Screw, M6 x 1.00 x 16, Buttonhead Bl

Washer, M8, Flat, Black

Screw, M8 x 1.25 . 90, HHCap, Blk

Clamp, VSD Board

Pad, VSD Clamp

Nut, M5 Hex Zinc Plated

Screw, M5 x 0.80 x 50 HHC

Washer, M6, Flat Wide

Screw, M6 x 1.00 x 16 Buttonhead, Bl

Screw, M6 x 1.00 x 16 HHCap

Washer, M6, Split Lock, Zinc

Washer, M6, Flat Zinc

Guide Wire .500

Washer, .406 x .812 x .065 Flat

Spacer Nylon .125 x .500 x 1.120

Screw, M8 x 1.25 x 20 HHCap

Washer, M8, Split Lock

Screw, M8 x 1.25 x 25, HHCap

Screw, .250 - 20 x .75 HX Wash Hd

Assy., CHR/Ergo Bar Housing, LH

Assy., CHR/Ergo Bar Housing, RH

Belt, Walking, 130, Black

Assy., Siderail, 2100, RH

Assy., Siderail, 2100, LH

77

2

2

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Warranty

Code

1

ClubTrack

®


SM27654

SM27660

SM27664

SM27665

SM27675

SM27676

SM27677

SM27678

SM27679

SM27684

SM27689

SM27764

SM27885

SM27888

SM27892

SM27893

SM27897

SM27898

SM27951

SM27952

SM33511-002



SM27648-00

SM27649-00

SM36125-001

SM40012-001

SM27488

SM41387

27677

27678

S27679

27684

27689

27664

S27885

S27888

S27648-

00

S27649-

00

27654

S27660

S27664

27665

27675

27676

S27982

S27893

S27897

S27898

27951

27952

33511-

002

36125-

001

40012-

001

27488

Assy., Endcap, Siderail, Left Gray

Assy., Endcap, Siderrail, Right Gray

Pad, Leveling, Swivel 1/2” - 13

SV Assy., Upright Support, RH, LED

Assy., Ergo Bar Keypanel

PCBA, Ergo Bar

Assy., Retainer, Frt Roller Shaft

Spacer, Soft Deck

Assembly, Stiffner, Siderail, LH

Assembly, Stiffner, Siderail, RH

SV Assy., Upright Support, LH, LED

Weldment, Controller Support

Assembly, Headframe, Steel

Screw, Selt Tapping, #6 x 3/8

Spares, Tripleflex Hardware, 2100

Kit, Rear Suport, 2100

Kit, Transport Wheel Hardware, 210

Kit, Grade Weldment, Hdware 2100

SV Assy., Upright Support LH LCD

SV Assy., Upright Support RH LCD

Assy., Cable, Lower C50 TM Com

Assy., Cable, Upper C50 TM Com

Kit, Tripleflex, 510/612

Grade Wheel Spares Kit

Magnetic Switch Assembly

Assy., VSD

41387 Assembly, PCB, AC Drive 3

Appendix C

2

2

1

1

3

3

1

2

1

1

1

1

3

3

1

3

3

3

3

2

1

1

1

1

3

Warranty

Code

3

3

ClubTrack

®


78

Appendix C

Table 6-5. 110V Parts Only


27384 SM27384

SM27317

SM27319

SM27320

SM27962

SM35774-002

SM27378

SM27386

SM27966

27317

27319

27320

27962

35774-

002

27378

27386

27966

Assy., Config Plate, 2100, 110V

Filter, Noise RFI

Circuit Breaker, ME

Treadm Powcrd ST55/65 2100

Assy., Transformer, 2100 Treadmill

PCBA, Config Plate 510/612

Washer, M6, Flat, Stainless

Assy., Cable, C50 Ergobar

Actuator, Linear, 110V, 2100 TM



27385 SM27385

SM27317

SM27308

SM27962

SM36498-002

27317

27308

27962

36498-

002


Filter, Noise RFI

Circuit Breaker, ME


PCBA, TM Volt Config 230V



SM27125

SM27573

SM27140

SM27317

SM27308

SM27127

SM36498-002

27125

27573

27140

27317

27308

27127

36498-

002

Choke Assembly, 2100 Euro TM

Nut, M5, Hex, Zinc Plated


Filter, Noise RFI

Circuit Breaker, ME


PCBA, TM Volt Config 230V

79

1

1

1

1

1

Warranty

Code

1

1

ClubTrack

®


1

1

1

1

1

1

1

Warranty

Code

1

1

1

1

Warranty

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Appendix D

Using a Multimeter

How to Use a Multimeter

This is a basic overview of multimeters. For in depth directions, please use the manual provided with your multimeter.

Whats Does a Multimeter Do?

A multimeter combines the functions of three instruments: ammeter (measures current), voltmeter

(measures voltage), and ohmmeter (measures resistance).

Electronic signals are usually thought of in terms of voltage. For that reason, and because it is an easier measurement to take, we will use the volts setting. We will not want to use the ammeter setting to troubleshoot fitness equipment.

The ohmmeter setting is used to determine whether there is an open circuit (a bad connection or break in the wires) or a short circuit (two wires that normally would not come in contact with each other have been pinched together or crossed in some way).

Ohmmeters work by passing a small current through the wire or component and measuring the voltage produced.

Type of Multimeters

Multimeters are available in digital and analog models. Digital meters give an output in numbers usually on a LCD. Analog meters move a needle along a scale.

We recommend using a digital meter. While analog meters can be very cheap, they are difficult for beginner to read accurately, especially on resistance scales. Also, the components are delicate and easily damaged.

Settings

For the beginner the multimeter can be intimidating because of the range of settings available. The diagrams on page 75 show what settings to use when checking voltage and resistance on the fitness equipment. Perhaps more importantly, it shows which settings are not needed.

There are two types of digital multimeters commonly available:

• switched range and

• autoranging.

Switched range meters require you to choose the appropriate position from the many choices available on the dial. For example, if the dial is switched to 20VDC, 20 volts is the maximum voltage that can be measured. This is important when you want to read small increments in voltage accurately. For example, if the required voltage is 13.5 volts and the meter is set too high, you may only see 13 volts on the readout.

Setting the meter to a lower maximum will show 13.5 volts.

Autoranging meters automatically adjust the range to give an accurate reading. This type of meter is more expensive but much easier to use.

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Appendix D

Switched Range Meter

Set here to check DC voltage

20 will be the most used setting for measuring

DC voltage output

Set here to check resistance (ohms)

Or here to listen for an audible response

(useful when testing a sensor)

Autoranging Meter

Set here to check AC or DC voltage

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Set here to check resistance (ohms)

Set here to check AC voltage

These are for checking amps and are not needed for our purposes

Black (negative) lead always goes here

Set here for an audible response

The remaining three are for amps settings

Black (negative) lead always goes here

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Appendix D

Checking Resistance

Use this procedure to check for broken wires:

1 Set the multimeter to the lowest OHMs (resistance) range.

2 Attach the test leads on both ends of the wire being tested.

3 Observe the reading.

• A short circuit will read less than approximately 3 ohms. This is the correct reading for an undamaged wire.

• An open circuit will usually read infinite; on a digital meter it will have an error code. This signals a broken or cut wire.

Use this procedure to test for crossed wires. In most circumstances all indivudual wires in a cable will be insulated from each other. When a wire is pinched, it becomes short circuited to an adjacent wire. This can cause problems resulting in blown fuses or fried components.

1 Set the multimeter to the lowest OHMs (resistance) range.

2 Attach one test lead of the multimeter to one wire and check all adjacent wires. This can all be done at one end of the cable. However, the other end of the cable must be disconnected from the circuit board.

All wires should be insulated from each other and therefore test open.

3 Observe the reading.

Checking Voltage

Use this procedure to check voltage output:

1 Determine whether the voltage is AC or DC voltage, and choose the appropriate setting on the multimeter.

2 Set the multitmeter to the lowest setting that is still higher than the highest output of the component being tested.

3 Place the black and red leads or probes on the appropriate corresponding wires, pins, or connectors.

4 Observe the reading, and proceed according to the troubleshooting sections in this manual.

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Appendix E

International Power Plug Configurations

Table 6–11. International Power Plugs

Power Cords System

G

Country

UK

Part Number

SMQ30736-037

C, E, F Europe SMQ30736-039

J Swiss SMQ300736-027

K Australia SMQ30736-041

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Specifications

Voltage

Amperage

Motor

Display

Length

Width

Height

Weight

Max User Weight Supported

Belt

Belt/Deck Lubrication

Belt Tracking Method

Speed Range

Elevation Range

Number of Functions

Heart Rate Monitoring

Workout Programs

Language Options

Operating Temperature

Storage Temperature

Operating Humidity (non-condensing)

Storage Humidity (non-condensing)

Atmospheric Pressure (Operating)

Atmospheric Pressure (Shipping and

Storage)

* Domestic/international 220VAC model

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Appendix F

115VAC (220VAC)*

20A (10A)*

4.8 hp, 230VAC, 60 Hz, 3 Phase

Back-lit LCD (2100LC), dot matrix

(2100LE)

88 in. (224 cm)

35 in. (89 cm)

59 in. (150 cm)

400 lbs. (181 kg)

400 lbs. (181 kg)

20 in. X 60 in. (51 cm X 152 cm)

Proprietary low-friction polymer that requires no waxing or lubrication

Crowned front and rear rollers center the belt automatically

0.5 to 12 mph (.8 kph to 19.3 kph)

0 to 15% (Option: -3 to 12%)

Ten: Heart rate, elapsed time, calories burned, caloreis burned per hour, watts, METS, resistance level, rpm, distance, and workout profile

Polar-compatible wireless and contact heart rate

Fourteen: Quick Start, Manual,

Fat Burner, Calorie Burner, Speed

Intervals, HR Zone Trainer, 5K

Run, 10K Boulder Run, 9 Hole

Walk, Custom Speed Intervals, HR

Interval, Custom Calorie, Fit Test, and

Firefighter Fit Test

English, German, Spanish, French,

Italian, Dutch, Swedish, and Japanese

50–90

o

F (10–32 o

C)

-13–122 o

F (-25–50 o

C)

3–95% relative (Limited to 90 maximum dew point) o

F

3–95% relative (Limited to 90 maximum dew point) o

F

8.60–15.0 psia, 445–775 mm Hg absolute

8.22–15.0 psia, 425–775 mm Hg absolute

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Important Contact Numbers

If you need assistance, please have both the serial number of your machine and the date of purchase available when you contact the appropriate Nautilus office listed below.

For technical assistance and a list of distributors in your area, please call or fax one of the following numbers.

OFFICES IN THE UNITED STATES:

• TECHNICAL/CUSTOMER SERVICE

Nautilus, Inc.

World Headquarters

16400 SE Nautilus Drive

Vancouver, Washington, USA 98683

Phone: 800-NAUTILUS (800-628-8458)

Email: [email protected]

Fax: 800-523-1049

• MANUFACTURING FACILITY

Nautilus, Inc.

10757 East Ute

Tulsa, Oklahoma, USA 74116

• CORPORATE HEADQUARTERS

Nautilus, Inc.

World Headquarters

16400 SE Nautilus Drive

Vancouver, Washington, USA 98683

Phone: 800-NAUTILUS (800-628-8458)

INTERNATIONAL CUSTOMER SERVICE:

• INTERNATIONAL OFFICE

Nautilus International S.A.

Rue Jean Prouvé 6

1762 Givisiez / Switzerland

Tel: + 41-26-460-77-77

Fax: + 41-26-460-77-70

Email: [email protected]

INTERNATIONAL OFFICES:

• SWITZERLAND OFFICE

Nautilus Switzerland S.A.

Tel: + 41-26-460-77-66

Fax: + 41-26-460-77-60

• GERMANY and AUSTRIA OFFICE

Nautilus GmbH

Tel: +49-2204-610-27

Fax: +49-2204-628-90

• ITALY OFFICE

Nautilus Italy s.r.l.

Tel: +39-031-51-10-86

Fax: +39-031-34-24-97

• UNITED KINGDOM OFFICE

Nautilus UK Ltd.

Tel: +44-1908-267-345

Fax: +44-1908-267-346

• CHINA OFFICE

Nautilus Representative Office

Tel: +86-21-523-707-00

Fax: +86-21-523-707-09

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Nautilus StairMaster ClubTrack 2100 Series Service manual

ClubTrack

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2100 Series

Treadmill

Service Manual

PN 000-6583 Rev AA (2/20/2006)

Important—Please Read

Contents

Maintenance

Console Codes

Troubleshooting Electrical Problems

Troubleshooting Mechanical Problems

Assembly Illustrations

Appendixes

P

Maintenance

Contents

Viewing Maintenance Information

Routine Maintenance Schedules

Cleaning

Adjusting Belt Tension

Adjusting Belt Tracking

Replacing the Walk Belt

Replacing the Contact Heart Rate (CHR) Sensors

Replacing the Lens

Updating the Console Firmware

P

Console Codes

Contents

Overview

Cardio

Owner-Deﬁned Custom

Machine Status

Diagnostic

Diagnostic 2

Magnetic Key Limit Access Control

P

Troubleshooting Electrical

Problems

Contents

Common Electrical and Electronic Problems

Error Reporting

VSD

Troubleshooting Flowcharts

Problems with the Drive Motor

Replacing the Drive Motor

Magnetic Key Problems

Wiring Schematics

P

Troubleshooting Mechanical

Problems

Contents

Common Mechanical Problems and Solutions

P

Assembly Illustrations

Contents

Assembly Parts Lists

Assembly Drawings Overview

P

Appendixes

Contents

Required Tools

Differences Between 2100 and 510/612 Motor Wiring

Replaceable Parts Lists

Using a Multimeter

International Power Plug Conﬁgurations

Speciﬁcations

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