Nautilus StairMaster ClubTrack 2100 Series Service Manual Download

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ClubTrack

2100 Series Treadmill Service Manual

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

LED

Flashing

Off

DS1

Belt is running

Belt is stopped

DS2

Motor Overload

* or once per second for proper

console communication

No console communication

DS3

Power to the console and Drive

Processor

n/a

No power present

DS4

Power to Drive Motor Control Circuits

n/a

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.

VSD

Summary of Contents for StairMaster ClubTrack 2100 Series

Page 1: ...ClubTrack 2100 Series Treadmill Service Manual PN 000 6583 Rev AA 2 20 2006...

Page 2: ...certi ed 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 certi ed service perso...

Page 3: ...rmware 13 Console Codes Overview 16 Cardio 16 Owner De ned Custom 19 Machine Status 22 Diagnostic 25 Diagnostic 2 26 Magnetic Key Limit Access Control 27 Troubleshooting Electrical Problems Common Ele...

Page 4: ...SD 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 Appendi...

Page 5: ...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 Senso...

Page 6: ...requent routine maintenance may be required Daily Inspect the power cord and walking belt for wear Check the position of the walking belt Verify it is not rubbing against the frame The belt should be...

Page 7: ...Clean the interior of the treadmill following the procedure below 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 of...

Page 8: ...enough for you to move it from side to side on the front or rear roller Adjusting Belt Tension Adjustment Bolts 35 0 889 mm 889 mm 35 0 DO NOT USE ALL YOUR WEIGHT TO RESIST THE BELT MOVEMENT TOO MUCH...

Page 9: ...y 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 2 1 If the belt moves to the right turn the ri...

Page 10: ...s 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 2 4 Place a 9 16 wrench on the head o...

Page 11: ...r drive belt over pulley to remove 2 5 Remove the two 2 front retainer bolts at each end of the front roller 2 6 Lift the front roller at its pulley end and pull it out of the opposite side rail Impor...

Page 12: ...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 ippin...

Page 13: ...rface 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 5 2 Lift the deck with the installed new walk belt and place it on the c...

Page 14: ...ive 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 7 5 After align...

Page 15: ...g 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 r...

Page 16: ...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 Disconnec...

Page 17: ...ine on the ribbon cable will be on the right if the cable is installed properly 3 Turn power back on The LED on the AVR FISP will ash yellow as data is downloaded to the console When the download is c...

Page 18: ...ents 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 De ned Custom 19 Customize...

Page 19: ...s 23 Number of Workouts 23 Distance Traveled 23 Software Revision 24 Con guration 24 TM Drive 24 Maintenance Hours 24 Program Selection 24 Diagnostic 25 Diagnostic 25 Display Test 25 Key Test 25 Seria...

Page 20: ...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 dow...

Page 21: ...different if the treadmill was customized Table 2 3 Exercise Time Step No Press Keys On Console Display What you will see 1 CLEAR 2 2 ENTER TIME 2 ENTER ENTER TIME 20 3 SPEED or SPEED Time changes fro...

Page 22: ...NTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized Table 2 7 Cool Down Time Step No Press Keys On Console Display What you will see 1...

Page 23: ...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...

Page 24: ...ing could be different Table 2 13 Change Units Step No Press Keys On Console Display What you will see 1 CLEAR 3 1 CHANGE UNITS 2 ENTER USA UNITS 3 SPEED or SPEED Toggles between USA UNITS and METRIC...

Page 25: ...t you will see 1 CLEAR 3 5 CONTRAST 2 ENTER CONTRAST 2 2 27 45 2 5 MPH 3 SPEED or SPEED press and hold Changes contrast in the upper LCD screen 4 INCLINE UP or INCLINE DOWN press and hold Changes cont...

Page 26: ...MAGKEY OFF 3 SPEED or SPEED Toggles between OFF and ON 4 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different Table 2 20 Set Defaults Step No Press Keys On Console Di...

Page 27: ...r machine status without having to scan through all the choices perform the following steps for that listed option Table 2 22 Run Time Hours Step No Press Keys On Console Display What you will see 1 C...

Page 28: ...u will see 1 CLEAR 4 5 TM DRIVE VERSION 2 ENTER TM DRIVE VERSION xx where x is the version number 3 CLEAR THE RESULTS YOU WANT Table 2 28 Maint Hours Step No Press Keys On Console Display What you wil...

Page 29: ...L TEST RESERVED RESERVED RESERVED RESERVED RESERVED BUS VOLTS GRADE ACT 3 ENTER Selected choice 4 CLEAR DIAGNOSTIC 5 CLEAR THE RESULTS YOU WANT To scan through the list of diagnostic tests and view di...

Page 30: ...ctual grade setting 3 CLEAR TWICE THE RESULTS YOU WANT 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...

Page 31: ...R THE RESULTS YOU WANT 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...

Page 32: ...NTER 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 t...

Page 33: ...nic 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...

Page 34: ...Series Treadmill Service Manual 30 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 Wiri...

Page 35: ...ar There is an insuf cient power source Make sure the outlet voltage is 115VAC USA or 230VAC International The treadmill is not on its own dedicated circuit Plug the treadmill into its own 20 amp dedi...

Page 36: ...eadmill and which requires immediate attention Table 3 3 Error List Label Type Response Description NO ERROR N A Displayed in the Error Log if no events Placeholder label PROGRAM ERROR Error Start up...

Page 37: ...MIT ERROR Error During change Goes to idle Treadmill slowly stops Treadmill E201 grade position outside limits GRD MOVE ERROR Error During change Goes to idle Treadmill slowly stops Treadmill E211 gra...

Page 38: ...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 E...

Page 39: ...mmunication No console communication DS3 Power to the console and Drive Processor n a No power present DS4 Power to Drive Motor Control Circuits n a No power to P20 or VSD problem DS1 and DS2 ashing t...

Page 40: ...of P1 and TP7 and pin 8 of P1 on VSD Board are 18VDC Check that the voltage between the red and black wires reads 14VAC Is the voltage good Replace the VSD Board Remove Console and disconnect J4 harn...

Page 41: ...onfiguration Plate Assembly No Short pins 1 and 2 of Q8 on the VSD Board Does the Actuator Motor run Replace the Actuator Motor Yes No Replace the VSD Board Is a Grade Move Error present Cycle the pow...

Page 42: ...om contact plates on each handgrip Is the voltage good Remove the contact plates from handgrips and recheck voltage End Is the CHR working End No Yes No Yes Replace the Controller Processor PCB Cycle...

Page 43: ...ey in use Replace the Ergo Keypad and or the Ergo PCB Remove the Magnetic Key and inspect for rust Is the Ergo PCB corroded Replace the Ergo PCB No Yes Is the Magnetic Key rusted Replace the Magnetic...

Page 44: ...nplug 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 2 1 Unplug P17 from the VSD board BEFORE REMOVING THE GRADE A...

Page 45: ...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 G...

Page 46: ...ws Tighten the screws until the bushings are ush Note When installing the shoulder bushing turn the bushings until the at side of the bushings match the at side of the mounting holes on the swing arm...

Page 47: ...he 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 1 0 Remove the Treadmill Hood 1 1 Turn the trea...

Page 48: ...e 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 2 4 Remove the four 4 washers and rubber isolators...

Page 49: ...e 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 ywheel drive p...

Page 50: ...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...

Page 51: ...47 ClubTrack 2100 Series Treadmill Service Manual 120V Wiring Schematic...

Page 52: ...48 ClubTrack 2100 Series Treadmill Service Manual 230V European Wiring Schematic...

Page 53: ...49 ClubTrack 2100 Series Treadmill Service Manual 230V Non European Wiring Schematic...

Page 54: ...Troubleshooting Mechanical Problems 4 Contents Common Mechanical Problems and Solutions 50 Walking Belt 50 Noises 50 PART...

Page 55: ...sound There is a bad roller bearing Replace the roller The motor has a bad bearing Replace the motor 2 Banging noise when the person is running One or more compression mounts are worn normally the one...

Page 56: ...t 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 En...

Page 57: ...52 ClubTrack 2100 Series Treadmill Service Manual PCBA 68 Controller Keypanel 69 Controller Bottom Housing 70 Contents...

Page 58: ...7350 Decal StairMaster Right 2100 1 27544 Compression Mount Deck 8 27351 Decal StairMaster Left 2100 1 27551 Wheel Polyoe n 2 27377 Washer M8 Flat Stainless 16 27552 Rotary Tensioner 1 27378 Washer M6...

Page 59: ...7594 25 20 x 75 Thread Cutting Hex Washer Hd 8 27680 Housing ErgoBar Mid Upper 1 27595 Plate Grade Nut Block Mounting 1 27681 Housing ErgoBar Mid Lower 1 27601 Insert Threaded Metric 6MM 18 27682 Logo...

Page 60: ...Torque fastener to 188 inch pounds 21 Nm 3 Torque fastener to 35 inch pounds 4 Nm 4 Torque fastener to 240 inch pounds 27 Nm 5 Torque fastener to 10 inch pounds 1 Nm 6 Torque fastener to 44 inch pound...

Page 61: ...56 ClubTrack 2100 Series Treadmill Service Manual SIde Rails...

Page 62: ...57 ClubTrack 2100 Series Treadmill Service Manual Headframe...

Page 63: ...58 ClubTrack 2100 Series Treadmill Service Manual Grade Weldment 3...

Page 64: ...59 ClubTrack 2100 Series Treadmill Service Manual Slider Bed...

Page 65: ...60 ClubTrack 2100 Series Treadmill Service Manual Drive Motor...

Page 66: ...61 ClubTrack 2100 Series Treadmill Service Manual Front Roller Assembly...

Page 67: ...62 ClubTrack 2100 Series Treadmill Service Manual VSD Board...

Page 68: ...63 ClubTrack 2100 Series Treadmill Service Manual Upright Weldment...

Page 69: ...64 ClubTrack 2100 Series Treadmill Service Manual Controller Support...

Page 70: ...65 ClubTrack 2100 Series Treadmill Service Manual Hood Assembly and End Caps...

Page 71: ...66 ClubTrack 2100 Series Treadmill Service Manual Hand Grips and Ergo Bar...

Page 72: ...67 ClubTrack 2100 Series Treadmill Service Manual Cabling...

Page 73: ...764 27955 27956 6X 27764 9 04 50 21613 27475 1 27471 PCBA Conf LED 27472 PCBA Conf LCD PCBA Detail A Con rm the placement of 3 jumpers across PC0 PC3 and PC5 located in the upper right hand corner of...

Page 74: ...69 ClubTrack 2100 Series Treadmill Service Manual 27908 27911 27909 27474 B B B B B B B 27906 27905 27682 27904 27907 Controller Keypanel...

Page 75: ...70 ClubTrack 2100 Series Treadmill Service Manual 27656 13X 22276 Controller Bottom Housing...

Page 76: ...red 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 Con guration...

Page 77: ...box wrench Removing and installing upper grade actuator mount 3 4 wrench Adjusting feet 15 16 open end box wrench Adjusting motor drive belt tension 5 mm Allen wrench Removing and installing console...

Page 78: ...200V 3 phase AC induction Has 3 wires for connecting to 3 phase power input Console C50 with LED or LCD display Commercial contact heart rate CHR system has higher performance than 510 612 Separate Er...

Page 79: ...4 French SM27145 SM27145 German SM27146 SM27146 Italian SM27147 SM27147 Spanish SM27148 SM27148 English SM27149 SM27149 User Guide SM27483 SM27483 Table 6 3 Accessories Part Number Description Notes S...

Page 80: ...Keypanel LH English 2 SM27909 27909 C50 Keypanel RH English 2 SM27911 27911 C50 Keypanel Mid English 2 SM27955 27955 PCBA Contact HR 2100 Treadmill 1 SM27470 27470 Assy Controller C50 LED n a SM27471...

Page 81: ...612 Front Roller Assy 1 SM27424 27424 Block Grade Nut 1 SM27425 27425 Support Grade Weldment Mach 1 SM27426 27426 Assy Nutplate Foot 1 SM27430 27430 Bracket Assembly Tensioner 1 SM27436 27436 Guard F...

Page 82: ...SM27570 27570 Clamp VSD Board 1 SM27571 27571 Pad VSD Clamp 1 SM27573 27573 Nut M5 Hex Zinc Plated 1 SM27574 27574 Screw M5 x 0 80 x 50 HHC 1 SM27575 27575 Washer M6 Flat Wide 1 SM27576 27576 Screw M...

Page 83: ...Assembly Stiffner Siderail RH 3 SM27679 S27679 SV Assy Upright Support LH LED 3 SM27684 27684 Weldment Controller Support 3 SM27689 27689 Assembly Headframe Steel 3 SM27764 27664 Screw Selt Tapping 6...

Page 84: ...tor Linear 110V 2100 TM 1 Table 6 6 220V Parts Only Part Number Level 1 Level 2 Level 3 Description Warranty Code SM27385 27385 Assy Con g Plate 2100 240V 1 SM27317 27317 Filter Noise RFI 1 SM27308 27...

Page 85: ...ive 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 dif cult for beginner to read accu...

Page 86: ...check AC voltage Black negative lead always goes here These are for checking amps and are not needed for our purposes Set here to check resistance ohms Or here to listen for an audible response usefu...

Page 87: ...use 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 Thi...

Page 88: ...l Service Manual Appendix E International Power Plug Con gurations Table 6 11 International Power Plugs Power Cords System Country Part Number G UK SMQ30736 037 C E F Europe SMQ30736 039 J Swiss SMQ30...

Page 89: ...d per hour watts METS resistance level rpm distance and workout pro le Heart Rate Monitoring Polar compatible wireless and contact heart rate Workout Programs Fourteen Quick Start Manual Fat Burner Ca...

Page 90: ...of purchase available when you contact the appropriate Nautilus of ce listed below For technical assistance and a list of distributors in your area please call or fax one of the following numbers INTE...

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