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ClubTrack

2100 Series Treadmill Service Manual

Replacing the Grade Actuator Motor

Replacing the Grade Actuator Motor

1.0 Remove the Treadmill Hood

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

2.1

Unplug P17 from the VSD board.

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.

DANGEROUS VOLTAGES ARE PRESENT UNDER

THE TREADMILL HOOD. EXERCISE CAUTION WHEN

PERFORMING SERVICE TO THE ELECTRICAL COMPONENTS

UNDER THE HOOD.

Unplug

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Содержание StairMaster ClubTrack 2100 Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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