StairMaster 2100 Series Treadmill Service Manual
Contents
1. OS v0 6 61018 68 ClubTrack 2100 Series Treadmill Service Manual Controller Keypanel 84940 ClubTrack 2100 Series Treadmill Service Manual 69 Controller Bottom Housing N N N 32 ClubTrack 2100 Series Treadmill Service Manual 70 PART Appendixes Contents Appendix A Required 72 Appendix B Differences Between the 2100 510 612 Motor WING eee is dd 73 Appendix C Replaceable Parts Lists 74 Appendix D Using a Multimeter 80 Appendix E International Power Plug Configurations 83 Appendix 5 5 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 wrench General 13 mm socket Removing and installing tracking bolts front roller retainers motor hardware and grade block hardware 10 mm socket Removing and installing deck screws VSD mounts configuration mounts and grounding screws 9 16 socket Removing and installing upper grade actuator mount adjusting motor 22440 0 40 3 belt tension 9 16 open end box wrench open end box wrench Removing and installing upper grade actuator2. 22 Machine Status 23 PRU TG u ir Ad 23 Number of Workouts 23 Distance Traveled eter 23 Software Revision 24 uuu u uy u 24 TM Drive 24 Maintenance Hours 24 Program Selection 24 E 25 25 Display LN 25 Key usa 25 Soe nien gn tai ista sa ee 26 BUS VORS haqa eee d dare www 26 Grade AGL A ati 26 2 Le 26 en 26 Error a 27 Maintenance Hours 27 Magnetic Key Limit Access Control 27 27 Activation cues GG azote bia 27 088 GU 28 Magnetic Key as Emergency Stop 28 ClubTrack 2100 Series Treadmill Service Manual 15 Cardio Overview There are five groups of console codes as follows Cardio codes starting with 2 Owner Defined C
3. IV 6290953 196428 i g i 4 i 82d AV1dSId i 286128 i sr 408839044 i our 1331 i i i a i N i JINQOW i i LOVINOO lt 17922 B LOVLNOO L 47 ClubTrack 2100 Series Treadmill Service Manual 230V European Wiring Schematic 100 986868 CIRCUIT BREAKER A18W3SSV MOLOIN S3KOLUMS ClubTrack 2100 Series Treadmill Service Manual alvid 8 WE ID B j Bc QITWISNI Q a Q pe anne 196128 EI i ENS 9 02642 gt TSNVdASy E i 824 AVIdSIQ i i i AHO 1331 H H 2 i 4 831 i i gt 90 8 z eyepdn i 0 Z1 6 NMOS L i WOLZ 8 T3A3T dOL i i i 13NOVW YH 19V1NOO i 804 39 E TINQVIHL 971 370017 I i YILSYWYIYLS SMILLAVN l n E 230V Non European Wiring Schematic ED YOLOW 100 98655
4. LONI SNIVIN CIRCUIT BREAKER N 9 a 8 A18W3SSV S3KOLIMS alvid IV TIWOVSYL 91310012 HOVELENTO YALSVINUIVLS SNTILAWN G3TW1SNI C td C 56228 sod p in s em 11214 i i 8 025 2 i gt i 9 e 8d AW14SIQ i 286128 4 H sr i 82d i ue 1431 H N i i i i amp anaon i o 1uBUqv 90 812 eyepdn 0 Z1 6 NMOS 1 10912 13A3T dOL i CN H SdIMOGNVH 1991409 2 0 0 0093 pov IVHONVH 49 ClubTrack 2100 Series Treadmill Service Manual PART Troubleshooting Mechanical Problems Contents Common Mechanical Problems and Solutions 50 Walking Belt et 50 NOISES a 50 Common Mechanical Problems and Potential Causes Common Mechanical Problems and Solutions Table 4 1 Walking Belt 1 Walking belt is too far to the left The belt is tracking Adjust the tracking Refer or right improperly to Part 1 to correct the problem Walking belt slips b
5. Or here to listen for an audible response useful when testing a sensor Autoranging Meter Set here to check AC or DC voltage Set here to check resistance ohms 10ADC VO tavar COM AUTO SELECTION Set here to check 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 ClubTrack 2100 Series Treadmill Service Manual 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 l
6. Plug Hole Rib Lock 53 Bracket Actuator 1 Assembly Bracket Actuator 1 Decal StairMaster Right 2100 1 Decal StairMaster Left 2100 1 Washer MB Flat Stainless 1 8 1 25 16 Button Head Assemly Cable C50 ErgoBar ms Plate Motor Mounting Roller Assembly Drive 1 Block Grade Nut 1 Description 27535 Bed Slider 612 2100 1 27840 Washer M3 Flat Zinc Plated _____ 6 27542 x1 0 x 16 Button Head 27544 Mount Deck 18 Oty 27559 ___ MBx125x70ButtonHead f8 MBx125HexNut 752 490 x 1 063 x 098 Neoprene 753 MBx125x60HexHeadCap 795 Washer M6 Flat Black Oxide 2 27567 M6 x 1 0 x 16 Button Head Black 2 1 mus wast wz Pd x 1 00 x16 Hex Head Cap rd mus Waster ClubTrack 2100 Series Treadmill Service Manual Assembly Parts Lists 27579 Washer Flat Zinc Plated 27582 Rivet 1875 Dia x 375 Grip Black 27583 Guide Wire 500 27585 Washer 406 x 1 25 x 047 Steel Zinc 27649 EndCap Siderall Right f1 27650 JWeldment Rear Frame Support f1 27654 Leveling Pad 500 13 UNC 2A 1 88 27660 27666 27675 2 27588 27676 2 27677 27678 27679 27764 Screw Thread Forming 6 32 x 375 27903 Decal Magnetic Switch 2100 M6 x 1 00 x 16 Hex Head Cap
7. 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 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 ClubTrack 2100 Series Treadmill Service Manual 11 Replacing the Lens Replacing the Contact Heart Rate CHR Sensors 1 O CO N Remove the old sensors Clean the old adhesive off the plastic contact point using rubbing alcohol Make sure that the wire connection tab is bent from a V shape to a U shape and attach the wire to the tab Peel the paper off the sensor plate s adhesive tape Press the sensor plate firmly onto the plastic contact point Install one zip tie around each side of the sensor for both the left and right CHR sensors 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 14 1 2 1 3 1 4 1 5 1 6 1 7 1 8 13 Remove the three 3 15 torx screws from the bottom back of the controller Remove the seven 7 button head scr
8. Assembly Illustrations Contents Assembly Parts 53 Assembly Drawings 55 Side 72 ino er uiuo ada eM et URN 56 L E 57 Grade 58 Slider Bed u u as nuw 59 Dive i una 60 Front au au aa bt b a amu sua ss 61 VSD BOATA al 62 Upright Weldment 1 aaa 63 64 Hood Assembly and End 65 Grips and Ergo Bar tieu 66 Cabling ETT 67 Controller nennen Controller HOUSING uuu atento ec ClubTrack 2100 Series Treadmill Service Manual Contents 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 Description 22016 22027 22077 22160 22845 22878 23729 27068 27069 27300 27350 27351 27377 27378 27379 27386 27388 27410 27415 27417 27424 27425 27426 27430 27436 27441 27443 Felt Adhesive Backed Washer 6 Flat Stainless
9. the rear of the console The red line on the ribbon cable will be on the right if the cable 15 installed properly 3 Turn power back on The LED on the AVR FISP will flash yellow as data is downloaded to the console When the download is complete the LED will turn to solid green e The download takes one minute 4 Unplug the AVR ribbon cable from 47 ClubTrack 2100 Series Treadmill Service Manual 13 PART Console Codes Contents OVe VISW a c 16 16 u cu us oe cuui 16 User WeIght eT 17 Exercise uu 17 User Age prr 17 Target Heart Rate 18 Treadmill 18 COOLIO MID C 18 Quick Start u 18 ita adita Rt id 19 Owner Defined Custom 19 ren ne ee 19 20 Contents Change UNIS 20 i 20 1 11 10 21 Contrast 2100 LC only 21 rH oil 21 Side 22 Enable Mag ROY ticis 22 Set Defa lts dun da i a a l b 22 Machine Stat s
10. 50 ClubTrack 2100 Series Treadmill Service Manual Contents Assembly Illustrations Assembly Parts Lists sie et di it 53 Assembly Drawings Overview neuen nino nitet units 55 Side ata LD pe ou ia f 56 ACUI ANAS NN ooo 57 Grade Weldment 58 A 59 Driver 60 Front 61 VSD 62 WeldMenit L uuu uuu Sua naa usa 63 Controller Support 64 Hood Assembly and End 65 Hand Grips and Ergo Bar 66 eoe 67 POBA PE 68 Controller Me o 69 Controller Bottom Housing sisien i 70 Appendixes Appendix A Required 5 72 Appendix B Differences Between 2100 M tor WINN 73 Appendix C Replaceable Parts Lists 74 Appendix D Using Multimeter 80 Appendix E International Power Plug Configurations 83 Appendix F Specifications 84 ji ClubTrack 2100 Series Treadmill Service Manual PART Maintenance Contents
11. CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized Table 2 3 Exercise Time Press Keys oispiay What you wiles 2 a m s eram Default setting Setting could be different if the treadmill was customized Table 2 4 User Age Step No Press Keys On Console Display What you will see CLEAR 2 3 ENTER AGE 2 ENTER ENTERAGE 40 SPEED or SPEED Age changes from 10 99 4 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized ClubTrack 2100 Series Treadmill Service Manual 17 Cardio Table 2 5 Target Heart Rate Step No Press Keys On Console Display What you will see L CLEAR 2 4 THR PERCENT 2 JENTER PERCENT 70 SPEED or SPEED THR percentage changes from 50 85 4000 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized Table 2 6 Treadmill Speed Press Keys JA What you wiles 2 fem zm 37 SPEED orsPeco s euam Default setting Setting could be different if the treadmill was customized Table 2 7 Cool Down Time Step Press Keys On Console Display What you
12. Treadmill will not reach maximum Speed limit control may be Refer to Part 2 for adjusting speed activated treadmill maximum speed Treadmill will not reach maximum Time limit control may be activated Refer to Part 2 for adjusting time treadmill maximum time ClubTrack 2100 Series Treadmill Service Manual 31 Error Reporting Table 3 2 Electronic Issues Walking belt stops and no error User hit the Ergo stop button Press START to resume message appears workout Ergo PCB is not grounded Ground the Ergo PCB CHR does not work Contact plates have excessive Replace the contact plates if moisture under them 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 NO ERROR Displayed in the Error Log if no Placeholder label events PROGRAM Error Start up Stops operation ALL Microprocessor fails self test ERROR program
13. 27586 27587 1 1 27591 27592 27593 27594 27595 27601 27602 27605 10 x 1 50 x 30 Hex Head 27612 Screw M3 x 0 5 x 10 Self Tapping Pan Hd Torx 27590 x 1 25 x 20 Hex Head I 5 g co ClubTrack 2100 Series Treadmill Service Manual 54 Assembly Drawings Overview Assembly Drawings Overview The information in the table below refers to specific notes represented by 1 gt found on the drawings in the section Refer to these notes when replacing parts because they mention critical torque specs The symbol throughout the drawings refers to the assembly revision Table 5 2 Notes Pertaining to Assembly Drawings rasa Trae inch pounds e hepy areae vetore assem _ Ppa Herron 29 reas vetore assem Cut to 2 inch 5 cm Apply to top center EndCap rib 13 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 2100 Series Treadmill Service Manual Side Rails ClubTrack 2100 Series Treadmill Service Manual 56 Headframe 06522 9 test 065 2 265 7 Xb o 69027 fis 6920 XZ XC 0
14. Do not over tighten the deck screws DO OVER TIGHTEN THE DECK SCREWS OVER TIGHTENING THE DECK SCREWS WILL DAMAGE THE COMPRESSION MOUNTS Replacing the Walk Belt 7 0 Reinstalling the Front Roller 711 Slide the front roller inside the walking belt 72 Insert the end of the roller opposite the pulley into the cut out on the side rail 7 3 With your free hand slip the motor drive belt onto the pulley 74 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 75 After alignment of the Front Roller and Flywheel place belt on the Front Roller and Flywheel 76 Place 5 16 wrench on nut of Tensioner and turn counter clockwise creating tension on the bent and 10 ClubTrack 2100 Series Treadmill Service Manual Replacing the Contact Heart Rate CHR Sensors 74 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 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 tighten the adjustment bolts
15. Hex Zinc Plated SM27140 27140 Config Plate 2100 220V SM27317 27317 Filter Noise SM27308 27308 EN Circuit Breaker ME SM27127 27127 EN Assy Transformer 2100 Treadmill SM36498 002 36498 TM Volt Config 230V 002 79 ClubTrack 2100 Series Treadmill Service Manual 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 need
16. Manual No Elevation Movement Treadmill will not elevate Isa Grade Move No Error present Yes Unplug P18 and check for 118VAC between the blue and brown wires Is the voltage good v Cycle the power Does the treadmill elevate Upgrade the firmware Replace fuse F2 Yes 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 Replace Actuator Motor run Replace the VSD Board m m ClubTrack 2100 Series Treadmill Service Manual 28 End Troubleshooting Flowcharts No Perform keypad test CLEAR 6 1 Does GRADE and GRADE work Replace the Controller Processor PCB Replace the Keypad Assembly Troubleshooting Flowcharts Non Functional CHR CHR does not function J Check for 2VDC between the top and bottom contact plates on each handgrip Remove the No contact plates from handgrips and recheck voltage Is the voltage good Yes Is the voltage is good Replace the CHR Cycle the power PCB Replace the CHR making sure the wire tabs do not contact e
17. SPEED to select ON Press ENTER 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 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
18. memory check sum error Display will be blank and the console will beep twice STATIC RAM Error Start up Stops operation ALL Microprocessor fails self test ERROR 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 EEPROM ERROR Error Start up Stops operation ALL Microprocessor fails self test EEPROM chksum error All of the EPROM values will be loaded with the defaults No error message appears TM HW COM Error Anytime Goes to idle Treadmill Treadmill UART hardware link failure ERROR slowly stops TM COM ERROR Error Anytime Goes to idle Treadmill Treadmill E204 drive communication slowly stops failure low DRIVE ERROR Error Program operation Goes to idle Treadmill E209 output switching fault Treadmill stops quickly low 32 ClubTrack 2100 Series Treadmill Service Manual Error Reporting Table 3 3 Error List OUT CUR ERROR Error Program operation Goes to idle Treadmill E208 output current too low Treadmill slowly stops BELT OVRLD Warning During movement Displays Treadmill E207 moderate drive ERROR message until the user presses overload CLEAR Designed to inform the user that the belt or deck will need to be replaced soon Error Program operation Goes to idle Treadmill E203 high drive overload Treadmill slowly stops SYS OVRLD ERROR DRV MON ERROR Erro
19. mount and installing upper grade actuator mount 000 Steel Wool or Scotch Brite Cleaning the wax from front and rear rollers pad ClubTrack 2100 Series Treadmill Service Manual 72 Appendix B Differences Between 2100 and 510 612 Motor Wiring ClubTrack 2100 ClubTrack 510 612 Config Plate Config Plate Transformer output is 12VAC Not the same e Transformer output is 20VAC transformer as on 510 612 Line filter is Corcom F7585B for 230V Line filter is Corcom F7585B for all models models F7585A for 120V 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 Grade Motor WHITE x RED BLACK x x ORANGE BLUE BROWN Main Motor Main Motor Leeson 230V 3 phase AC induction e Baldor 200V 3 phase AC induction Has 3 wires for connecting to 3 phase power Has 3 wires for connecting to 3 phase input power input Has 2 more wires that are thermal switch outputs These are normally closed but will open if motor overheats Console Console C50 with LED or LCD display Commercial contact heart rate CHR system has higher performance than 510 612 Separate Ergo Board contains telemetry 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
20. the VSD E208 Replace the VSD E207 Replace the belt or deck if worn otherwise press CLEAR E203 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 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 Electrical failure on the drive electronics Solution Replace the VSD Motor blocked by obstruction Solution Remove the obstruction E210 Replace the VSD E212 Verify that the 3 jumpers are attached correctly on the VSD board If problem persists replace VSD board E211 Replace the VSD or grade motor VSD Table 3 6 LED Patterns for PC Boards P N 27920 amp 27115 Only when belt is running When belt is stopped Power to the console No power to the console Note If the VSD detects an error 051 and 052 will blink 34 ClubTrack 2100 Series Treadmill Service Manual VSD Table 3 6 LED Patterns for PC Board P N 41387 LED fon DS1 Belt is running Belt is stopped DS2 Motor Overload or once per second for proper No console communication console communication 053 Power to the console and Drive n a No power present Processor 084 Power to Drive M
21. the front handrail the cord will pull the key off and stop the treadmill walk belt 28 ClubTrack 2100 Series Treadmill Service Manual PART Troubleshooting Electrical Problems Contents Common Electrical and Electronic Problems 31 Table 3 1 Electrical Issues 21 Table 3 2 Electronic Issues 31 Error 32 Error B 32 EREE 33 Error Resolution 34 34 LED Patterns uapa bri 34 Troubleshooting Flowcharts 35 Replacing the Grade Actuator Motor 39 Problems with the Drive Motor 41 Contents Replacing the Drive 42 Magnetic Key Problems 45 peeing 5 45 120V Wiring Schematic 46 230V European Wiring 47 230V Non European Wiring Schematic 48 30 ClubTrack 2100 Series Treadmill Service Manual Common Electrical and Electronic Problems Common Electrical and Electronic Problems The following tables provide possible causes and solutions to the most common
22. 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 There is no display Circuit breaker on the treadmill Set the treadmill circuit breaker hood is off to ON Treadmill power cord is not plugged Plug in the power cord then set in the treadmill circuit breaker to ON There is no power at the wall outlet Check the building circuit breaker There is an internal electrical Refer to the wiring schematics problem located in this section of the manual There is a blown fuse Replace F1 or Circuit breaker trips during normal There is a power fault nspect walk belt for wear operation There is an insufficient power Make sure the outlet voltage source is 115VAC USA or 230VAC International The treadmill is not on its own Plug the treadmill into its own dedicated circuit 20 amp dedicated electrical outlet Treadmill will not change grade Replace blown fuse F2 There is an internal problem Cycle the circuit breaker switch on the treadmill Replace the grade actuator motor Grade actuator motor runs but Grade actuator motor is bad Replace the grade actuator grade never changes motor Table 3 2 Electronic Issues Treadmill will not change grade Old firmware is installed Upgrade the firmware
23. will see CLEAR 2 7 COOLDOWN TIME 2 JENTER COOLDOWN TIME 2 IE SPEED or SPEED um down time changes from 2 10 4 ENTER UPDATING CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized Table 2 8 Quick Start Step No Press Keys On Console Display What you will see 1 2 8 QUICK START 2 JENTER QUICK START E SPEED or SPEED Starting speed changes from 1 5 mph 4 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized 18 ClubTrack 2100 Series Treadmill Service Manual Table 2 9 Decline Step No Press Keys On Console Display What you will see CLEAR 2 9 DECLINE or SPEED Toggles between OFF and ON 4 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different if the treadmill was customized Owner Defined Custom Owner Defined Custom You can customize several owner defined parameters to conform to your individual requirements including e changing the workout time limit e changing the units between English and metric e choosing the type of heart rate input e choosing the console language e changing the contrast e changing the treadmill s maximum speed e enabling or disabling the sidelight during Intro Mode e enabling the magnetic key and e resetting the factory defau
24. 2 Inspect the rubber isolators for wear If they are bad replace them 33 Slide the replacement motor onto the headframe motor mount studs 3 4 Install the rubber isolators and washers onto the studs 35 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 37 Connect the five 5 wires from the motor to P5 P7 P8 and P9 on the VSD board 40 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 42 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 SS 44 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 comp
25. 22 27122 Assy Harness Jumper Male QD SM27353 27353 Decal ClubTrack 2100 LC Left 5 27354 27354 Decal ClubTrack 2100 LC Right ClubTrack 2100 Series Treadmill Service Manual 74 EJ E EIL 8 2207 22077 38 16NC FinishHex mm ME E ss Appendix C Table 6 4 Common Parts 110V 220V and 240V Versions Code 75 ClubTrack 2100 Series Treadmill Service Manual Appendix C Table 6 4 Common Parts 110V 220V and 240V Versions Code Je me memes sme mes woeren jme mes r me iS ma T seew nez 0x ewone em E ClubTrack 2100 Series Treadmill Service Manual 76 SM27467 SM27477 5 27478 5 27485 5 27487 5 27490 5 27535 5 27536 5 27537 5 27540 5 27541 5 27542 5 27552 Appendix C Table 6 4 Common Parts 110V 220V and 240V Versions Code 77 ClubTrack 2100 Series Treadmill Service Manual Appendix C Table 6 4 Common Parts 110V 220V and 240V Versions Part Number Level 1 Level 2 Level 3 Description Warranty Code SM27648 00 527648 Assy Endcap Siderail Left Gray 3 00 527649 Assy Endcap Siderrail Right Gray 3 00 27654 Pad Leveling Swivel 1 2 13 5 27649 00 5 27654 5 27660 SM27664 SM2766
26. 5 SM27675 SM27676 SM27677 SM27678 SM27679 i _ Assy __ KM mE Hl sss HEN NEN SM27764 284 Sett Tapping 6x 38 ja p i E E NEN NEN HE Spacer Soft Deck Assembly Stiffner Siderail LH Assembly Stiffner Siderail RH SV Assy Upright Support LH LED SM27892 SM27893 SM27897 SM27898 5 27951 5 27952 5 33511 002 33511 002 36125 001 Assy Retainer Frt Roller Shaft SM27885 527885 Spares Tripleflex Hardware 2100 Kit Tripleflex 510 612 5 36125 001 2 Grade Wheel Spares Kit 40012 Magnetic Switch Assembly 001 27488 Assy VSD 01387 Assembly PCB AC Drive 3 1 5 40012 001 1 1 1 1 1 1 1 1 1 1 2 1 5 27488 5 41387 ClubTrack 2100 Series Treadmill Service Manual 78 Appendix C Table 6 5 110V Parts Only Code SM27962 27962 Assy Transformer 2100 Treadmill SM35774 002 NE 35774 an PCBA Config Plate 510 612 002 SM27378 27378 Washer M6 Flat Stainless SM27386 EHE 27386 E Assy Cable C50 Ergobar SM27966 BEEN 27966 EN Actuator Linear 110V 2100 TM Table 6 6 220V Parts Only Code SM36498 002 36498 mE PCBA TM Volt Config 230V 002 Table 6 7 240V Parts Only Code SM27125 27125 Assembly 2100 Euro SM27573 27573 M5
27. 5 775 Hg absolute 84 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 OFFICES IN THE UNITED STATES e TECHNICAL CUSTOMER SERVICE Nautilus Inc World Headquarters 16400 SE Nautilus Drive Vancouver Washington USA 98683 Phone 800 NAUTILUS 800 628 8458 Email customerservice nautilus com Fax 800 523 1049 e MANUFACTURING FACILITY Nautilus Inc 10757 East Ute Tulsa Oklahoma USA 74116 e CORPORATE HEADQUARTERS Nautilus Inc World Headquarters 16400 SE Nautilus Drive Vancouver Washington USA 98683 Phone 800 NAUTILUS 800 628 8458 85 For technical assistance and a list of distributors in your area please call or fax one of the following numbers INTERNATIONAL CUSTOMER SERVICE INTERNATIONAL OFFICE Nautilus International S A Rue Jean Prouv 6 1762 Givisiez Switzerland Tel 41 26 460 77 77 Fax 41 26 460 77 70 Email technics nautilus com INTERNATIONAL OFFICES e SWITZERLAND OFFICE Nautilus Switzerland S A Tel 41 26 460 77 66 Fax 41 26 460 7 7 60 GERMANY and AUSTRIA OFFICE Nautilus GmbH Tel 49 2204 610 27 Fax 49 2204 628 90 e ITALV OFFICE Nautilus Italy s r l 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 e CHINA OFFICE N
28. 6510 D L Les c XC XC 86816 XC ClubTrack 2100 Series Treadmill Service Manual 57 Grade Weldment ClubTrack 2100 Series Treadmill Service Manual Drive Motor A18W3SSV SIDV4ANS 6SZ XV 19512 Xv VOSLZ Xv 9 XV eos c xv CI 60 ClubTrack 2100 Series Treadmill Service Manual Front Roller Assembly 2 27573 i 4X 27590 4X 27592 4X 27591 2 DO 2x 27574 10X 27583 61 ClubTrack 2100 Series Treadmill Service Manual ClubTrack 2100 Series Treadmill Service Manual VSD Board 62 Hood Assembly and End Caps 65 ClubTrack 2100 Series Treadmill Service Manual Hand Grips and Ergo Bar ClubTrack 2100 Series Treadmill Service Manual Cabling 67 ClubTrack 2100 Series Treadmill Service Manual PCBA jonpoid 10 poods pue J991109 Ajjuopr osou p V4OA JO puey 1981 Joddn ut pooo coq pue d 880198 sroduinf 4 MIJU 53901 99646 21912 22722 gt 041 14746 99118 9 L
29. Board heart rate and magnetic stop key inputs Cables Drive Board e 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 halfcables are mated together when the Console is first installed 73 ClubTrack 2100 Series Treadmill Service Manual 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 Table 6 3 Accessories Partnumber ewm Jowrezmnatzni Table 6 4 Common Parts 110V 220V and 240V Versions Code 5 20423 20423 1 8 7 515 5 20473 20473 1 8 4 5 21135 21135 Loom Flexible 350 ID SM24309 24309 5 271
30. CTION ENTER Program name followed by the total number of times that program was used INCLINE or INCLINE 1 Cycles through program names EN CLEAR MACHINE STATUS 5 CLEAR THE RESULTS YOU WANT 24 ClubTrack 2100 Series Treadmill Service Manual Diagnostic Use the diagnostic codes to test various components of the machine such as the e display e keyboard and e serial port The diagnostic codes also allow you to get a report on the treadmill s e drive bus voltage and e actual grade setting Table 2 30 Diagnostic Step Press Keys On Console Display What you will see CLEAR 6 ENTER DIAGNOSTIC INCLINE UP or INCLINE DOWN DISPLAY TEST KEY TEST SERIAL TEST RESERVED RESERVED RESERVED RESERVED RESERVED BUS VOLTS GRADE ACT Selected choice 4 CLEAR DIAGNOSTIC 5 CLEAR THE RESULTS YOU WANT To scan through the list of diagnostic tests and view diagnostic Information Table 2 31 Display Test Press Keys On Console Display What you will see 42 JCLEAR 6 0 DISPLAY TEST ENTER Display LEDs or LCD pixels in alter nating fashion 3 CLEAR TWICE THE RESULTS YOU WANT Table 2 32 Key Test Step No Press Keys On Console Display What you will see 3 CLEAR 6 1 KEY TEST 2 JENTER PRESS KEY NC PANEL KEY press and hold The name of the key you are pressing W CLEAR TWICE THE RESULTS YOU WANT ClubTrack 2100 Series Treadmill Se
31. HE MOTOR 1 0 Remove the Treadmill Hood 11 Place two 2 5 inch 13 cm blocks securely under the treadmill headframe 12 Turn the treadmill circuit breaker off and unplug the treadmill power cord 13 Remove the six 6 screws on the treadmill hood 14 Lift off the hood 2 0 Remove the Grade Actuator Motor 21 Unplug P17 from the VSD board 40 ClubTrack 2100 Series Treadmill Service Manual 2 2 2 3 2 4 2 5 2 6 2 1 Replacing the Grade Actuator Motor Remove the grade actuator ground wire using a 10 millimeter socket wrench Remove the two 2 8 millimeter hex bolts and shoulder bushings that secure the swing arm to the grade nut block 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 Withdraw the steel cylinder bushing from the bronze bearing Unscrew the grade block containing the actuator nut from the actuator drive screw 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 3 2 3 3 3 4 Lubricate and insert the steel cylinder bushing on the new actuator bronze bearing 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 Reinstall the ground wire using screw and star washer previously remoev
32. Key Press Keys On Console oispiay What you wiles 2 emn OFF _ 3 SPEED orSPEED roges between OFF anan s euam Default setting Setting could be different Table 2 20 Set Defaults Step No Press Keys On Console Display What you will see CLEAR 3 9 SET DEFAULTS 2 ENTER UPDATING then DONE 5 CLEAR THE RESULTS YOU WANT Machine Status Use the machine status codes to view maintenance information such as the e machine run time hours e number of workouts e distance traveled e console version e configuration setting e motor drive version e machine run time hours since last cleared for servicing purposes and e the individual program selection count 22 ClubTrack 2100 Series Treadmill Service Manual Machine Status To scan through and change the owner defined codes perform the following steps Table 2 21 Machine Status Press Keys On Console Display What you will see CLEAR 4 ENTER MACHINE STATUS INCLINE UP or INCLINE DOWN RUN HOURS WORKOUTS DISTANCE CONSOLE VERSION CONFIGURATION TM DRIVE VERSION MAINT HOURS PROGRAM SELECTION Value for selected choice 4 CLEAR MACHINE STATUS 5 CLEAR THE RESULTS YOU WANT 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 Press Keys On Console Display What you w
33. MUM 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 I e 889 mm 889 mm 350 1 4 ClubTrack 2100 Series Treadmill Service Manual 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 596 696 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 5 If you feel the belt slip on the front roller increase the tension of each adjustment bolt by 1 2 turn and re test If you feel the belt slip again check the tensioner adjustment 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 gra
34. StairMaster ClubTrack 2100 Series Treadmill Service Manual 000 6583 Rev 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 ClubTrack 2100 please call Nautilus Customer Service at 800 864 1270 USA or 41 26 460 77 77 outside USA A WARNING DANGEROUS VOLTAGES ARE PRESENT INSIDE THE TREADMILL SERVICING BY OTHER THAN AUTHORIZED NAUTILUS SERVICE PERSONNEL MAY RESULT IN ELECTRIC SHOCK OR OTHER INJURY 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 Contents Maintenance Viewing Maintenance Information 2 Routine Maintenance 2 Cleaning 2 Adjusting Belt Tens
35. Viewing Maintenance Information 2 Routine Maintenance 2 Daily uuu REC AVR 2 Cleaning eer ere ete EE 2 NP es cca tated sat 2 2 u 2 osa sie se 3 Treadmill Interior 3 Adjusting Belt 3 Adjusting Tracking 5 Replacing the Walk Bell 5 Replacing the Contact Heart Rate CHR Sensors 12 Replacing Nc Ur E 12 Updating the Console Firmware 13 Cleaning Viewing Maintenance Information The total time and distance the treadmill has been in use can be viewed using the Machine Status console codes This information can help you schedule treadmill maintenance and check treadmill usage 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 Routine Maintenance Schedules Performing routine maintenance will help prevent unnecessary wear to the treadmill and or injury to the us
36. ach other inside the Ergo Bar Assembly Is the CHR working Yes Replace the Controller Processor PCB End 38 ClubTrack 2100 Series Treadmill Service Manual Non Functional Ergo Bar Ergo Bar does not function Cycle the power STUCK KEY ERROR present Replace the Ergo Keypad and or the Ergo PCB End Is the Magnet Key in use Remove the Magnetic Key and inspect for rust Is the Magnetic Key rusted Replace the Magnetic Key No Y Remove and inspect the Ergo PCB for corrosion Is the Ergo PCB corroded Replace the Ergo PCB End ClubTrack 2100 Series Treadmill Service Manual No Troubleshooting Flowcharts Inspect Ergo PCB ribbon cable from pod cover for crimped wire Is the cable crimped Replace the Ergo PCB Replace the cable 39 Replacing the Grade Actuator Motor Replacing the Grade Actuator Motor WARNING DANGEROUS VOLTAGES ARE PRESENT UNDER THE TREADMILL HOOD EXERCISE CAUTION WHEN PERFORMING SERVICE TO THE ELECTRICAL COMPONENTS UNDER THE HOOD CAUTION 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 T
37. artment 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 ClubTrack 2100 Series Treadmill Service Manual 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 5 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 ClubTrack 2100 Series Treadmill Service Manual 120V Wiring Schematic LAdNI SNIVW e JEN BREAKER NOILVUNDIJNOD 90 81 Z 50 26 1 13 401 SNOISH3A TIHINQV38 L 91310012 HOVALANIO N31SVWMIVLS 100 98656 TIVLSNI 10N OG 24 02622 SUSAN 34 3010 SIHILMS NWH3HL
38. autilus Representative Office Tel 486 21 523 707 00 Fax 486 21 523 707 09 ClubTrack 2100 Series Treadmill Service Manual
39. cess 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 WARNING 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 1 N Turn the treadmill circuit breaker off and unplug the treadmill power cord Remove the six 6 screws on the treadmill hood Lift off the hood Clean inside the unit Reinstall the hood and the six 6 screws Plug in the treadmill power cord and switch on the treadmill circuit breaker Adjusting Belt Tension WARNING SECURE LONG HAIR AND LOOSE CLOTHING BEFORE WORKING NEAR THE TREADMILL WALKING SURFACE OR PULLEYS ClubTrack 2100 Series Treadmill Service Manual 3 Adjusting Belt Tension DO 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 MAXI
40. d surface unuseable Important Do not apply any cleaners or petroleum products to the deck surfaces Wax Good Side No Wax Bad Side 8 ClubTrack 2100 Series Treadmill Service Manual 43 44 45 46 Replacing the Walk Belt Inspect the motor drive belt for wear and cracking Cracking is prevalent between the grooves on the belt 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 Stand each roller on one end and rotate it Listen for any squeaking sounds and verify that the rollers spin smoothly Vacuum the deck and inside the motor housing 5 0 Installing the New Walk Belt 5 1 5 2 9 3 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 Lift the deck with the installed new walk belt and place it on the compression mounts 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 6 2 6 3 ClubTrack 2100 Series Treadmill Service Manual Align the deck mounting holes with the compression mounts Install all twelve 12 deck screws and hand tighten Use a 10 mm socket to tighten all the screws Put pressure on the deck next to the screw you are tightening Important
41. de 2 Increase speed to six mph and make the following adjustment 21 If the belt moves to the right turn the right adjustment bolt 1 4 turn clockwise 22 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 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 13 Lift off the hood ClubTrack 2100 Series Treadmill Service Manual 5 Replacing the Walk Belt 2 0 Remove the Rollers 2 1 Remove the end cap by removing the adjustment bolts Adjustment Bolts 22 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 of the bolt mounting the Tensioner and turn counter clockwise until Tensioner loosens 6 ClubTrack 2100 Series Treadmill Service Manual Replac
42. e Manual Magnetic Key Limit Access Control Table 2 37 Error Log Step No Press Keys On Console Display What you will see 1 CLEAR 7 0 ERROR LOG 2 JENTER ERROR if any or NO ERROR INCLINE UP or INCLINE DOWN A list of errors 4 CLEAR THE RESULTS YOU WANT Table 2 38 Maintenance Hours Step No Press Keys On Console Display What you will see CLEAR 7 1 MAINT HOURS xxx where x is the current maintenance hours setting SPEED SPEED Zero or a setting of your choosing 3 ENTER UPDATING 4 CLEAR 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 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 trademark S logo on the key faces the user The magnet will activate the control Magnetic Key ClubTrack 2100 Series Treadmill Service Manual 27 Magnetic Key Limit Access Control N Place the magnetic key in its location on the Ergo bar On the keypad press CLEAR 3 8 and ENTER Press the SPEED or
43. e 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 ClubTrack 2100 Series Treadmill Service Manual 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 Ibs 181 kg 400 Ibs 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 F 10 32 C 13 122 F 25 50 3 95 relative Limited to 90 F maximum dew point 3 95 relative Limited to 90 F maximum dew point 8 60 15 0 psia 445 775 mm Hg absolute 8 22 15 0 psia 42
44. ed in Step 2 2 Insert the black wire into pin 4 on P17 as shown below and plug P17 onto the VSD board lip side up ClubTrack 2100 Series Treadmill Service Manual 41 Problems with the Drive Motor 4 0 Zero the Grade Actuator Motor 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Plug the Actuator cable into the VSD Plug the Power Cord into the outlet and turn the machine on 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 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 Insert a new grade nut into the grade block and secure it with the two 2 lock washers and 4 millimeter screws 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 Lubricate the grade block and secure it to the swing arm using the two 2 shoulder bushings and 8 millimeter 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 Press the QUICK START key then INCLINE INCREASE DECREASE keys to verify operation 5 0 Rei
45. er 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 e Inspect the power cord and walking belt for wear e 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 e Check the optional side handrails to ensure they are fastened securely e Remove potential hazards from the treadmill area Cleaning Keeping the StairMaster 2100 LC LE treadmill clean on a regular basis will help to improve operation and increase the lifespan of the components 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 A STAIRMASTER APPROVED TECHNICIAN BEFORE IT CAN BE USED AGAIN Daily e Keep the treadmill and controller free of dust and debris Use damp sponge to wipe the exteriors and walking belt do not soak surfaces Dry all surfaces thoroughly 2 ClubTrack 2100 Series Treadmill Service Manual Adjusting Belt Tension Weekly Elevate the treadmill to maximum incline and vacuum the floor under it to prevent ex
46. ews that hold the console onto the controller support weldment and lift the controller off carefully Disconnect the contact heart rate wire from the contact heart rate CHR module Disconnect the ribbon cable from the power control board assembly PCBA Disconnect the communication cable from the PCBA Remove the thirteen 13 T 15 torx screws from the back of the controller assembly Disconnect the three 3 keypad ribbon cables from the PCBA processor assembly Remove the six 6 screws from the PCBA display processor assembly and remove it Remove the nine 9 screws that hold the lens and remove it from the front controller assembly 2 0 Reinstalling the Lens 12 2 1 22 2 3 2 4 2 9 Attach the lens to the front controller assembly with nine 9 screws Apply blue Loctite to the six 6 screws Attach the PCBA display processor assembly with the six 6 screws Connect the three 3 keypad cables Reinstall the controller by repeating steps 1 1 1 6 under 1 0 Removing the Lens in reverse order ClubTrack 2100 Series Treadmill Service Manual Updating the Console Firmware Updating the Console Firmware A WARNING 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 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
47. ill see 1 CLEAR 4 0 RUN HOURS ENTER Total run time hours since last servicing JCLEAR THE RESULTS YOU WANT Table 2 23 Number of Workouts Press On Consoe 2 _______ 37 wemesursvouwwr Table 2 24 Distance Traveled A Press Kevs On Console Displav What vou will see 1 CLEAR 4 2 DISTANCE ENTER Total distance users have traveled using the treadmill 3 CLEAR THE RESULTS YOU WANT ClubTrack 2100 Series Treadmill Service Manual 23 Machine Status Table 2 25 Software Revision Press Keys On Console Display What you will see 3 CLEAR 4 3 CONSOLE VERSION ENTER CBD2G2 Vxx xxxx where x is the version number 3 CLEAR THE RESULTS YOU WANT Table 2 26 Configuration step No Press Keys On oispiay What you wiles eum YOUWANT Table 2 27 TM Drive Press Keys On Console Display What you will see 3 CLEAR 4 5 TM DRIVE VERSION ENTER TM DRIVE VERSION xx where x is the version number CLEAR THE RESULTS YOU WANT Table 2 28 Maint Hours Step Press Keys On Console Display What you will see 1 CLEAR 4 6 MAINT HOURS ENTER MAINT HOURS xxx x where x is the total number of hours since the machine was last serviced 3 CLEAR THE RESULTS YOU WANT Table 2 29 Program Selection Step No Press Keys On Console Display What you will see CLEAR 4 7 PROGRAM SELE
48. ing the Walk Belt b Lift up on the Tension Wheel and slide the motor drive belt over pulley to remove 25 Remove the two 2 front retainer bolts at each end of the front roller 26 Liftthe 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 ClubTrack 2100 Series Treadmill Service Manual 7 Replacing the Walk Belt 27 Slip the motor drive belt off the front roller pulley 28 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 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 33 Slide the deck out from between the belt 40 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 ba
49. ion 22222222 22 2 3 Adjusting Belt Tracking 5 Replacing the Walk Bell uuo rr 5 Replacing the Contact Heart Rate CHR Sensors 12 Replacing the Lens 12 Updating the Console Firmware 13 Console Codes OVETVIEW re 16 CM net 16 Owrer Defined Custom 19 Machine Status 22 L uu ER 25 Diagnosti Su a Lau 26 Magnetic Key Limit Access Control 27 Troubleshooting Electrical Problems Common Electrical and Electronic Problems 41 uei eiit TREE 32 VSD 34 Troubleshooting Flowcharts 35 Replacing the Grade Actuator Motor 39 Problems with the Drive Motor 41 Replacing the Drive Motor 1 42 Magnetic Key Problems i en d e 45 Wiring Schematics DM 45 Troubleshooting Mechanical Problems Common Mechanical Problems and Solutions
50. le 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 e switched range and e 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 ClubTrack 2100 Series Treadmill Service Manual 80 Appendix D 81 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
51. lts Table 2 11 Customize Press Keys On Console CLEAR 3 ENTER INCLINE UP or INCLINE DOWN Only available on the 2100 LC model Display What you will see CUSTOMIZE MAX TIME CHANGE UNITS HR INPUTS RESERVED LANGUAGE CONTRAST MAX SPEED SIDE LIGHTS ENABLE MAGKEY SET DEFAULTS ClubTrack 2100 Series Treadmill Service Manual 19 Owner Defined Custom 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 Step Press Keys On Console Display What you will see CLEAR 3 0 MAX TIME 3 SPEED or SPEED Time limit of your choosing 4 UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different Table 2 13 Change Units Step Press Keys On Console Display What you will see CLEAR 3 1 CHANGE UNITS 2 JENTER USA UNITS SPEED or SPEED Toggles between USA UNITS and METRIC UNITS 4 ENTER UPDATING CLEAR THE RESULTS YOU WANT Default setting Setting could be different Table 2 14 HR Inputs Step No Press Keys On Console Display What you will see CLEAR 3 2 HR INPUTS EITHER INPUT LOCKED INPUTS EITHER INPUT TELEMETRY ONLY HAND ONLY BOTH HR OFF UPDATING THE RESULTS YOU WANT Default setting Setting could be different 20 ClubTrack 2100 Series Treadmill Service Manual Table 2 15 Lang
52. nstall the Treadmill Hood 5 1 5 2 5 3 Install the treadmill hood over the motor compartment Install the six 6 screws in the treadmill hood and tighten 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 42 ClubTrack 2100 Series Treadmill Service Manual 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 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 mo
53. otor Control Circuits n a No power to P20 or VSD problem 051 and 052 flashing together indicates error condition and shows automatic resets of the system Troubleshooting Flowcharts Use the flowcharts on the pages 36 40 to help vou localize and correct electrical and electronic problems ClubTrack 2100 Series Treadmill Service Manual 35 Troubleshooting Flowcharts No Display There is UN display Is 053 lit 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 Replace the VSD Board Remove Console End 2 and disconnect J4 harness on Console Processor PCB Check that the voltage between pins 1 black and 2 brown and pins 2 and 8 purple of the wire harness reads 18VDC Is the voltage good Replace the Main Cable Replace the Processor PCB L 36 Check fuses F1 F3 and F4 on Configuration Plate Assembiv Are the fuses good Remove P14 on the VSD Board Check that the voltage between the red and black wires reads 14VAC Is the voltage good Replace the VSD Board Replace the blown fuse Replace the Configuration Plate Assembly ClubTrack 2100 Series Treadmill Service
54. owest OHMs resistance range 2 Attach one test lead of the multimeter to 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 ClubTrack 2100 Series Treadmill Service Manual 82 Appendix E International Power Plug Configurations 5 6 11 International Power Plugs Power Power Cords Part Number SMQ30736 037 SMQ30736 039 T in 83 ClubTrack 2100 Series Treadmill Service Manual Specifications Electrical Physical Functionality Environmental 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 Languag
55. r Program operation Goes to idle Treadmill E210 current monitoring Treadmill slowly stops circuit failure CONFIG RQRD Error Start up Stops operation Treadmill E212 configuration not allowed Error During change Goes to idle Treadmill E201 grade position outside Treadmill slowly stops limits Error During change Goes to idle Treadmill E211 grade system Treadmill slowly stops detected an non requested response Error Program operation Goes to idle TM E new drive is commanded to Treadmill slowly stops change speed but doesn t GRD LIMIT ERROR GRD MOVE ERROR SPD CHANGE ERROR STUCK KEY Error Start up Stops operation One of the keypad keys are stuck in an active state Reports only Stuck key Table 3 4 Future Errors CS HW COM Warning Start up Stops CSAFE but ALL CSAFE UART hardware link ERROR continues user selection failure CS COM ERROR Warning Anytime Stops CSAFE but ALL CSAFE communication failure continues program STUCK KEY Start up Locks out key Reports which key is stuck POWER LOSS Warning Anytime Goes to idle Treadmill Loss of power to the motor drive slowly stops electronics ClubTrack 2100 Series Treadmill Service Manual 33 VSD Table 3 5 Error Resolution Ear sr O 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 Replace
56. rvice Manual Diagnostic 2b Diagnostic 2 Table 2 33 Serial Tests Step No Press Keys On Console Display What you will see CLEAR 6 2 SERIAL TESTS 2 ENTER RUNNING PASS or FAIL 3 CLEAR DIAGNOSTIC 4 CLEAR THE RESULTS YOU WANT Table 2 34 Bus Volts Step No Press Keys On Console Display What you will see 3 6 8 BUS VOLTS ENTER BUS VOLTS xxx where is the drive board bus voltage reading 3 CLEAR TWICE THE RESULTS YOU WANT Table 2 35 Grade Act Press Keys On Console Display What you will see CLEAR 6 9 GRADE ACT e GRADE ACT x x where x is the actual 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 To scan through and change the owner defined codes perform the following steps Table 2 36 Diagnostic 2 Step Press Keys On Console Display What you will see CLEAR 7 ENTER DIAGNOSTIC 2 2 iNctINE UP or INCLINE DOWN ERROR LOG MAINT HOURS ENTER not necessary for Selects the option you want and hours displays the results CLEAR DIAGNOSTIC 2 CLEAR THE RESULTS YOU WANT To view a particular machine status without having to scan through all the choices perform the following steps for that listed option 26 ClubTrack 2100 Series Treadmill Servic
57. tor phase wires P7 and 8 or P8 and P9 Replacing the Drive Motor A WARNING 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 11 Turn the treadmill circuit breaker off and unplug the treadmill power cord 12 Remove the six 6 screws on the treadmill hood 13 Lift off the hood 2 0 Remove the Motor 21 Disconnect P7 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 ClubTrack 2100 Series Treadmill Service Manual 43 Replacing the Drive Motor 22 Place a 9 16 wrench on the head of the bolt mounting the Tensioner and turn counter clockwise until Tensioner loosens 23 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 2 4 Remove the four 4 washers and rubber isolators from the motor mount studs Note the arrangement of the isolator mounts 25 Loosen the two 2 set screws fastening the flywheel drive pulley to the motor shaft and then remove the flywheel drive pulley 44 ClubTrack 2100 Series Treadmill Service Manual Replacing the Drive Motor 3 0 Install Motor 3 1 the new flywheel on the new motor shaft 3
58. uage Step No Press Keys On Console Display What you will see CLEAR 3 4 LANGUAGE 2 ENTER ENGLISH SPEED or SPEED ENGLISH GERMAN SPAN ISH FRENCH ITALIAN DUTCH SWEDISH JAPANESE 4 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different Table 2 16 Contrast 2100 LC only Press Keys Console Display What you will see 1 CLEAR 3 5 CONTRAST ENTER CONTRAST 2 2 27 45 2 5 MPH SPEED or SPEED press Changes contrast in the upper LCD hold screen INCLINE UP or INCLINE DOWN Changes contrast in the lower LCD press and hold screen 5 ENTER UPDATING mM CLEAR THE RESULTS YOU WANT Default setting Setting could be different Table 2 17 Max Speed Step Press Keys On Console Display What you will see CLEAR 3 6 MAX SPEED 2 JENTER MAX SPEED SPEED or SPEED Maximum treadmill speed of your choosing 4 ENTER UPDATING CLEAR THE RESULTS YOU WANT Default setting Setting could be different ClubTrack 2100 Series Treadmill Service Manual Owner Defined Custom 21 Machine Status Table 2 18 Side Lights Step No Press Keys On Console Display What you will see CLEAR 3 7 SIDE LIGHTS 2 ENTER SIDE LIGHTS or SPEED Toggles between OFF and ON 4 ENTER UPDATING 5 CLEAR THE RESULTS YOU WANT Default setting Setting could be different Table 2 19 Enable Mag
59. ustom 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 e default weight workout time e age e percentage of Maxmum Heart Rate for Target HR in HR Zone Trainer e treadmill speed e default cool down time e initial speed for Quick Start and e incline minimum Refer to the following table to scan through and change the cardio settings Table 2 1 Defaults Step Press Keys On Console Display What you will see CLEAR 2 ENTER DEFAULTS INCLINE UP or INCLINE DOWN ENTER WT RESERVED ENTER TIME ENTER THR PERCENT SPEED RESERVED COOLDOWN TIME QUICK START DECLINE a EIT e 16 ClubTrack 2100 Series Treadmill Service Manual Cardio Refer to the following tables to change individual default workout settings without scanning through all the selections Table 2 2 User Weight Step Press Keys On Console Display What you will see CLEAR 2 0 ENTER WT 2 ENTER ENTERWT 175 3 SPEED or SPEED Weight changes from 50 400 Ibs 4 ENTER UPDATING 5
60. ut the front The walk belt tension is Adjust the belt tension roller turns improperly set Refer to Part 1 to correct the problem Walking belt hesitates Adjusting The motor drive belt is Replace the motor drive belt the walking belt tension is slipping Adjust the motor drive belt ineffective tension The VSD is bad Replace the VSD Table 4 2 Noises 1 There is a grinding 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 One or more compression Replace the compression is running mounts are worn normally mounts 3 the ones in the front There is a squeaking noise when The unit may not be level Check the leveling feet on the deck wa kon Ine cec The deck is contacting the Replace the deck side rails the time when the belt is running 91 The motor drive belt is Make sure the grooves on misaligned the belt are seated correctly in the grooves on the front roller pulley and the motor flywheel The motor flywheel is Realign the motor flywheel misaligned with respect to the front roller pulley There is a squeaking noise all The motor drive belt is worn Relace the motor drive belt Note Remove the motor drive belt to isolate if the problem to a roller or the drive motor ClubTrack 2100 Series Treadmill Service Manual 50 PART
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