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Quinton ClubTrack Service Manual

Summary of ClubTrack

  • Page 1

    000377-833 033387-005 rev new ® treadmill service manual clubtrack ® clubtrack plus ® hr clubtrack c hr clubtrack plus c medtrack ® cr60 medtrack ® sr60

  • Page 2

    Trademarks quinton, clubtrack, clubtrack plus, and medtrack are registered trademarks of quinton instrument company. Clubtrack 3.0, hr clubtrack, hr clubtrack plus, hyperdrive, q-series, and series 90 are trademarks of quinton instrument company. All other product and company names are trademarks or...

  • Page 4: Preface

    Preface this manual contains information for servicing and repairing the following quinton ® hyperdive ™ treadmills to the module level: clubtrack ® p/n 00377 clubtrack plus ® p/n 00382 hr clubtrack ™ p/n 00402 hr clubtrack plus ™ p/n 00425 medtrack ® cr60 p/n 00380 medtrack ® sr60 p/n 00390 the man...

  • Page 5: Contents

    Contents preface overview clubtrack ® . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 medtrack ® . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 configuration plate . . . . . . . . . . . . . . . . . . . . . 1-2 power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 operation ....

  • Page 6

    Troubleshooting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 electrical problems . . . . . . . . . . . . . . . . . . . . . 3-2 electronic problems . . . . . . . . . . . . . . . . . . . . . 3-3 error codes . . . . . . . . . . . . . . . . . . . . . . . 3-3 service mode . . . . . ....

  • Page 7

    Replacing the rollers . . . . . . . . . . . . . . . . . . . 4-23 replacing the walk belt or deck . . . . . . . . . . . . . 4-24 replacing compression mounts . . . . . . . . . . . . . . 4-25 replacing the deck . . . . . . . . . . . . . . . . . . . . 4-25 adjusting the walk belt . . . . . . . . . . . ...

  • Page 8

    Controllers . . . . . . . . . . . . . . . . . . . . . . . . . C-3 accessories for heart rate monitoring . . . . . . . . . . . C-5 field functional tests complete field functional test . . . . . . . . . . . . . . . D-1 test the controller displays . . . . . . . . . . . . . . D-1 test the multi displa...

  • Page 9: Overview

    Overview clubtrack ® quinton’s clubtrack series of treadmills are motorized treadmills with built-in controllers and are designed for fitness exercise. The series includes the clubtrack, p/n 00377; hr clubtrack with heart rate monitoring, p/n 00402; clubtrack plus, p/n 00382; and the hr clubtrack pl...

  • Page 10: Configuration Plate

    Configuration plate power the circuit breaker on the front of the treadmill hood controls the power to the treadmill. The circuit breaker must be set to on for the treadmill to run. ) turn off the circuit breaker before connecting or disconnecting the treadmill from the wall outlet. Operation the co...

  • Page 11: Controllers

    Controllers quinton up grade speed power down stop belt start belt cool down select faster slower stop belt units clear clubtrack and medtrack sr60/cr60 clubtrack clubtrack compatible compatible tm tm heart rate monitoring leds hr clubtrack controller with heart rate monitoring stage start belt next...

  • Page 12

    Stop belt down up previous menu start belt f1 speed units f3 f2 menu slower cool down stop belt faster grade power mph km/h quinton fitness equipment pcba 35452 keypanel 35260 controller assy 35258 hr clubtrack plus controller with heart rate control overview 1-4.

  • Page 13: Theory Of Operation

    Theory of operation overview the treadmill consists of three major assemblies: controller, headframe, and deck and roller. Controller assembly the controller assembly, which is mechanically attached to the deck, is the user interface. The user presses a key on the controller to enter a command. The ...

  • Page 14

    Headframe assembly the headframe assembly includes the drive and grade systems and the electronics that drive these systems. A three-phase ac motor drives the walk belt by supplying torque and speed to the drive pulley through a drive belt. A dc motor drives the front of the treadmill up and down to...

  • Page 15

    User inputs the user enters all control commands through the keypanel. The controller scans the membrane switches on the keypanel. The controller pcba interprets switch closure, updates the displayed values, and sends control commands to the drive board. Output displays the controller assembly uses ...

  • Page 16

    Input power module the input power module receives line power from the power outlet. When sold for use in the united states and canada, these treadmills use 115 vac power. When sold for use in europe and the united kingdom, the treadmills use 230 vac power. Drive board the treadmill drive board uses...

  • Page 17

    Heart rate monitoring option the heart rate monitoring function is a wireless system based on existing hardware purchased from polar electro, inc. The system consists of a transmitter worn on the chest of the user and a receiver mounted inside the controller enclosure. Electronics inside the belt se...

  • Page 18: Troubleshooting

    Troubleshooting the tables and flow charts in this chapter cover the following potential problems: • electrical problems: power, cable connections • electronic problems: pcb, test points, signals • mechanical problems: noise, vibration, grade, speed, belts see chapter 4 for repair and replacement pr...

  • Page 19: Electrical Problems

    Electrical problems use this table when: • the treadmill will not start. • there is no display on the controller. • the treadmill stops unexpectedly. Possible cause action treadmill not plugged in plug power cord into appropriate outlet. Power not on press the power key on controller. Limited access...

  • Page 20: Electronic Problems

    Electronic problems error codes the treadmill performs an electronic self-test each time that it is powered up. If a problem is detected during either power-up or operation, an error code appears on the display. Note the code recorded by the owner, then reference the table of error codes. If you rep...

  • Page 21

    Code indication recommended action e203 motor overload caused by one of the following: 1. Runner heavier than weight/speed envelope. 1. Restrict use to people within the weight/ speed specifications. 2. Deck wear 2. Check deck wear; replace if necessary. 3. Motor lead disconnected or loose 3. If the...

  • Page 22: Service Mode

    Service mode the treadmill provides a service mode for troubleshooting the electronics. To enter the service mode, press stop belt , faster , and slower simultaneously. P000 appears in the select display, indicating that no key is pressed. In the clubtrack plus, the word service scrolls across the t...

  • Page 23: Displays

    (continued) units p010 start course* p011 resume course* p012 cool down p013 faster p014 slower p015 *clubtrackplus only displays to test the displays on the key panel: 1. Enter the service mode. 2. Simultaneously press stop belt , grade up , and grade down . 3. The display cycles through one digit ...

  • Page 24: Hr Clubtrack Plus

    ) the clubtrack plus is in both open-loop speed and open-loop grade modes simultaneously. Approximate speed and grade range: 1.0 to 12.0 mph (1.6 to 19.3 km/h) 0 to 15 %, 0 to 8.53 ° . Speed 1. Enter the service mode. 2. Press up , faster , and slower simultaneously to enter open-loop speed mode. 3....

  • Page 25: Hr Clubtrack Plus

    The entire display should be off or dark. A corrupted pixel would be white. 4. Contrast the contrast changes smoothly from maximum contrast to minimum. Large jumps in contrast could indicate a failure in the contrast circuit or lcd. 5. Fluorescent tube brightness test the tube adjusts to its three p...

  • Page 26

    Signals on control cable pins pin no. Vsd (j12) pin no. Dpu (j1) signal 1 1 t+ (transmit+) 2 2 t - (transmit - ) 3 3 r+ (receive+) 4 4 r - (receive - ) 5 5 gnd (ground) 6 6 n/c 7 7 gnd (ground) 8 8 +12 vdc 9 9 +12 vdc note: j12 is a d-sub connector. J1 is a mascon connector. Heart rate monitoring op...

  • Page 27: Mechanical Problems

    Problem possible cause remedy no signal on controller 1. No electrode contact 1. Reposition chest belt, re-wet electrodes. 2. Faulty chest belt 2. Test signal using different belt transmitter or a pulse simulator; replace old belt if faulty. 3. Faulty receiver 3. Test the belt transmitter using a di...

  • Page 28: Drive Belt

    Problem possible cause action walk belt slipping 1. Improper walk belt tension. 1. Adjust walk belt tension. 2. Incorrect drive belt tension or drive belt worn. 2. Check drive motor belt. Adjust tensioner or replace drive belt if necessary. Walk belt not tracking belt misaligned or tracking adjustme...

  • Page 29

    Error code flow chart: ephi and eplo ephi bus voltage is too high check line voltage. Too high ? Have customer get building maintenance to correct voltage problem. Too low? Yes yes replace vsd is ds3 on? Trans- former output no replace transformer connect meter, then power up. Check transformer outp...

  • Page 30

    Error code flow chart: e001 e001 vsd microprocessor chip failure e002 vsd micropro- cessor eprom/ ram failure e201 grade error e206 inadvertant reset replace vsd pcba enter service mode verify grounding system is wired correctly and is intact e202 speed error e205 software tachometer fault calibrate...

  • Page 31

    Error code flow chart: e204 e204 communications error verify communication cable connection at each end. Error persists? Finished. Verify cable pins are not bent or broken or cable damaged. Damaged cable? Replace cable. Error persists? Finished yes yes no replace controller. Replace vsd. No less tha...

  • Page 32

    Error code flow chart: e203 e203 error overcurrent is motor turning? Check for obstructions in motor pulleys or belt yes runner outside weight/ speed envelope are all motor leads connected? Worn deck? Excessive deck wear indicated. Replace deck. Reconnect disconnected leads. Restrict use to people w...

  • Page 33

    Drive motor does not turn error code present? Perform key- panel test key test fail check ds1 led on vsd board procede to error code flow chart replace controller assembly cycle power. Led should be on momentarily then off. On then off? Press start is ds1 on? Replace vsd replace vsd check motor lead...

  • Page 34

    Treadmill will not elevate proceed to error code flow chart. Yes error code present? Perform keypanel test. Replace controller assembly. Yes key test fail check and free rack gear. Yes rack gear jammed? Replace fuse and retest. Yes f3, 4, 5, or 6 fuse blown? Caution! Disconnect power and wait for hi...

  • Page 35: Cautions/warnings

    Repair/replacement and calibration the procedures that follow apply to the hyperdrive clubtrack, clubtrack plus, hr series, and medtrack rehabilitation treadmills. The pcb assemblies are field-replaceable modules; no procedures are included for component-level repair. This includes: • variable speed...

  • Page 36: Tools

    • be sure treadmill area is free of liquid spills before removing hood. Burns • allow pulleys, motor, and other treadmill parts to cool sufficiently before touching them. • unplug the treadmill immediately if signs of overheating occur. Mechanical • be sure the treadmill power cord is unplugged befo...

  • Page 37: Field Functional Tests

    Field functional tests you must perform a field functional test after any of the procedures in this chapter are performed. The applicable test is specified after each section in this chapter. Appendix d, field functional tests, contains complete test instructions. The vsd pcba generates high voltage...

  • Page 38: Field Functional Test

    5. Remove the three #8 phillips-head screws located on the back of the hood, above the kick plate 6. Grasp the front section of the hood cover at the top and bottom center. Pull and lift to remove while feeding the power cord through the hood cover opening. 7. Use a long screwdriver to remove the tw...

  • Page 39

    End caps lh (33309-001) rh (33180-001) hood cover (32748-001) front walk belt (33509-002) siderail cover, rh (19489-002) metal siderail, rh (32707-003) clubtrack and medtrack sr60 (32707-004) medtrack cr60 vsd card cage (32975-002) controller upright metal siderail, lh (32709-003) clubtrack and medt...

  • Page 40: Field Functional Test

    Replacing the configuration plate on north american units, the configuration plate module includes the power cord, which is attached to the plate. On international units, the power cord is removable and is not part of the configuration plate module. 1. Turn off the treadmill circuit breaker, then re...

  • Page 41: Replacing The Power Cord

    Replacing the power cord hard-wired cords tools: heyco strain relief hand pliers 1. Remove the configuration plate as described above. 2. Use strain relief pliers to squeeze the strain relief on the power cord and pull it free of the configuration plate. 3. Clip the power cord wire ties. 4. Remove t...

  • Page 42: Field Functional Test

    4. Remove the two screws that hold the configuration plate to the headframe; the screws are located below the plate. Move the plate out of the way. A important: in the following steps, note the connection points and the colors of the wires as you remove them from the vsd board. All of the wires are ...

  • Page 43: Replacing The Tensioner

    Replacing the tensioner the tensioner may need to be replaced if the poly-v belt slips, if the idler pulley bearing makes noise, or if the tensioner roller is damaged. Do not attempt to disassemble the tensioner. The internal springs are tightly compressed and could cause injury if released. 1. Turn...

  • Page 44

    Test speed operation 1. Place a chalk mark or piece of tape on the walk belt across the direction of travel. 2. Place another mark or piece of tape on the top of the siderail cover. 3. Start the walk belt and increase its speed to 4.0 mph. 4. Count how many times the belt rotates in 2 minutes. This ...

  • Page 45: Field Functional Test

    4. Use a ½ -inch socket wrench to remove the end cap from each siderail. 5. Use a ½-inch wrench to remove the four -inch hex bolts that hold the two front-roller retainers to the frame. There are two bolts on each side of the roller assembly. 6. Slide the drive roller assembly to the left and remove...

  • Page 46: Field Functional Test

    1. Turn off the treadmill circuit breaker and remove the power cord from the power outlet. 2. Remove the treadmill hood as previously described. 3. Release the drive belt tensioner and remove the poly-v belt from the motor drive pulley as previously described. 4. Remove the configuration plate as pr...

  • Page 47: Replacing The Transformer

    Replacing the transformer 1. Turn off the treadmill circuit breaker and remove the power cord from the power outlet. 2. Remove hood as previously described. To prevent high voltage electrical shock: before working on or around any electrical or mechanical component under the hood, wait at least two ...

  • Page 48: Replacing The Grade Motor

    Replacing the grade motor a place a clean sheet of cardboard or a clean rag on the treadmill deck before starting this procedure. Do not elevate the treadmill. 1. Block the treadmill headframe securely with wooden blocks to ensure that the treadmill will not drop when you remove the grade motor. 2. ...

  • Page 49: Field Functional Test

    C. The grade motor chain is aligned correctly. A popping sound in the chain indicates that it is misaligned. Field functional test to verify that the treadmill is operating properly, perform field test no. 4. See appendix d, field functional tests, for specific instructions. Replacing the grade moto...

  • Page 50: Grade Pot Wires

    Replacing the grade potentiometer (pot) 1. Turn off the treadmill circuit breaker and unplug the power cord. Remove the treadmill hood as previously described. Maintain caution throughout the following steps. 2. Release the grade pot setscrew. 3. Remove the grade pot gear. 4. Remove the nut that hol...

  • Page 51: Field Functional Test

    1. Insert each pin into the connector housing until it clicks slightly. The flanges will be visible through the slots in the housing. Red wire: slot 4 black wire: slot 5 2. Verify that the pin has engaged by pulling lightly on the wire. A the slot positions above apply to the clubtrack, clubtrack pl...

  • Page 52

    A in order to enter open loop, the grade must be positive. 10. Enter open-loop grade mode: a. Press power . B. Simultaneously press stop , faster , and slower on the controller to place the treadmill in service mode. The display will read 0.0 p000 0.0. C. Simultaneously press faster , up , and down ...

  • Page 53: Field Functional Test

    4. Decrease the grade until the gears bounce two or three times. While increasing the grade, push lightly on the top of the rack gears. This should cause both rack gears to mesh in exactly the same place. 5. Run the rack gears down past the bottom of the headframe. Hold the limit switches closed to ...

  • Page 54

    4. Shake each gear lightly at the top to determine which rack gear is jammed. If there is no play in a rack gear, it is jammed. 5. Remove the rack gear wheels from the rack gear. 6. Remove the upright assembly: a. Unbolt the six hex-head fasteners to let the treadmill uprights pivot. Note the order ...

  • Page 55: Field Functional Test

    16. Calibrate the grade potentiometer (see calibration procedures at end of chapter). 17. Test the treadmill grade. Verify that: a. It operates over the full range of 0-15%. B. There is no binding when it moves up or down. C. The grade motor chain is aligned correctly. A popping sound in the chain i...

  • Page 56: Field Functional Test

    9. Align the grade sprocket and grade motor sprocket, then tighten the setscrew on the sprocket. 10. Replace the grade motor chain as described. 11. Reassemble the siderails, uprights, and walk belt. 12. Reassemble the rack gear. 13. Adjust the walk belt tension. 14. Calibrate the grade potentiomete...

  • Page 57: Field Functional Test

    7. Operate the treadmill to verify that it reaches the upper and lower grade limits (15% and 0%). Field functional test ensure that the grade will traverse from minimum to maximum and back. Walk deck assembly replacing the rollers 1. Turn off the treadmill circuit breaker and unplug the power cord. ...

  • Page 58: Field Functional Test

    Field functional test to verify proper operation, perform field test no. 3. See appendix d, field functional tests, for specific instructions. Replacing the walk belt or deck a all instructions are given as if you were exercising on the treadmill. Whenever you install a new walk belt, you should ins...

  • Page 59: Field Functional Test

    Replacing compression mounts inspect the compression mounts each time you change the walk belt. Replace the mounts if worn. 1. Remove the deck as previously described. 2. Locate and unscrew the compression mounts from the inside of each siderail; there are five long mounts and three short mounts on ...

  • Page 60: Adjusting The Walk Belt

    . Adjusting the walk belt walk belt tension adjust the tension: • whenever the belt slips or moves unsteadily during operation • after installing a new walk belt. Two adjustment methods are specified. Method 1 is preferred, but two belt tension calipers (quinton p/n 30113-001) are required. A both a...

  • Page 61: Walk Belt Tracking

    4. Alternately turn the left and right adjustment screws one-half turn until the distance between the tape or pencil marks is 50.203 inch (±0.016) on both sides. Do not overtighten the adjustment screws. Overtightening may damage the walk belt and roller assemblies. 5. Remove the tape. 6. Adjust the...

  • Page 62: Controller Assembly

    Controller assembly the controller assembly includes the keypanel, the pcba, and the enclosure that holds them to the treadmill: • the clubtrack and medtrack cr60 and sr60 use the enhanced display processor unit (edpu). • the clubtrack plus uses the motivational control unit (mcu). • the hr clubtrac...

  • Page 63: Replacing The Pcba

    Field functional test to verify that the treadmill is operating properly, perform field test no. 5. See appendix d, field functional tests, for specific instructions. Replacing the pcba 1. If possible, raise the treadmill to maximum height (15% grade). 2. Turn the treadmill off and disconnect the po...

  • Page 64: Configuring The Controller

    Replacing the fluorescent tube (hr clubtrack plus) 1. Remove the pcba as described above (replacing the pcba). 2. Remove the lcd display from the keypanel and place it face up. 3. Remove the single screw that holds the white plastic fluorescent tube housing together. 4. Remove the fluorescent tube a...

  • Page 65: Removing The Keypanel

    Treadmill configuration no. Clubtrack cp3 clubtrack plus cp3 hr clubtrack cp3 hr clubtrack plus cp3 medtrack sr60 cp3 medtrack cr60 cp1 no configuration cp- - 3. _ for the hr clubtrack plus, enter the configuration by using the menu choices on the service mode screen. _ for the other treadmills, hol...

  • Page 66: Cumulative Use

    Field functional test to verify that the treadmill is operating properly, perform field test no. 5. See appendix d, field functional tests, for specific instructions. Cumulative use the cumulative use feature lets you determine the amount of wear on the belt and motor by displaying the total distanc...

  • Page 67: Limited Access Switch

    To open custom mode, 1. Turn the power key off. 2. Press and hold the menu key, then press power . 3. Select maintenance information. Limited access switch if the limited access control is on, the treadmill will not operate unless the magnetic key is on the quinton logo on the controller. Disabling ...

  • Page 68: Speed Calibration

    5. Lower the grade until the treadmill is level. Measure from the bottom of the siderail to the floor at both the front and rear of the treadmill. Adjust the grade until both measurements are identical. 6. Rotate the grade pot shaft with a screwdriver until the grade display reads 0.0 . 7. Tighten t...

  • Page 69: Preventive Maintenance

    Preventive maintenance • before working on the treadmill or its components, turn off the treadmill circuit breaker and unplug the power cord. • high voltages remain under the treadmill hood for a few minutes even after the plug has been removed. • secure long hair, loose clothing, and jewelry before...

  • Page 70

    2. Use a damp sponge to wipe the exteriors and walking belt; do not soak surfaces. Dry all surfaces thoroughly. • never wipe the deck under the belt, even when replacing a belt. Wiping can ruin the surface. • do not use detergents or cleaning agents on any part of the deck. • do not let liquid enter...

  • Page 71

    Abrasives or chemicals such as steel wool or alcohol as they can damage the electrodes permanently. Battery the estimated life of the belt transmitter is 2500 hours of use. For a replacement belt and for recycling the old transmitter belt, contact polar electro at 800/227-1314. Storage store the bel...

  • Page 72: Safety Requirements

    Safety requirements read this manual in full before operating the treadmill. • do not start the treadmill when someone is standing on the belt. • keep speed and grade at the lowest settings when someone is getting on and off the treadmill. • keep the area underneath and around the treadmill clear. •...

  • Page 73: Symbol Definitions

    National fire protection association standard for health care facilities, nfpa 99-1993. The leakage currents specified in the standards are for current frequencies up to 1khz. The aami standard test load provides the proper attenuation for frequencies above 1 khz. This load circuit, illustrated on t...

  • Page 74: Specifications

    Specifications clubtrack ® (00377, 00402) and medtrack ® rehabilitation treadmills (00380, 00390) performance maximum rated load clubtrack & medtrack sr: 320 lb (145 kg) medtrack cr: 400 lb (181.4 kg) belt speed range: ± 0.2 mph (continuously adjustable) clubtrack & medtrack sr: 1.0 to 12 mph (1.6 t...

  • Page 75

    Power requirements dash number voltage/hz current draw in amps min. Branch circuit amps clubtrack - p/n 00377 -001 99 - 132v, 60hz 20* 20 -002 through -006 198 - 250v, 50/60hz 10 10 -007 90 - 132v, 50/60 hz 20 20 -008 180 - 250v, 50/60hz 10 10 -009 198 - 250v, 60hz 10* 15 medtrack cr - p/n 00380 med...

  • Page 76

    Rate of change two increments (or decrements) per second for the first three seconds, five per second thereafter until you either release the key or reach the high/low limit. Accuracy within ± 0.5% actual grade during unchanging operation multi-function display 4-digit display. Displays exercise par...

  • Page 77

    Clubtrack plus ® treadmills (p/n 00382, 00425) performance maximum rated load 320 lb (145 kg) belt speed range (continuously adjustable) 1.0 to 12 mph (1.6to 19.3 k/h) grade range 0 to 15% physical weight 400 lb (181.4 kg) nominal walking surface 20 in. X 60 in. (51 cm x 150 cm) treadmill dimensions...

  • Page 78

    Clubtrack plus ® controller (p/n 00382) speed (3-digit display) units miles per hour (mph) or kilometers per hour (km/h) range 1 to 12 mph, 1.6 to 19.3 km/h increment 0.1 mph accuracy within ± 0.2 mph (0.32 km/h) of actual speed during unchanging operation, 1 mph (1.6 km/h) during speed decrease. Sh...

  • Page 79

    Hr clubtrack plus ™ with heart rate control (p/n 00425) speed (3-digit display) units miles per hour (mph) or kilometers per hour (km/h) range 0 to 12 mph, 0 to 19.3 km/h increment 0.1 mph, 0.16 km/h accuracy within ± 0.2 mph (0.32 km/h) of actual speed during unchanging operation, 1 mph (1.6 km/h) ...

  • Page 80

    Percent vs angle relationship for treadmill grade rise run θ grade = rise run tan θ = rise run grade = tan θ θ = arctan(grade) (note: 15% grade grade = 0.15) grade angle (°) grade angle (°) grade angle (°) 0.0% 0.00 5.0% 2.86 10.0% 5.71 0.5% 0.29 5.5% 3.15 10.5% 5.99 1.0% 0.57 6.0% 3.43 11.0% 6.28 1...

  • Page 81: Part Numbers

    Part numbers final assemblies item part number clubtrack fitness treadmill assembly 00377 hr clubtrack fitness treadmill with heart rate monitoring assembly 00402 clubtrack plus treadmill assembly 00382 hr clubtrack plus fitness treadmill with heart rate control assembly 00425 medtrack cr 60 treadmi...

  • Page 82: Spares

    Electrical power cord north america japan 100v u.K germany france spain italy japan 200v 30610-004 30610-004 30736-012 30736-015 30736-015 30736-015 30736-013 30736-020 strain relief 01227-006 configuration plate north america international 32776-001 32776-002 pcba assy, drive 32975-002 drive drive ...

  • Page 83: Controllers

    Controllers clubtrack ® p/n 00377 pcba 33518-001 keypanel english german french italian spanish japanese 33504-001 33504-003 33504-005 33504-007 33504-009 33504-011 controller assy (pcba & keypanel) english german french italian spanish japanese 034506-001 034506-003 034506-005 034506-007 034506-009...

  • Page 84

    Medtrack ® cr60 p/n 00380 & sr60 p/n 00390 pcba 33518-001 keypanel english german french italian spanish japanese 33504-002 33504-004 33504-006 33504-008 3 3504-010 33504-012 controller assy (pcba & keypanel) english german french italian spanish japanese 34506-002 34506-004 34506-006 34506-008 3450...

  • Page 85

    Hr clubtrack plus ™ upgrade kit (convert any hyperdrive™ treadmill to hr clubtrack plus) english, u.S.A. German french italian spanish japanese 35371-001 35371-002 35371-003* 35371-004* 35371-005 35371-006* * these versions may be available in the future. Accessories for heart rate monitoring transm...

  • Page 86: Field Functional Tests

    Field functional tests the vsd pcba generates high voltage which is present whenever ds4 and ds5 are illuminated: never touch the pcba when ds4 and ds5 are on. Bleeder resistors on the vsd pcba bleed off the high voltage in approximately two minutes. Do not touch the vsd pcba until ds4 and ds5 have ...

  • Page 87

    Clubtrack, hr clubtrack, medtrack sr60, and medtrack cr60 problem possible cause solution seven segment displays lock up with all 8s and do not go blank. Esd (static) make sure control panel is properly grounded. Check the following: _ all star washers are installed _ green wire goes to vsd pcb _ co...

  • Page 88

    B. Test the multi display observe the center multi display on the controller. If an error code is displayed, refer to error codes in chapter 3, troubleshooting. C. Test the controller operation test the controller keys 1. To enter service mode, press stop belt+faster+slower. P000 appears in the sele...

  • Page 89

    • when this is completed, the leds light up individually, starting from the top. The select leds light up first, followed by the units leds. • after the leds are tested, all digits in all three displays simultaneously count up from 0 to 9 (no decimal points are illuminated during this count). Test t...

  • Page 90: E. Test Speed Operation

    Treadmill measurement clubtrack 14 in ± in hr clubtrack clubtrack plus hr clubtrack plus medtrack sr60 medtrack cr60 14 in ± in 6. Ensure that the grade will traverse from minimum to maximum and back. 7. Replace the hood (refer to removing treadmill hood in chapter 4, repair/replacement and calibrat...

  • Page 91: Field Test No. 1

    Steps. If additional pressure is required to keep the belt moving, replace the belt and deck. G. Test the walk belt operation 1. With the walk belt speed at maximum, observe the tracking. If it needs adjustment, refer to walk belt tracking in chapter 4, repair/replacement and calibration. 2. With th...

  • Page 92

    Clubtrack, hr clubtrack, medtrack sr60, and medtrack cr60 problem possible cause solution seven segment displays lock up with all 8s and do not go blank. Esd (static) make sure control panel is properly grounded. Check the following: _ all star washers are installed _ green wire goes to vsd pcb _ co...

  • Page 93: Field Test No. 2

    Field test no. 2 ) the following steps must be performed with the treadmill completely assembled, except as noted. With the power cord connected to the correct outlet, turn on the circuit breaker. A. Test the controller displays clubtrack ® , hr clubtrack™, medtrack ® sr60, and medtrack ® cr60 obser...

  • Page 94: C. Test The Grade

    Clubtrack plus ® for the clubtrack plus, the normal sequence is: • seven segment displays show all 8s (888 8888 888). • tri-color display flashes all green, all red, all yellow. • seven segment displays blink, then go blank. • multi display briefly shows configuration code (00 cp.-x 0.0). • normal d...

  • Page 95

    2. Place another mark or piece of tape on the top of the siderail cover. 3. Start the walk belt and increase its speed to 4.0 mph. 4. Count how many times the belt rotates in two minutes. This should be 62 ± 3 revolutions for all treadmill models. Clubtrack ® , clubtrack plus ® , hr treadmills, medt...

  • Page 96: Field Test No. 4

    Field test no. 4 ) the following steps must be performed with the treadmill completely assembled, except as noted. With the power cord connected to the correct outlet, turn on the circuit breaker. A. Test the grade operation 1. Remove the hood (refer to removing treadmill hood in chapter 4, repair/r...

  • Page 97

    With the power cord connected to the correct outlet, turn on the circuit breaker. A. Test the controller displays clubtrack ® , hr clubtrack™, medtrack ® sr60, and medtrack ® cr60 observe the controller displays during initialization. For the clubtrack, clubtrack with heart rate monitor, medtrack sr...

  • Page 98: Clubtrack Plus

    Clubtrack plus ® for the clubtrack plus, the normal sequence is: • seven segment displays show all 8s (888 8888 888). • tri-color display flashes all green, all red, all yellow. • seven segment displays blink, then go blank. • multi display briefly shows configuration code (0.0 cp.-x 0.0). • normal ...

  • Page 99

    Stop belt p004 input+ p005 input— p006 enter* p007 select p007 next stage* p008 start belt p009 units p010 start course* p011 resume course* p012 cool down p013 faster p014 slower p015 *clubtrack plus only test the key panel displays press stop belt+up+down. • the display cycles though one digit at ...

  • Page 100

    2. Place the polar watch receiver next to the pulse simulator to begin receiving. The watch will display the digital heart rate. 3. Check the rate displayed on the watch against the rate displayed on the controller. If the controller differs by five beats, replace the receiver (p/n 34295) and re-tes...

  • Page 101: Assembly Drawings

    Assembly drawings p/n assembly 32706 transformer 32975 cage assembly, drive pcba 32776 configuration plate 32976 clubtrack/medtrack cr60/sr60 control panel 34238 hr clubtrack control panel 33046 clubtrack plus control panel, motivational 34664 hr clubtrack plus control panel 33170 harness assembly, ...

  • Page 147: Index

    Index a adjusting the walk belt 4-25 assemblies 2-1 assembly drawings d-1 b battery life, heart rate transmitter 5-3 c calibration procedures 4-32 —grade pot 4-32 —speed and grade 4-33 calipers 4-26 card cage 4-7 chain 4-15 chest belt, battery 5-3 chest belt, cleaning 5-2 chest belt, storage 5-3 cir...

  • Page 148

    Microprocessor, theory 2-5 models 1-1 n noise 3-10 o open-loop mode 3-6 operation 1-3 options 1-4 overview 1-1 p p000 3-4 part numbers c-1 pcba, replacing4-28 pinion shaft 4-21 poly-v belt, replacing4-10 power 1-3 power cord 4-6 pulse simulator 3-8 r rack gears 4-17 rack gears, jammed 4-19 receiver,...