Nautilus StairMaster ClubTrack 2100 Series User manual

ClubTrack® 2100 Series
Treadmill
�
Service Manual
PN 000-6583 Rev AA (2/20/2006)

© 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.
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 [phone] (outside USA).
DANGEROUS VOLTAGES ARE PRESENT INSIDE THE
TREADMILL. SERVICING BY OTHER THAN AUTHORIZED
NAUTILUS SERVICE PERSONNEL MAY RESULT IN ELECTRIC
SHOCK OR OTHER INJURY.
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Contents
i
ClubTrack® 2100 Series Treadmill Service Manual
Maintenance
Viewing Maintenance Information .........................................2
Routine Maintenance Schedules ...........................................2
Cleaning ................................................................................2
Adjusting Belt Tension ...........................................................3
Adjusting Belt Tracking ..........................................................5
Replacing the Walk Belt ........................................................5
Replacing the Contact Heart Rate (CHR) Sensors .............12
Replacing the Lens ..............................................................12
Updating the Console Firmware ..........................................13
Console Codes
Overview..............................................................................16
Cardio ..................................................................................16
Owner-Defined Custom .......................................................19
Machine Status ....................................................................22
Diagnostic ............................................................................25
Diagnostic 2 .........................................................................26
Magnetic Key Limit Access Control .....................................27
Troubleshooting Electrical Problems
Common Electrical and Electronic Problems ......................31
Error Reporting ....................................................................32
VSD .....................................................................................34
Troubleshooting Flowcharts ................................................35
Replacing the Grade Actuator Motor ...................................39
Problems with the Drive Motor ............................................41
Replacing the Drive Motor ...................................................42
Magnetic Key Problems ......................................................45
Wiring Schematics ..............................................................45
Troubleshooting Mechanical Problems
Common Mechanical Problems and Solutions ....................50

ii
Contents
ClubTrack® 2100 Series Treadmill Service Manual
Assembly Illustrations
Assembly Parts Lists ...........................................................53
Assembly Drawings Overview .............................................55
Side Rails ............................................................................56
Headframe ...........................................................................57
Grade Weldment .................................................................58
Slider Bed ............................................................................59
Driver Motor .........................................................................60
Front Roller Assembly .........................................................61
VSD Board ..........................................................................62
Upright Weldment ................................................................63
Controller Support ...............................................................64
Hood Assembly and End Caps ............................................65
Hand Grips and Ergo Bar ....................................................66
Cabling ................................................................................67
PCBA ...................................................................................68
Controller Keypanel .............................................................69
Controller Bottom Housing ..................................................70
Appendixes
Appendix A—Required Tools ...............................................72
Appendix B—Differences Between 2100
and 510/612 Motor Wiring ..............................................73
Appendix C—Replaceable Parts Lists ................................74
Appendix D—Using a Multimeter ........................................80
Appendix E—International Power Plug Configurations .......83
Appendix F—Specifications ................................................84

Maintenance
1
Contents
Viewing Maintenance Information .........................................2
Routine Maintenance Schedules ...........................................2
Daily ...................................................................................2
Cleaning ................................................................................2
Daily ...................................................................................2
Weekly ...............................................................................3
Treadmill Interior ................................................................3
Adjusting Belt Tension ...........................................................3
Adjusting Belt Tracking ..........................................................5
Replacing the Walk Belt ........................................................5
Replacing the Contact Heart Rate (CHR) Sensors .............12
Replacing the Lens ..............................................................12
Updating the Console Firmware ..........................................13
PART

ClubTrack® 2100 Series Treadmill Service Manual
2
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 user. The
maintenance schedules are meant only to serve as a guide. Depending on where and how the treadmill is being
used, more frequent routine maintenance may be required.
Daily
• Inspect the power cord and walking belt for wear.
• Check the position of the walking belt. Verify it is not rubbing against the frame. The belt should be evenly
spaced on the deck within 0.25 inches. Adjust the belt if necessary.
• Check the optional side handrails to ensure they are fastened securely.
• Remove potential hazards from the treadmill area.
Cleaning
Keeping the StairMaster® 2100 LC/LE treadmill clean on a regular basis will help to improve operation and increase
the lifespan of the components.
Daily
• Keep the treadmill and controller free of dust and debris. Use a damp sponge to wipe the exteriors and walking
belt; do not soak surfaces. Dry all surfaces thoroughly.
Cleaning
DRY MOP THE DECK UNDER THE BELT ONLY. DO NOT ADD
ANY LUBRICANTS—ADDING LUBRICANTS CAN RUIN THE
PROPRIETARY FRICTION-CONTROL SURFACE.
DO NOT USE DETERGENTS OR CLEANING AGENTS ON ANY PART
OF THE DECK.
DO NOT LET LIQUID ENTER THE TREADMILL OR CONTROLLER. IF
IT DOES, THE EQUIPMENT MUST BE INSPECTED AND TESTED
FOR SAFETY BY A STAIRMASTER®-APPROVED TECHNICIAN
BEFORE IT CAN BE USED AGAIN.
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ClubTrack® 2100 Series Treadmill Service Manual 3
Weekly
• Elevate the treadmill to maximum incline and vacuum the floor under it to prevent excess dust and dirt from
interfering with operation.
• If the magnetic key is being used, check it for rust. If you detect rust, replace the magnet. Rust on the magnetic
key will cause power-up problems.
Treadmill Interior
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 Turn the treadmill circuit breaker off, and unplug the treadmill power cord.
2 Remove the six (6) screws on the treadmill hood.
3 Lift off the hood.
4 Clean inside the unit.
5 Reinstall the hood and the six (6) screws.
6 Plug in the treadmill power cord, and switch on the treadmill circuit breaker.
Adjusting Belt Tension
Adjusting Belt Tension
DANGEROUS VOLTAGES ARE PRESENT UNDER THE TREADMILL HOOD.
EXERCISE CAUTION WHEN PERFORMING SERVICE TO THE ELECTRICAL
COMPONENTS UNDER THE HOOD.
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SECURE LONG HAIR AND LOOSE CLOTHING BEFORE WORKING NEAR THE
TREADMILL WALKING SURFACE OR PULLEYS.
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ClubTrack® 2100 Series Treadmill Service Manual
4
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.
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.
Adjusting Belt Tension
Adjustment Bolts
35.0"
(889 mm)
(889 mm)
35.0"
DO NOT USE ALL YOUR WEIGHT TO RESIST THE BELT MOVEMENT.
TOO MUCH RESISTANCE APPLIED TOO LONG (MORE THAN TWO
SECONDS) MAY SHUT DOWN THE SYSTEM. (VARIOUS ERROR
MESSAGES WILL APPEAR IF THIS OCCURS. CYCLE POWER TO
RESUME NORMAL OPERATION.)
DO NOT OVERTIGHTEN THE WALKING BELT. DO NOT TORQUE
ADJUSTMENT SCREWS BEYOND 80 IN-LBS (9 N-M) MAXIMUM.
OVERTIGHTENING THE BELT WILL REDUCE BELT LIFE AND
DAMAGE THE ROLLER BEARINGS.
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ClubTrack® 2100 Series Treadmill Service Manual 5
3 Turn the adjusting bolts clockwise by equal amounts until the marks are between 35-3/16 inches and 35-5/16
inches apart. Proper tension for the walking belt is between .5%–.6%. This should be about six full turns of
each adjustment bolt from the point where the belt begins to stretch. Important: Do not exceed 35-5/16 inches.
4 Test the belt by running on the belt at about four mph. Hold the handrail lightly and resist the belt movement
with your feet.
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 grade.
2 Increase speed to six mph, and make the following adjustment:
2.1 If the belt moves to the right, turn the right adjustment bolt 1/4-turn clockwise.
2.2 If the belt moves to the left, turn the left adjustment bolt 1/4-turn clockwise.
3 After making an initial adjustment, run the treadmill for five minutes and observe how the belt tracks. If the belt
continues to move away from the center, adjust the appropriate side until properly centered.
Replacing the Walk Belt
Perform this procedure whenever the walk belt is still too loose after adjusting the tension or when the belt is worn
or frayed.
1.0 Remove the Treadmill Hood
1.1 Turn the treadmill circuit breaker off, and unplug the power.
1.2 Remove the six (6) screws on the treadmill hood.
1.3 Lift off the hood.
Replacing the Walk Belt
DO NOT CUT THE BELT—DOING SO WILL CAUSE THE REAR
ROLLER TO FALL AND SNAP THE ALIGNMENT PINS ON THE END
CAP.
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ClubTrack® 2100 Series Treadmill Service Manual
6
2.0 Remove the Rollers
2.1 Remove the end cap by removing the adjustment bolts.
2.2 From the rear of the machine, slide the molding off the side rails.
2.3 Remove the rear roller by lifting up the roller and sliding it out from under the belt.
2.4 Place a 9/16 wrench on the head of the bolt mounting the Tensioner and turn counter clockwise until
Tensioner loosens.
Replacing the Walk Belt
Adjustment Bolts

ClubTrack® 2100 Series Treadmill Service Manual 7
b. Lift up on the Tension Wheel and slide the motor drive belt over pulley to remove.
2.5 Remove the two (2) front retainer bolts at each end of the front roller.
2.6 Lift the front roller at its pulley end and pull it out of the opposite side rail. Important: The front roller is
heavy; be sure to support both ends.
Replacing the Walk Belt
Retainer Bolts

ClubTrack® 2100 Series Treadmill Service Manual
8
2.7 Slip the motor drive belt off the front roller pulley.
2.8 Fully lift the front roller out from between the walk belt.
3.0 Removing the Deck
3.1 Remove the twelve (12) deck screws that secure the deck to the side rails. Important: Apply pressure on
the deck next to the screw to keep the compression mount from turning with the screw; otherwise, you
can strip the compression mount threads.
3.2 Lift the deck to one side.
3.3 Slide the deck out from between the belt.
4.0 Inspection and Cleaning
4.1 Check the compression mounts for any wear and cracking. Make sure they are tight.
4.2 Check the deck for signs of wear. Decks are waxed on both sides. If you are flipping the deck, wipe off
loose debris with a dry cloth. Inspect the wax on the unused side for deterioration. If the wax appears
crusty white and is not adhering to the deck surface, the deck should be replaced. To obtain optimum
belt life, always begin with a waxed deck surface. (Refer to the photos below for what is a good deck
surface—useable—and what is a bad surface—unuseable.)
Important: Do not apply any cleaners or petroleum products to the deck surfaces.
Replacing the Walk Belt
Wax—Good Side No Wax—Bad Side

ClubTrack® 2100 Series Treadmill Service Manual 9
4.3 Inspect the motor drive belt for wear and cracking. Cracking is prevalent between the grooves on the
belt.
4.4 Inspect the rollers for wax build-up (black deposits on the rollers). Use #000 steel wool or a Scotch-
Brite™ pad to clean the wax off the rollers.
4.5 Stand each roller on one end and rotate it. Listen for any squeaking sounds, and verify that the rollers
spin smoothly.
4.6 Vacuum the deck and inside the motor housing.
5.0 Installing the New Walk Belt
5.1 Slip the new belt over the deck. Make sure the deck’s waxed surface is on the up side and that the
arrow on the inside surface of the walk belt points in the proper direction of belt travel.
5.2 Lift the deck with the installed new walk belt and place it on the compression mounts.
5.3 Lift and slide the belt until the arrow is visible on top of the deck. Verify that it points toward the back
of the treadmill.
6.0 Attaching the Deck
6.1 Align the deck mounting holes with the compression mounts.
6.2 Install all twelve (12) deck screws and hand tighten.
6.3 Use a 10 mm socket to tighten all the screws. Put pressure on the deck next to the screw you are
tightening. Important: Do not over-tighten the deck screws.
Replacing the Walk Belt
DO NOT OVER-TIGHTEN THE DECK SCREWS. OVER-TIGHTENING
THE DECK SCREWS WILL DAMAGE THE COMPRESSION
MOUNTS.
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ClubTrack® 2100 Series Treadmill Service Manual
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7.0 Reinstalling the Front Roller
7.1 Slide the front roller inside the walking belt.
7.2 Insert the end of the roller opposite the pulley into the cut-out on the side rail.
7.3 With your free hand, slip the motor drive belt onto the pulley.
7.4 Install the two front roller retainer plates. Make sure the retainer plates seat in the grooves on the
rollers. Tighten all the screws on the retainer plates.
7.5 After alignment of the Front Roller and Flywheel, place belt on the Front Roller and Flywheel.
7.6 Place 5/16 wrench on nut of Tensioner and turn counter clockwise creating tension on the bent and
hold. The top two notches should line up.
Replacing the Walk Belt
Cut-Out
Groove

ClubTrack® 2100 Series Treadmill Service Manual 11
7.7 Place the 9/16 wrench back on the head of the mounting bolt and turn clockwise, until the bolt
tightens.
8.0 Reinstalling the Rear Roller
8.1 Slide the rear roller inside the belt and let it hang loose.
8.2 Slide the molding onto the side rails.
8.3 Install the alignment bolts through their holes in the end cap and into the holes on the roller.
8.4 Install the end cap onto the rear of the treadmill, making sure the alignment pins go into the holes on
the ends of the side rails.
8.5 Hand tighten the adjustment bolts.
8.6 Align the walk belt so that the edges of the belt are equal distance from the side rails.
8.7 Tighten the adjustment bolts to take the slack out of the walk belt.
8.8 Perform the belt tension and belt tracking procedures outlined on pages 4–6.
9.0 Reinstall the Treadmill Hood
9.1 Install the treadmill hood over the motor compartment.
9.2 Install the six (6) screws in the treadmill hood and tighten.
9.3 Plug the AC power cord into the treadmill, and turn on the treadmill circuit breaker switch.
Replacing the Contact Heart Rate (CHR) Sensors
Hole

ClubTrack® 2100 Series Treadmill Service Manual
12
Replacing the Contact Heart Rate (CHR) Sensors
1 Remove the old sensors.
2 Clean the old adhesive off the plastic contact point using rubbing alcohol.
3 Make sure that the wire connection tab is bent from a V-shape to a U-shape, and attach the wire to the tab.
4 Peel the paper off the sensor plate's adhesive tape.
5 Press the sensor plate firmly onto the plastic contact point.
6 Install one “zip tie” around each side of the sensor for both the left and right CHR sensors.
7 Using a knife or scissors, carefully remove the “zip ties” from the sensors after 24 hours. Important: The “zip
ties” must remain on the sensors for at least 24 hours.
Replacing the Lens
1.0 Removing the Lens
1.1 Remove the three (3) T-15 torx screws from the bottom back of the controller.
1.2 Remove the seven (7) button head screws that hold the console onto the controller support weldment,
and lift the controller off carefully.
1.3 Disconnect the contact heart rate wire from the contact heart rate (CHR) module.
1.4 Disconnect the ribbon cable from the power control board assembly (PCBA).
1.5 Disconnect the communication cable from the PCBA.
1.6 Remove the thirteen (13) T-15 torx screws from the back of the controller assembly.
1.7 Disconnect the three (3) keypad ribbon cables from the PCBA/processor assembly.
1.8 Remove the six (6) screws from the PCBA display/processor assembly and remove it.
1.9 Remove the nine (9) screws that hold the lens and remove it from the front controller assembly.
2.0 Reinstalling the Lens
2.1 Attach the lens to the front controller assembly with nine (9) screws.
2.2 Apply blue Loctite® to the six (6) screws
2.3 Attach the PCBA display/processor assembly with the six (6) screws.
2.4 Connect the three (3) keypad cables.
2.5 Reinstall the controller by repeating steps 1.1–1.6 under “1.0 Removing the Lens” in reverse order.
Replacing the Lens

ClubTrack® 2100 Series Treadmill Service Manual 13
Updating the Console Firmware
1 Turn the power off.
2 Plug the data ribbon cable from the AVR FISP onto J7. J7 is accessible through the small hole on the left side
next to the louvers on the rear of the console. The red line on the ribbon cable will be on the right if the cable is
installed properly.
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.
• The download takes one minute.
4 Unplug the AVR FISP ribbon cable from J7.
Updating the Console Firmware
J7
PLUG P7 and CONNECTOR J7 ARE KEYED. DO NOT CONNECT
P7 TO J7 BACKWARDS; OTHERWISE, THE PCBA/PROCESSOR
ASSEMBLY CAN BE DAMAGED.
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Console Codes
2
Contents
Overview..............................................................................16
Cardio ..................................................................................16
Defaults ............................................................................16
User Weight .....................................................................17
Exercise Time ..................................................................17
User Age ..........................................................................17
Target Heart Rate ............................................................18
Treadmill Speed ...............................................................18
Cool-Down Time ..............................................................18
Quick Start .......................................................................18
Decline .............................................................................19
Owner-Defined Custom .......................................................19
Customize ........................................................................19
Max Time .........................................................................20
PART

15
ClubTrack® 2100 Series Treadmill Service Manual
Change Units ...................................................................20
HR Inputs .........................................................................20
Language .........................................................................21
Contrast (2100 LC only) ...................................................21
Max Speed .......................................................................21
Side Lights .......................................................................22
Enable Mag Key ..............................................................22
Set Defaults .....................................................................22
Machine Status ....................................................................22
Machine Status ................................................................23
Run-Time Hours ...............................................................23
Number of Workouts ........................................................23
Distance Traveled ............................................................23
Software Revision ............................................................24
Configuration ...................................................................24
TM Drive ..........................................................................24
Maintenance Hours ..........................................................24
Program Selection ...........................................................24
Diagnostic ............................................................................25
Diagnostic ........................................................................25
Display Test ......................................................................25
Key Test ...........................................................................25
Serial Tests ......................................................................26
Bus Volts ..........................................................................26
Grade Act .........................................................................26
Diagnostic 2 .........................................................................26
Diagnostic 2 .....................................................................26
Error Log ..........................................................................27
Maintenance Hours ..........................................................27
Magnetic Key Limit Access Control .....................................27
Overview ..........................................................................27
Activation ........................................................................27
Deactivation .....................................................................28
Magnetic Key as an Emergency Stop .............................28
Contents

16
ClubTrack® 2100 Series Treadmill Service Manual
Overview
There are five groups of console codes as follows: Cardio (codes starting with 2), Owner-Defined Custom (codes
starting with 3), Machine Status (codes starting with 4), Diagnostic (codes starting with 6), and Diagnostic 2 (codes
starting with 7). Each group of codes is defined below. To access these console codes and the options within each
group, follow the instructions for each section.
Cardio
You can customize several default settings on the ClubTrack 2100 to conform to your individual requirements,
including changing the:
• default weight,
• workout time,
• age,
• percentage of Maxmum Heart Rate for Target HR in HR Zone Trainer,
• treadmill speed,
• default cool-down time,
• initial speed for Quick Start, and
• incline minimum.
Refer to the following table to scan through and change the cardio settings:
Table 2–1. Defaults
Step No. Press Keys On Console Display (What you will see)
1 CLEAR, 2, ENTER DEFAULTS
2INCLINE UP or INCLINE DOWN ENTER WT, RESERVED,
ENTER TIME, ENTER AGE, THR
PERCENT, SPEED, RESERVED,
COOLDOWN TIME, QUICK
START, DECLINE
3 ENTER Selected choice
4 SPEED + or SPEED - Default value changes
5 ENTER UPDATING
6 CLEAR DEFAULTS
7 CLEAR THE RESULTS YOU WANT
Cardio