Quinton ClubTrack, Service Manual

Page 1: ...000377 833 033387 005 Rev New TREADMILL SERVICE MANUAL ClubTrack ClubTrack Plus HR ClubTrackc HR ClubTrack Plusc MedTrack CR60 MedTrack SR60...

Page 2: ...e Manual Publication Number 000377 833 Text Number 033387 005 Rev New Copyright 1995 1997 Quinton Instrument Co All rights reserved Quinton Instrument Company 3303 Monte Villa Parkway Bothell WA 98021...

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Page 4: ...ich are differentiated by dash number see Appendix C Part Numbers The manual is designed for Quinton authorized service personnel with proper training There are no user serviceable parts in the treadm...

Page 5: ...ly 2 2 Controller Assembly 2 2 Keypanel 2 2 User Inputs 2 3 Output Displays 2 3 Additional Functions 2 3 Controller to Treadmill Interface 2 3 HR ClubTrack Plus Interface 2 3 Headframe Assembly 2 3 In...

Page 6: ...ings 4 1 Tools 4 2 Field Functional Tests 4 3 Removing Treadmill Hood 4 3 Replacing the Configuration Plate 4 6 Replacing the Power Cord 4 7 Replacing the VSD Board Card Cage Assembly 4 7 Replacing th...

Page 7: ...ccess Switch 4 33 Calibration Procedures 4 33 Grade Potentiometer Grade Pot 4 33 Speed Calibration 4 34 Grade Calibration 4 34 Preventive Maintenance Recommended Service 5 1 Routine Maintenance 5 1 Va...

Page 8: ...r Displays D 1 Test the Multi Display D 2 Test the Controller Operation D 3 Test the Grade Operation D 4 Test Speed Operation D 5 Test the Deck Friction D 5 Test the Walk Belt Operation D 6 Field Test...

Page 9: ...us provides manual and programmed operation The HR ClubTrack Plus adds Heart rate control interval programming and a computer interface MedTrack The MedTrack rehabilitation treadmills are designed for...

Page 10: ...eadmill from the wall outlet Operation The controller which is mounted above the front handrail is a computerized panel used to operate the treadmill All commands including power are entered by pressi...

Page 11: ...ClubTrack Controller with Heart Rate Monitoring STAGE START BELT NEXT STAGE SELECT START COURSE RESUME COURSE COOL DOWN INPUT ENTER STOP BELT DOWN CLEAR POWER GRADE UP STOP BELT SLOWER FASTER Quinton...

Page 12: ...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...

Page 13: ...e 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 controller processes the user entered information...

Page 14: ...sembly is attached to the headframe and supports the rear of the treadmill It provides the platform for the walk belt The drive belt supplies torque to the walk belt through the drive roller pulley Co...

Page 15: ...icates with the treadmill drive board through a standard RS422 interface The controller sends commands to the treadmill drive board and receives acknowledge and status statements from the treadmill dr...

Page 16: ...speed to the front roller of the treadmill through a poly V belt and a set of speed reduction pulleys A flywheel integral to the motor poly V pulley is used to average the pulsing runner loads Grade...

Page 17: ...r The microprocessor measures the time between digital pulses then calculates and displays beats per minute Transmitter The transmitter is imbedded inside the chest belt and begins transmitting as soo...

Page 18: ...h stethoscope Ohm meter High voltage is present under the hood when the treadmill is plugged into a power source residual high voltage remains for a few minutes after the power is removed Turn off the...

Page 19: ...3 through F6 are blown 1 Check the primary transformer windings for continuity P N 327065 001 Should be 2 ohms or less 2 Replace fuses and if the fuses blow again isolate mechanical assembly and ensur...

Page 20: ...ler PCBA interrupt failure Replace controller E105 Controller PCBA NVRAM failure Re initialize NVRAM 1 Press Stop Faster and Slower to enter Service Mode 2 Press Stop and Cool Down to reinitialize For...

Page 21: ...ocked by obstruction 6 Remove obstruction E204 VSD and controller not communicating Verify cable connections at both ends Check for bent or broken pins replace if required If error persists replace VS...

Page 22: ...ion To display the firmware revision level of the PCB assemblies 1 Enter the service mode 2 Simultaneously press Stop Belt and Grade Up The controller firmware revision level appears in the Select dis...

Page 23: ...lays simultaneously count up from 0 through 9 No decimal points light during this count Tri color Display ClubTrack Plus P N 000382 only To test the color display on the ClubTrack Plus 1 Enter the ser...

Page 24: ...p Belt Faster and Slower simultaneously to exit the service mode do not press the Power key 4 Press and hold Up or Down to change grade 5 When testing is finished press Clear or press Power twice to e...

Page 25: ...test resets the contrast to the default value HR ClubTrack Plus LCD External RS232 Port Test The controller automatically tests the RS232 chip during power up using an internal loop back test To test...

Page 26: ...lt and controller appear to be operating correctly the user s heart rate may not be detectable by the system Problem Possible Cause Remedy Heart rate reading is erratic or absent Poor electrode contac...

Page 27: ...iver 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...

Page 28: ...on Knocking orthumping Rate increases or decreases with walking belt speed Front orrearroller pulley assembly bearings Isolate and replace roller assembly Squealing similar to loose automobile fan bel...

Page 29: ...t voltage problem Too low Yes Yes Replace VSD Is DS3 On Trans former output 24 6 VAC No Replace transformer Connect meter THEN power up Check transformer output J7 pin 9 and 10 CAUTION Disconnect powe...

Page 30: ...set Replace VSD PCBA Enter Service Mode Verify grounding system is wired correctly and is intact E202 Speed Error E205 Software tachometer fault Calibrate Pot Error Persists Replace grade Pot and reca...

Page 31: ...eplace cable Error persists Finished Yes Yes No Replace controller Replace VSD No Less than 17 0 VAC Yes Replace transformer Clip a volt meter onto F1 and F2 fuse holder base closest to J3 THEN turn o...

Page 32: ...nected Worn deck Excessive deck wear indicated Replace deck Reconnect disconnected leads Restrict use to people within specified weight speed envelope Yes No Yes No CAUTION Disconnect power and wait f...

Page 33: ...er LED should be on momentarily then off On then off Press Start Is DS1 on Replace VSD Replace VSD Check motor leads for good connections Does motor turn Complete CAUTION Disconnect power and wait for...

Page 34: ...voltage indicator to go off Remove grade motor connector at J2 on VSD PCB Place meter across J2 pin 2 and 4 THEN connect treadmill power Press the Up then the Down key on the controller DC voltage ap...

Page 35: ...l Quinton Technical Service 1 800 426 0538 Before servicing the treadmill read the safety requirements listed in Appendix A A Do not use this manual when servicing Series 90 Q Series or ClubTrack 3 0...

Page 36: ...en someone is on the treadmill Improper lifting can cause back strain It also can cause injury to others if the treadmill is dropped Lifting the treadmill requires at least two people Tools Phillips a...

Page 37: ...mill to its maximum height if possible 2 Turn off the circuit breaker on the treadmill and unplug the treadmill from the power outlet To prevent high voltage electrical shock Before working on or arou...

Page 38: ...f inch towards the rear until the rear screws disengage from the key slots 9 Spread the sides of the hood slightly apart to clear the uprights Tilt the hood upward then slide it back and lift it off t...

Page 39: ...Controller Upright Metal siderail LH 32709 003 ClubTrack and MedTrack SR60 32709 004 MedTrack CR60 Siderail Cover LH 19488 002 Hood 32744 001 Sample treadmill with hood cover removed 10 24 x 1 25 blac...

Page 40: ...ican units 3 wires 115v or 2 wires 230v International units 2 wires Note the wire colors and connection points 5 Remove the two 20 hex head screws holding the configuration plate to the headframe Do n...

Page 41: ...or on the configuration plate and plug in the new cord Field Functional Test To verify that the treadmill is operating properly perform Field Test No 2 See Appendix D Field Functional Tests for specif...

Page 42: ...me and remove the plate 13 Remove the four Phillips screws holding the card cage 14 Remove the VSD card cage assembly and return it to Quinton 15 Replace the sil pad for the switching module before in...

Page 43: ...he pulleys 5 Place the new tensioner onto the headframe in the same position as before and loosely bolt it to the headframe 6 Use either a inch open end wrench or a large adjustable wrench to turn the...

Page 44: ...placing the Tensioner and or Adjusting the Walk Belt in this chapter 7 Ensure that the speed will traverse from minimum to maximum and back Walk Belt Test Procedure 1 With the walk belt speed at minim...

Page 45: ...lbs 2 Using a large screwdriver or punch tap the retainer down above each bolt to secure the shaft 3 Assemble the treadmill following Steps 1 6 above in reverse order 4 Tension the drive belt as descr...

Page 46: ...e flywheel onto the motor shaft and loosely tighten the setscrews 10 Replace the motor by following Steps 4 through 8 in reverse order Use Loctite 242 adhesive on the motor mount studs before installi...

Page 47: ...and connection points Cut the plastic cable ties that secure the transformer wiring 4 Remove the Phillips head screws that hold the transformer to the headframe 5 Discard the old transformer Replace w...

Page 48: ...e the four screws that attach the grade motor to the headframe then remove the motor 5 Replace with a new grade motor following Steps 3 4 in reverse order Use a straight edge to align the sprockets 6...

Page 49: ...n 1 Support the head frame with six inch wood blocks 2 Use a flathead screwdriver to pop off the C clip master link on the chain If the link is inaccessable you will have to remove the motor 3 Slide o...

Page 50: ...e cable from the VSD board 6 Replace with a new potentiometer then reassemble following Steps 2 6 in reverse order See Grade Pot Wires below 7 Tighten the grade pot nut to 20 inch pounds torque 8 When...

Page 51: ...e headframe onto six inch wooden blocks to take the weight off the wheels 3 Turn off the treadmill circuit breaker and unplug the treadmill 4 Remove the hood as previously described 5 If the rack gear...

Page 52: ...seconds to react to a command 11 Requires two people Hold the limit switches closed to let the rack gear travel beyond its normal range Rotate the grade POT as required to maintain a positive grade d...

Page 53: ...ed as spacers in the correct arrangement b Install wheel bolts in the proper holes b torque the bolts tightly to 46 ft lb 4 ft lb 10 Increase the grade until the wheels touch the floor 11 Grease rack...

Page 54: ...two hex head bolts securing each siderail to the headframe Reach the bolts through the holes in the siderail A If you are replacing only one rack gear it is necessary to remove only the siderail close...

Page 55: ...acing the Pinion Shaft 1 Remove the right siderail then remove the rack gear as previously described in Replacing a Jammed Rack Gear 2 Restore treadmill power then use the grade motor to turn the pini...

Page 56: ...When a roller on the limit switch reaches a trigger in each rack gear a lever moves outward opening the switch and stopping the grade motor Two grade limit switches one on each side of the treadmill a...

Page 57: ...tween the siderails toward the rear of the treadmill 5 Replace the rollers and reassemble the treadmill following Steps 1 4 in reverse order See Installing the Front Shaft earlier in this chapter 6 Ad...

Page 58: ...d to the siderails at the front of the hood A When replacing the screws the gap between the siderail cover and the head of each screw must be 0 050 inch 0 010 approximately the thickness of a dime 4 G...

Page 59: ...ex Maintenance Kit p n 33511 001 Field Functional Test To verify that the treadmill is operating properly perform Field Test No 3 See Appendix D Field Functional Tests for specific instructions Replac...

Page 60: ...4 on the other side of the belt using the other caliper 6 Set the dials of both calipers to zero 7 Alternately tighten each tension adjustment screw in 0 1 increments until both sides read 0 4 Ensure...

Page 61: ...Start the treadmill and let it run for at least one minute at minimum speed and grade Do not start the treadmill when some one is on the walk belt 2 Make the following adjustment to the right adjustme...

Page 62: ...rews and the handrail Be careful not to scratch the uprights 3 Use a inch Allen wrench to remove the six socket screws from the rear cover of the enclosure 4 Use a inch Allen wrench to remove the two...

Page 63: ...cable from the PCBA If you have the optional heart rate monitoring function unplug the Polar PCB connector from the controller PCBA HR ClubTrack Plus treadmills p n 00425 a Disconnect the ribbon cable...

Page 64: ...the controller assembly 3 Remove the two screws holding the assembly to the keypanel 4 Remove the receiver assembly 5 Use the two mounting screws to install the new receiver assembly Reassemble the co...

Page 65: ...multaneously pressing Stop Belt Slower and Faster Field Functional Test To verify that the treadmill is operating properly perform Field Test No 1 See Appendix D Field Functional Tests for specific in...

Page 66: ...tifunction display by 10 to obtain the cumulative total in miles or hours 4 Record the mileage and the date for your records 5 Press Clear to reset the display for operation Time To determine the tota...

Page 67: ...enever you replace the grade pot either rack gear or the pinion shaft 1 Disconnect power and remove the hood as previously described 2 Loosen the setscrew that holds the grade pot gear to the grade po...

Page 68: ...the treadmill is nearly all the way to the top of the rack gear when the display reads 15 10 Turn the treadmill circuit breaker off disconnect the power cord and replace the hood Speed Calibration The...

Page 69: ...s necessary When service is required repairs can be done to the modular level Routine Maintenance Visual Inspection Inspect the power cord and walking belt for wear Check the position of the walking b...

Page 70: ...components at least every six months Adjust the inspection schedule as needed To avoid electric shock turn off the treadmill circuit breaker and unplug the treadmill before removingthe hood Before wor...

Page 71: ...t 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 belt in a warm dry place away from direct s...

Page 72: ...Increased risk due to leakage current can result if this equipment is not grounded properly The treadmill must be on an appropriate dedicated electrical circuit Nothing else should be connected to th...

Page 73: ...against electric shock particularly regarding allowable leakage current reliability of the protective earth connection when present On power connected to mains Type BF equipment contains an F type iso...

Page 74: ...er MedTrack CR 0 to 15 in 60 secs max with 400 lb user PHYSICAL Weight 400 lb 181 4 kg Nominal walking surface 20 in x 60 in 51 cm x 152 cm Treadmill dimensions width x length x height 31 in x 87 25 i...

Page 75: ...ent is computed as described in section 430 24 of the National Electrical Code FUSE RATINGS F1 F2 250Vac 4A T 5 x 20 mm nominal F3 F4 F5 F6 250Vac 2A T 5 x 20 mm nominal ClubTrack MedTrack Controllers...

Page 76: ...ge 5 00 to 60 00 min sec mi 3 07 to 37 16 min sec km MedTrack range 8 20 to 99 59 min sec m 5 11 to 62 08 min sec km Increment 00 01 Zero speed when walk belt speed is zero the pace display indicates...

Page 77: ...o 90 F 10 to 32 C Storage 13 to 122 F 25 to 50 C Humidity non condensing Operating 3 to 95 relative Storage 3 to 95 relative Atmospheric pressure Operating 8 60 to 15 0 psia 45 to 775 mm Hg absolute S...

Page 78: ...o 96 00 min sec Stage time 0 00 to 6 00 min sec Elapsed distance Units miles or kilometers Range 0 to 99 9 miles or kilometers Increment 0 001 from 0 to 9 999 miles or kilometers 0 01 from 10 00 to 99...

Page 79: ...i or km Pace Units minutes seconds per mile or minutes seconds per kilometer Range 5 00 to 99 59 min sec mi 3 07 to 99 59 min sec km Increment 00 1 Zero speed when walk belt speed is zero the pace dis...

Page 80: ...ade 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 5 0 86 6 5 3 72 11 5 6 56 2 0 1 15 7 0 4 00 12 0 6 84 2 5 1 43 7 5 4 29 12 5 7 13 3 0 1 72 8...

Page 81: ...A 001 English U S A 198 250V 60 Hz 10A 009 English U K 198 250V 50 60 Hz 10A 002 German 198 250V 50 60 Hz 10A 003 French 198 250V 50 60 Hz 10A 004 Italian 198 250V 50 60 Hz 10A 005 Spanish 198 250V 50...

Page 82: ...Assy 33316 002 Grade POT Assy 33171 002 Grade Wheel Kit 33502 002 Grade Chain Kit 30448 001 Sprocket chain grade motor 19081 004 DECK Deck 30204 001 Front Roller 33507 002 001 CR60 Rear Roller Assy 3...

Page 83: ...nese 34298 001 34298 002 34298 003 34298 004 34298 005 34298 006 Controller Assy PCBA keypanel receiver English German French Italian Spanish Japanese 34297 001 34297 002 34297 003 34297 004 34297 005...

Page 84: ...3505 005 33505 006 Controller Assy PCBA keypanel English German French Italian Spanish Japanese 034505 001 034505 002 034505 003 034505 004 034505 005 034505 006 HR ClubTrack Plus with Heart Rate Cont...

Page 85: ...5371 002 35371 003 35371 004 35371 005 35371 006 These versions may be available in the future Accessories for Heart Rate Monitoring Transmitter Belt 34198 003 Pulse Simulator 34198 008 Polar Favor Wr...

Page 86: ...The appropriate test must be performed as verification whenever any of the procedures in Chapter 4 are used Complete Field Functional Test The following steps must be performed with the treadmill comp...

Page 87: ...may be from non approved vendor McKenzie Seven segment displays flash all 8s and then go blank and stay blank Limited access switch is activated Deactivate limited access switch see user manual ClubTr...

Page 88: ...nations 2 Press and hold each key in succession to display the appropriate code in the Select display the HR ClubTrack Plus displays text instead of code P000 should appear when you release each key K...

Page 89: ...rt rate function 1 Turn on the pulse simulator The LED on the front of the simulator will blink in synch with the signal 2 Place the Polar watch receiver next to the pulse simulator to begin receiving...

Page 90: ...bTrack ClubTrack Plus HR Treadmills MedTrack SR60 5 Increase the walk belt speed to 10 0 mph 6 Count the number of belt revolutions in two minutes This should be 155 3 revolutions MedTrack CR60 5 Incr...

Page 91: ...f disconnect the power cord from the outlet and place the treadmill back in service Field Test No 1 The following steps must be performed with the treadmill completely assembled except as noted With t...

Page 92: ...ctivate limited access switch see user manual 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 a...

Page 93: ...ollowing table for possible causes 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...

Page 94: ...ays 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 Grade Ensure that the grade w...

Page 95: ...back B Test the Deck Friction 1 Increase the treadmill grade to 15 maximum 2 Do not start the belt Stand on the treadmill walk belt and push away from the handrail The belt should begin rotating with...

Page 96: ...pair Replacement and Calibration 4 Increase the grade to 15 0 5 Measure the distance from the floor to the bottom front edge of the head Refer to the following table for the correct measurement Treadm...

Page 97: ...ck MedTrack SR60 and MedTrack CR60 Problem Possible Cause Solution Seven segment displays lock up with all 8s and do not go blank ED static Make sure control panel is properly grounded Check the follo...

Page 98: ...roller If an error code is displayed refer to Error Codes in Chapter 3 Troubleshooting C Test the Controller Operation To test for proper controller operation Test the Controller Keys 1 To enter Servi...

Page 99: ...9 no decimal points are illuminated during this count Perform the LCD display test pg 3 7 Test the Tri color Display ClubTrack Plus only 1 Press Next Stage Up Down until the test begins _ Vertical col...

Page 100: ...displayed on the controller If the controller differs by five beats replace the receiver P N 34295 and re test If the problem remains replace the controller assembly HR ClubTrack p n 34297 HR ClubTra...

Page 101: ...e 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 Limit S...

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Page 147: ...drive belt replacing 4 10 drive board 2 4 drive motor 4 11 E electrical problems 3 2 electronic problems 3 3 error codes 3 3 error code flow charts 3 11 E001 3 12 E203 3 14 E204 3 13 EPHI and EPLO 3 1...

Page 148: ...4 17 rack gears jammed 4 19 receiver theory 2 5 repair 4 1 roller assembly 2 4 rollers replacing 4 23 S safety requirements A 1 service mode 3 4 service recommended 5 1 speed range 3 6 symbol definit...