TREADMILL SERVICE MANUAL ClubTrack® ClubTrack Plus® HR ClubTrack HR ClubTrack Plus MedTrack®® CR60 MedTrack SR60 ® 000377-833 033387-005 Rev New
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 registered trademarks of their respective companies. Service Manual Publication Number 000377-833 Text Number 033387-005 Rev New Copyright © 1995, 1997 Quinton Instrument Co. All rights reserved.
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 MedTrack MedTrack P/N 00425 CR60 P/N 00380 SR60 P/N 00390 The manual covers domestic and international versions of the treadmills, which are differentiated by dash numbersee Appendix C, Part Numbers.
Contents Preface Overview ClubTrack® . . . . MedTrack® . . . . Configuration Plate Power . . . . . . . Operation . . . . . Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-2 1-2 1-3 Overview . . . . . . . . . . . . . . . Controller Assembly . . . . .
Troubleshooting Tools . . . . . . . . . . . . . . . . . . . Electrical Problems . . . . . . . . . . . . Electronic Problems . . . . . . . . . . . . Error Codes . . . . . . . . . . . . . . Service Mode . . . . . . . . . . . . . Firmware Revision . . . . . . . . . . Controller Keys . . . . . . . . . . . . Displays . . . . . . . . . . . . . . . Tri-color Display . . . . . . . . . . . Speed/Grade (Open-Loop Mode) . . . HR ClubTrack Plus™ LCD Display Test Testing Pin Signals . . . . . . . . . .
Replacing the Rollers . . . . . . . . . . . . . . . . . . Replacing the Walk Belt or Deck . . . . . . . . . . . . Replacing Compression Mounts . . . . . . . . . . . . . Replacing the Deck . . . . . . . . . . . . . . . . . . . Adjusting the Walk Belt . . . . . . . . . . . . . . . . Walk Belt Tension . . . . . . . . . . . . . . . . . Walk Belt Tracking . . . . . . . . . . . . . . . . . Controller Assembly . . . . . . . . . . . . . . . . . . Removing the Enclosure . . . . . . . . . . . . . .
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Accessories for Heart Rate Monitoring . . . . . . . . . . . C-5 Field Functional Tests Complete Field Functional Test . Test the Controller Displays Test the Multi Display . . . Test the Controller Operation Test the Grade Operation . . Test Speed Operation . . . . Test the Deck Friction . . . . Test the Walk Belt Operation Field Test No. 1 . . . . . . . . . Field Test No. 2 . . . . . . . . . Field Test No. 3 . . . . . . . . . Field Test No.
1 Overview ClubTrack Quintons 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 Plus, P/N 00425. The ClubTrack Plus provides manual and programmed operation. The HR ClubTrack Plus adds Heart rate control, interval programming, and a computer interface.
Configuration Plate ON I O OFF Circuit Breaker Power Cord Treadmills distributed for use outside the USA and Canada have detachable power cords. Power The circuit breaker on the front of the treadmill hood controls the power to the treadmill. The circuit breaker must be set to the treadmill to run. A ON for Turn off the circuit breaker before connecting or disconnecting the treadmill from the wall outlet.
Controllers SPEED GRADE POWER UNITS SELECT CLEAR UP FASTER SLOWER DOWN Quinton STOP BELT COOL DOWN START BELT STOP BELT PCBA 33518-001 Magnet Keypanel 33504 ClubTrack and MedTra ck SR60/CR60 19296-001 Controller Assy 34506 Heart Rate Monitoring LEDs TM COMPATIBLE CLUBTRACK TM PCBA 34296-001 Keypanel 34298 HR ClubTrack Contro ller with Heart Rate Monitoring SPEED GRADE POWER CLEAR Controller Assy 34297 UNITS SELECT UP START COURSE FASTER INPUT DOWN Quinton FITNESS EQUIPMEN
SPEED GRADE MPH POWER KM/H F1 UNITS F2 UP F3 PREVIOUS MENU QUINTON FITNESS EQUIPMENT STOP BELT FASTER SLOWER DOWN MENU START BELT COOL DOWN STOP BELT PCBA 35452 HR ClubTrack Plus Contro ller with Heart Rate Control Overview 1-4 Keypanel 35260 Controller Assy 35258
2 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 controller processes the user-entered information displays all exercise data sends commands to the head frame assembly.
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 simulate hills. The headframe assembly receives speed and grade commands from the controller.
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 LED displays mounted on the controller PCBA. These displays show pertinent treadmill information including target speed and grade and accumulated exercise information.
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 line power to develop 300 VDC which is then used to create three-phase power for the drive motor assembly.
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 sense electrical energy on the skin during a heart contraction. The transmitter emits a short electrical field burst.
3 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 procedures.
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 control activated , Place magnet on Quinton logo, then press Power twice but magnet not in place (off/on). To disable the control, remove magnet, then press +, -, and Power simultaneo usly.
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 replace a faulty PCB Assembly, return it to the factory and note the error code. Code Indication Recommended Action E001 Variable speed drive (VSD) Replace VSD.
Error Codes (continued) Code Indication E203 Motor overload caused by one Recommended Action 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 disconne cted or 3. If the motor does not turn, check the motor loose leads to ensure all leads are connected . One loose or disconne cted lead will cause overload. 4.
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 tri-color display. To exit the service mode, press and release the same three keys simultaneously or press Power twice to power up into normal mode.
(continue d) Units P010 Start Course* P011 Resume Course* P012 Cool Down P013 Faster P014 Slower P015 *ClubTrack Plus 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 at a time in each display, starting from left to right across the panel. Each digit displays the number 8 and the associated decimal point for one second, then turns off as the next one lights up. 4.
A 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. Press Stop Belt, Faster , and Slower simultaneously to exit the service mode; do not press the Power key. 4. Ensure that no one is standing on the walking belt, then press Start Belt . 5.
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 possible states, going from bright to dim to off, then back to bright. The sequence continues until you press the MENU key. 6. Fonts The screen displays the alphabet.
Signals on Control Cable Pins Pin No. VSD Pin No. DPU (J12) (J1) Signal 1 1 2 2 3 3 4 4 5 5 GND (Ground ) 6 6 N/C 7 7 GND (Ground ) 8 8 +12 VDC 9 9 +12 VDC T+ (Transmit+) T - (Transmit -) R+ (Receive+) R - (Receive -) NOTE: J12 is a D-sub connector. J1 is a MASCON connector.
Problem Possible Cause Remedy No signal on 1. No electrod e contact 1. Reposition chest belt, 2. Faulty chest belt 2. Test signal using controller re-wet electrod es. different belt transmitter or a pulse simulator; replace old belt if faulty. 3. Faulty receiver 3. Test the belt transmitter using a different receiver. If transmitter is working correctly, replace receiver.
Problem Possible Cause Action Walk belt slipping 1. Improper walk belt 1. Adjust walk belt tension. 2. Incorrect drive belt tension. 2. Check drive motor tension or drive belt belt. Adjust worn. tensioner or replace drive belt if necessary. Walk belt not tracking Belt misaligned or Adjust tracking. tracking adjustme nt bolt overtightene d. Walk belt worn Various Replace belt and deck. Walk deck worn Various Replace belt and deck.
Error Code Flow Chart: EPHI and EPLO EPLO EPHI BUS voltage is too high BUS voltage too low Check line voltage. Check line voltage. Too high ? Yes Have customer get building Yes maintenance to correct voltage problem. Too low? No No Yes Is DS3 On? Replace VSD No Transformer output < 24.6 VAC Yes Replace transformer BUS Voltage Troubleshooting 3-12 No CAUTION! Disconnect power and wait for high voltage indicator to go off. Connect meter, THEN power up.
Error Code Flow Chart: E001 E001 VSD Microprocessor chip failure E002 VSD Microprocessor EPROM/ RAM failure Verify grounding system is wired correctly and is intact Enter Service Mode Replace VSD PCBA E205 Software tachometer fault E202 Speed Error E206 Inadvertant Reset E201 Grade Error Calibrate Pot Error Persists Press Power or Clear Yes Replace grade Pot and recalibrate No Error Persists Error Persists Yes Yes Replace VSD Replace VSD Complete No No VSD Board Troubleshootin g 3-13
Error Code Flow Chart: E204 E204 Communications Error Check Ds2 on VSD board. Verify communication cable connection at each end. Error Persists? Ds2 On? (Micro 5V) Yes No Yes Verify cable pins are not bent or broken or cable damaged. CAUTION! Disconnect power and wait for high voltage indicator to go off. Clip a volt meter onto F1 and F2 fuse holder base closest to J3. THEN turn on power. Measure 22 VAC secondary. Replace controller. No Damaged cable? Finished. Yes No Less than 17.
Error Code Flow Chart: E203 E203 Error Overcurrent Is motor turning? No Check for obstructions in motor pulleys or belt Yes Runner outside weight/ speed envelope Restrict use to Yes people within specified weight/ speed envelope. CAUTION! Disconnect power and wait for high voltage indicator to go out. No Are all motor leads connected? No Reconnect disconnected leads. Check resistance between motor leads. Yes Worn deck? Excessive deck Yes wear indicated. Replace deck.
Cycle power. LED should be on momentarily then off. Drive motor does not turn Error code present? Yes Procede to Error Code Flow Chart On then off? CAUTION! Disconnect power and wait for high voltage indicator to go off. No Replace VSD Check resistance between motor leads.
Treadmill will not elevate Proceed to error code flow chart. Yes Error code present? No Perform keypanel test. Replace controller assembly. Yes Yes CAUTION! Disconnect power and wait for high 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. Check limit switch continuity between J1 pin 1 and 3, then pin 4 and 6. Press the Up, then the Down key on the controller.
4 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.
• 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 before working with chain, rack gear, belts, and pulleys. • Secure long hair, loose clothing, and jewelry before working near the treadmill, particularly near walking surfaces and rotating parts.
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, which is present whenever DS4 and DS5 are illuminated. Do not touch the VSD PCBA until DS4 and DS5 have gone out. Resistors on the PCBA bleed off the high voltage in approximately two minutes.
5. Remove the three #8 Phillips-head screws located on the back of the hood, above the kick plate #8-32 x 0.375L (35239-183) 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 two screws holding the hood to the front of the siderails. International units: Remove the #10 screws that hold the hood to the upright. #10 screws (10835-325) Push to remove. 8.
0.625 spacer (30895-001)0.625 spacer (30895-001) 0.625 spacer (30895-001) Instruction Panel ClubTrack Plus only (30910-00X) 0.375 spacer (30895-002) 10-24 x 1.50L (10830-335) 10-24 x 1.
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 remove the power cord from the power outlet. 2. Remove the hood as previously described. 3. Remove the two ¼-20 hex head screws that attach the power cord ground wires to the headframe.
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 the two hex nuts holding the power cord to the line filter: the hex nuts are behind the configuration plate, down and to the right. 5. Remove the groundwire. 6. Pull the power cord out of the configuration plate.
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 harnessed. Cut the plastic ties to free the wires as necessary. Reference wiring schematic. 5. Unplug the grade motor wires from the VSD board. 6. Unplug the isolation transformer wires. 7.
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 off the controller and the treadmill circuit breaker, then unplug the power cord from the power outlet. Alignment Marks Large Nut (Step 7) - part of tensioner 3 -16 x 2.
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 should be 62 ± 3 revolutions for all treadmill models. ClubTrack®, ClubTrack Plus™, HR ClubTrack™, HR ClubTrack Plus, MedTrack® SR60 5. Increase the walk belt speed to 10.0 mph. 6.
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 516 -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 the poly-V belt from the right side of the roller. 7. Replace with a new belt, then remount the front drive roller assembly. (When replacing the poly-V belt, be sure the belt is centered on the pulleys.
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 previously described. 5. Cut the wire ties that hold the drive motor cable to the headframe and disconnect the motor cable at the VSD board. 6. Remove the four hex nuts that hold the motor on the headframe.
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 minutes from the time you unplug the power cord and be sure the red LEDs on the VSD board are off. 3. Unplug the transformer wires from the VSD board. Note the wire colors and connection points.
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. Turn off the power and remove the hood as described. 3. Remove the cable ties that secure the grade motor wires, then disconnect the wire connector on the VSD board. 4.
Grade Motor Pinion Shaft Chain (30448-001) 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 Motor Chain To change the chain: 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.
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. Grade Pot (33171-002) Gear (30843-001) Setscrew, 10-32 x 0.25L (10833-144) 3. Remove the grade pot gear. 4. Remove the nut that holds the grade pot to the bracket. 5. Clip the cable ties and unplug the cable from the VSD board. 6.
Red wire: slot 4 Black wire: slot 5 BRN OR WHT 1. Insert each pin into the connector housing until it clicks slightly. The flanges will be visible through the slots in the housing. 45 2. Verify that the pin has engaged by pulling lightly on the wire. A The slot positions above apply to the ClubTrack, ClubTrack Plus, MedTrack SR60 and MedTrack CR60. Field Functional Test To verify that the treadmill is operating properly, perform Field Test No. 4.
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 . The display will read 0.0 P000 0.0. d. Simultaneously press Stop , Faster , and Slower to exit service mode. The display should read 0.0 P555 0.0. You are now in open loop mode.
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 allow the rack gear to travel beyond its normal lower limits. 6. Check under the bottom of the headframe to verify that the rack gears are meshing properly. The gears should protrude an equal distance. 7.
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: Upright Hex-head fasteners Pivot point Star washer Flat washer 5/16" Hex bolt a. Unbolt the six hex-head fasteners to let the treadmill uprights pivot. Note the order of the washer placement for reinstallation: the star washer is next to the upright bracket. b.
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 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.
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 potentiometer (see Calibration Procedures, page 4-33). 15. 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.
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 Phillips screws holding deck to siderails (10 PL) ¼-20 x 1.25L (10836-105) 5/16-18 x 0.75L (10819-246) Flat Washer (01164-005) Lock Washer (10511-010) Retainer (15689-002) Siderail cover removed Walk belt removed for clarity Rear screws (2 PL) ¼-20 x 2.
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 install a new deck or turn over the existing deck (the deck is reversible). Inspect the compression mounts each time you replace the walk belt and replace if worn. 1. Raise the treadmill to its maximum height.
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 each siderail. The front two mounts are attached with hex nuts underneath. L S L L S S L S L S = Short Mounts (32235-002) L = Long Mounts (32235-001) Aluminum spacer (32240-001) 3.
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 adjustment screws must be completely slack before starting this procedure. Method 1 (Calipers available) 1. Turn both tension adjustment screws clockwise until most of the slack is removed from the belt.
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 walk belt tracking. Walk Belt Tracking Adjust the tracking: • whenever the belt moves to one side • after installing a new walk belt • each time you adjust the walk belt tension.
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 ClubTrack uses the heart rate monitor (HRM). • The HR ClubTrack Plus uses the heart rate controller (HRC). You must configure the controller correctly after installing (pg 4-30). Removing the Enclosure 1.
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 power cord from the outlet. 3. Use a 18 inch Allen wrench to remove the six screws from the rear panel of the enclosure. 4. Use a 316 -inch Allen wrench to remove the two socket screws near the handrail 5.
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 and replace with new tube. 5. Reassemble in reverse order. Field Functional Test To verify that the treadmill is operating properly, perform Field Test No. 5.
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, hold down Stop Belt and press the + or - key until the correct configuration number appears in the center display. 4. Press Select to store the configuration.
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 distance or total time of use for each treadmill. This data can be useful for scheduling service. See separate procedure below for HR ClubTrack Plus (p/n 00425).
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 the Limited Access Switch 1. Remove the magnetic key and press Power to turn off the treadmill. 2.
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 the setscrew and verify that the display still reads 0.0. 8. Press Clear to exit open-loop mode. 9.
5 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 working near the treadmill, particularly near the walking surface or pulleys. Do not permit anyone to stand on the treadmill belt when it is started.
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 the interior of the treadmill or controller.
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 belt in a warm, dry place away from direct sunlight. Do not store in plastic or other material that can trap moisture. Do not store in soap and water bath.
A 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. Before each use of this equipment, check the power receptacle for signs of damage. Do not operate the equipment if the integrity of these items is in question.
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 the previous page, can be found in the referrenced ANSI standard. Symbol Definitions Quinton products display one or more of the following symbols. No one product displays them all.
B Specifications ClubTrack®(00377, 00402) and MedTrack® Rehabilitation Treadmills (00380, 00390) PERFORMANC E Maximum Rated Load Belt Speed Range: ± 0.2 mph (continuously adjustable) Rate of speed change Grade range ± 0.
POWER REQUIREMENT S Dash Number Voltage/H z Current Min.
Rate of change Accuracy Multi-function Display Elapsed time or countdown timer Elapsed distance Pace Calories Caloric rate METS Heart rate (option) Scan Weight 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. Within ± 0.5% actual grade during unchanging operation 4-digit display.
ClubTrack Plus® Treadmills (P/N 00382, 00425) PERFORMANC E Maximum rated load Belt speed range (continuously adjustable) Grade range PHYSICAL Weight Nominal walking surface Treadmill dimensions width x length x height Walking surface height from floor Handrail height from walking surface ENVIRONMENT AL Temperature Humidity (non-condensing) Atmospheric pressure 320 lb (145 kg) 1.0 to 12 mph (1.6 to 19.3 k/h) 0 to 15% 400 lb (181.4 kg) 20 in. x 60 in. (51 cm x 150 cm) 31 in. x 87.25 in. x 53 in. (78.
ClubTrack Plus®Controller (P/N 00382) SPEED Units Range Increment Accuracy GRADE Units Range Increment Accuracy MULTI-FUNCTION DISPLAY Elapsed time or countdown timer Exercise time Stage time Elapsed distance Pace Calories Caloric rate METS Weight (3-digit display) Miles per hour (mph) or kilometers per hour (km/h) 1 to 12 mph, 1.6 to 19.3 km/h 0.1 mph Within ± 0.2 mph (0.32 km/h) of actual speed during unchanging operation, 1 mph (1.6 km/h) during speed decrease.
HR ClubTrack Plus™ with Heart Rate Control (P/N 00425) SPEED Units Range Increment Accuracy GRADE Units Range Increment Accuracy LCD DISPLAY Time Elapsed distance Pace Calories Caloric rate METS Heart rate Enter Weight Enter Target Heart Rate Enter Exercise Time Serial interface Specifications B-6 (3-digit display) Miles per hour (mph) or kilometers per hour (km/h) 0 to 12 mph, 0 to 19.3 km/h 0.1 mph, 0.16 km/h Within ± 0.2 mph (0.32 km/h) of actual speed during unchanging operation, 1 mph (1.
Percent vs Angle Relationship for Treadmill Grade Rise θ Run Grade = Rise Run tan θ = Grade = tan θ θ = arctan(Grade) (Note: 15% Grade Grade 0.0% 0.5% 1.0% 1.5% 2.0% 2.5% 3.0% 3.5% 4.0% 4.5% 5.0% Angle (°) 0.00 0.29 0.57 0.86 1.15 1.43 1.72 2.00 2.29 2.58 2.86 Rise Run Grade 5.0% 5.5% 6.0% 6.5% 7.0% 7.5% 8.0% 8.5% 9.0% 9.5% 10.0% Grade = 0.15) Angle (°) 2.86 3.15 3.43 3.72 4.00 4.29 4.57 4.86 5.14 5.43 5.71 Grade 10.0% 10.5% 11.0% 11.5% 12.0% 12.5% 13.0% 13.5% 14.0% 14.5% 15.0% Angle (°) 5.71 5.
C Part Numbers Final Assemblies ITEM PART NUMBER ClubTrack Fitness Treadmill Assembly 00377 HR ClubTrack Fitness Treadmill with Heart 00402 Rate Monitoring Assembly ClubTrack Plus Treadmill Assembly 00382 HR ClubTrack Plus Fitness Treadmill with 00425 Heart Rate Control Assembly MedTrack CR 60 Treadmill Assembly 00380 MedTrack SR 60 Treadmill Assembly 00390 The following dash numbers apply to all treadmill part numbers above: English U.S.A. 001 99 - 132V, 60 Hz, 20A English U.S.A.
Spares ELECTRIC AL Power Cord North America Japan 100V U.
Controllers ClubTrack® P/N 00377 PCBA Keypanel English German French Italian Spanish Japanese Controller Assy (PCBA & keypanel) English German French Italian Spanish Japanese 33518-001 33504-001 33504-003 33504-005 33504-007 33504-009 33504-011 034506-001 034506-003 034506-005 034506-007 034506-009 034506-011 HR ClubTrack™ with Heart Rate Monitoring (HRM) P/N 00402 PCBA Keypanel English German French Italian Spanish Japanese Controller Assy (PCBA, keypanel, & receiver) English German French Italian Span
MedTrack® CR60 P/N 00380 & SR60 P/N 00390 PCBA Keypanel English German French Italian Spanish Japanese Controller Assy (PCBA & keypanel) English German French Italian Spanish Japanese 33518-001 PCBA Keypanel English German French Italian Spanish Japanese Controller Assy (PCBA & keypanel) English German French Italian Spanish Japanese 33519-002 ClubTrack Plus® P/N 00382 33504-002 33504-004 33504-006 33504-008 3 3504-010 33504-012 34506-002 34506-004 34506-006 34506-008 34506-010 34506-012 33505-001 33
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 Transmitter Belt Pulse Simulator Polar Favor Wrist Monitor 34198-003 34198-008 34198-009 A To avoid potential safety and electrical problems, use parts and accessories that meet Quinton specifications.
D 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 gone out. These procedures apply to all Quinton Hyperdrive treadmills (ClubTrack, ClubTrack Plus, HR ClubTrack, HR ClubTrack Plus, MedTrack SR, and MedTrack CR.
ClubTrack, HR ClubTrack, MedTra ck SR60, and MedTra ck CR60 Problem Possible Cause Solution Seven segment displays ESD (static) Make sure control lock up with all 8s and panel is properly do not go blank. grounded . Check the following: All star washers are installed Green wire goes to VSD PCB Continuity to ground on power cord plug Less than two ohms neutral to ground at the power outlet Hall Effect Sensor (SW 1) and screw on key panel may have excessive clearance.
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 Select display, indicating that no key is pressed. A On the ClubTrack Plus, the word Service scrolls across the tri-color display. On the HR ClubTrack Plus, the screen lists the tests described below.
• 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 the Tri-color Display (ClubTrack Plus®only) 1. Press Next Stage+Up+Down until the test begins. Vertical columns on the tri-color display light red, green, and then yellow for one second each.
Treadmill Measurement ClubTrack HR ClubTrack ClubTrack Plus 14 3 8 in ± 3 8 in HR ClubTrack Plus MedTrack SR60 MedTrack CR60 14 7 8 in ± 3 8 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 Calibration). E. Test Speed Operation 1. Place a chalk mark or piece of tape on the walk belt across the direction of travel. 2.
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 the walk belt speed at 3.0 mph, walk on the treadmill. 3. Grasp the handrail and resist the motion of the walk belt.
ClubTrack, HR ClubTrack, MedTrack SR60, and MedTrack CR60 Problem Possible Cause Solution Seven segment ESD (static) Make sure control panel is displays lock up properly grounded . with all 8s and do Check the following: not go blank. All star washers are installed Green wire goes to VSD PCB Continuit y to ground on power cord plug Less than two ohms neutral to ground at the power outlet Hall Effect Sensor (SW 1) and screw on key panel may have excessive clearance.
Field Test No. 2 A 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 Observe the controller displays during initialization.
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 display is shown on seven segment display (00 150 00). Tri-color display scrolls INPUT WT. +/- message.
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, 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. Increase the walk belt speed to 7.2 mph. 6.
Field Test No. 4 A 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/Replacement and Calibration). 2. Ensure the controller displays 0.0% grade. 3. Measure the distance from the floor to the lower edge of the siderail cover at the rear support and at the front grade wheel.
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 SR60, and MedTrack CR60, the normal sequence is: • • • • Seven segment displays show all 8s (888 8888 888). After 3 seconds, all displays go blank. Multi display briefly shows configuration code (0.0 CP.-x 0.0).
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 display is shown on seven segment display (00 150 00). Tri-color display scrolls INPUT WT. +/- message.
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 a time in each display, starting from left to right across the panel.
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-test. If the problem remains, replace the controller assembly: HR ClubTrack p/n 34297, HR ClubTrack Plus, p/n 35258. D.
E 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, Limit Switch 32783 Motor, Drive, AC Variable 32359 System Wiring 33171 Assembly, Grade Pot Assembly Drawings E-1
Index A E204 adjusting the walk belt assemblies 3-11 F 2-1 assembly drawings 3-13 EPHI and EPLO 4-25 D-1 field functional tests B E-1 field replaceable modules battery life, heart rate transmitter C calibration procedures grade pot chain 4-33 4-7 chest belt, battery 3-11 E001 3-12 E203 3-14 E204 3-13 EPHI and EPLO G chest belt, storage circuit breaker grade motor 5-3 chest belt, cleaning cleaning flow charts, error grade limit switches 4-15 classification 3-5
microprocessor, theory models N noise service mode A-1 3-4 service, recommended 3-10 speed range operation options T 3-6 1-3 tension 1-4 overview theory tools 3-1, 4-2 C-1 PCBA, replacing transmitter 4-28 4-6 pulse simulator R rack gears 3-8 receiver, theory rollers, replacing Index 2 2-5 4-1 roller assembly 3-6 troubleshooting 3-1, 3-2 V VSD board walk belt 4-19 4-23 4-7 3-9 tension replacing warnings 2-4 5-3 tri-color Display W 4-17 rack gears, jammed repai
