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.

Quinton Instrument Company

3303 Monte Villa Parkway, Bothell, WA 98021-8906
Telephone 425/402-2000 Fax 425/402-2001
USA and Canada:
Service: 800/426-0538
Sales: MedTrack 800/426-0347
ClubTrack 800/426-0337

Visit Quinton on the World Wide Web at www.quinton.com

INTERNATIONAL SALES
Latin America & Asia-Pacific
Telephone 425/402-2000 Fax 425/402-2001

Europe/Hoofddorp, The Netherlands

Telephone 31-23-5672400 Fax 31-23-5672410
Preface
This manual contains information for servicing and repairing
the following Quinton Hyperdive™ treadmills to the module level:
ClubTrack  P/N 00377

ClubTrack Plus  P/N 00382

HR ClubTrack  P/N 00402

HR ClubTrack Plus  P/N 00425


MedTrack CR60 P/N 00380


MedTrack SR60 P/N 00390

The manual covers domestic and international versions of the

treadmills, which 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
treadmills. Any attempt by non-Quinton-trained personnel to
service the treadmill may void the warranty. For service
information, call 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 series treadmills.

Preface - iii
Contents
Preface

Overview

ClubTrack® . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MedTrack® . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Configuration Plate . . . . . . . . . . . . . . . . . . . . . 1-2
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Theory of Operation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Controller Assembly . . . . . . . . . . . . . . . . . . 2-1
Headframe Assembly . . . . . . . . . . . . . . . . . . 2-2
Deck and Roller Assembly . . . . . . . . . . . . . . . 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
Input Power Module . . . . . . . . . . . . . . . . . . 2-3
Drive Board . . . . . . . . . . . . . . . . . . . . . . . 2-4
Drive Motor Assembly . . . . . . . . . . . . . . . . . 2-4
Grade Motor Assembly and System . . . . . . . . . . . 2-4
Deck and Roller Assembly . . . . . . . . . . . . . . . . . 2-4
Heart Rate Monitoring Option . . . . . . . . . . . . . . . 2-4
Transmitter . . . . . . . . . . . . . . . . . . . . . . . 2-5
Receiver . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Microprocessor . . . . . . . . . . . . . . . . . . . . . 2-5

Contents - v
 Troubleshooting

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Electrical Problems . . . . . . . . . . . . . . . . . . . . . 3-2
Electronic Problems . . . . . . . . . . . . . . . . . . . . . 3-3
Error Codes . . . . . . . . . . . . . . . . . . . . . . . 3-3
Service Mode . . . . . . . . . . . . . . . . . . . . . . 3-5
Firmware Revision . . . . . . . . . . . . . . . . . . . 3-5
Controller Keys . . . . . . . . . . . . . . . . . . . . . 3-5
Displays . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Tri-color Display . . . . . . . . . . . . . . . . . . . . 3-6
Speed/Grade (Open-Loop Mode) . . . . . . . . . . . . 3-6
HR ClubTrack Plus™ LCD Display Test . . . . . . . . . 3-7
Testing Pin Signals . . . . . . . . . . . . . . . . . . . 3-7
Heart Rate Monitoring Option . . . . . . . . . . . . . . . 3-8
Testing Heart Rate Accuracy . . . . . . . . . . . . . . 3-9
Mechanical Problems . . . . . . . . . . . . . . . . . . . . 3-9
Walk Belt . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . 3-10
Treadmill Noise . . . . . . . . . . . . . . . . . . . . 3-10
Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Repair/Replacement and Calibration

Cautions/Warnings . . . . . . . . . . . . . . . . . . . . . 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 the Tensioner . . . . . . . . . . . . . . . . . . 4-9
Replacing the Poly-V Drive Belt . . . . . . . . . . . . . . 4-10
Installing the Front Shaft . . . . . . . . . . . . . . . 4-11
Replacing the Drive Motor . . . . . . . . . . . . . . . . 4-11
Replacing the Transformer . . . . . . . . . . . . . . . . 4-13
Replacing the Grade Motor . . . . . . . . . . . . . . . . 4-14
Replacing the Grade Motor Chain . . . . . . . . . . . . . 4-15
Replacing the Grade Potentiometer (POT) . . . . . . . . 4-16
Grade Pot Wires . . . . . . . . . . . . . . . . . . . 4-16
Removing the Rack Gears . . . . . . . . . . . . . . . . 4-17
Reassembling the Rack Gears . . . . . . . . . . . . . . 4-18
Replacing a Jammed Rack Gear . . . . . . . . . . . . . . 4-19
Replacing the Pinion Shaft . . . . . . . . . . . . . . . . 4-21
Adjusting the Grade Limit Switches . . . . . . . . . . . 4-22
Walk Deck Assembly . . . . . . . . . . . . . . . . . . . 4-23
Contents - vi
 Replacing the Rollers . . . . . . . . . . . . . . . . . . . 4-23
Replacing the Walk Belt or Deck . . . . . . . . . . . . . 4-24
Replacing Compression Mounts . . . . . . . . . . . . . . 4-25
Replacing the Deck . . . . . . . . . . . . . . . . . . . . 4-25
Adjusting the Walk Belt . . . . . . . . . . . . . . . . . 4-26
Walk Belt Tension . . . . . . . . . . . . . . . . . . 4-26
Walk Belt Tracking . . . . . . . . . . . . . . . . . . 4-27
Controller Assembly . . . . . . . . . . . . . . . . . . . 4-28
Removing the Enclosure . . . . . . . . . . . . . . . 4-28
Replacing the PCBA . . . . . . . . . . . . . . . . . . 4-29
Replacing the Fluorescent Tube (HR ClubTrack Plus) . 4-30
Replacing the HR Receiver Assembly . . . . . . . . . 4-30
Configuring the Controller . . . . . . . . . . . . . . 4-30
Removing the Keypanel . . . . . . . . . . . . . . . . 4-31
Replacing the Controller Cable . . . . . . . . . . . . 4-31
Cumulative Use . . . . . . . . . . . . . . . . . . . . 4-32
Limited Access 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
Vacuuming Under the Treadmill Hood . . . . . . . . . . . 5-2
Replacement Schedules . . . . . . . . . . . . . . . . . . . 5-2
Heart Rate Monitoring Option . . . . . . . . . . . . . . . 5-2
Safety Requirements

Safety Requirements . . . . . . . . . . . . . . . . . . . . A-1

Symbol Definitions . . . . . . . . . . . . . . . . . . . . . A-2
Specifications

ClubTrack® and MedTrack® Rehabilitation Treadmills . . . . B-1

ClubTrack® & MedTrack® Controllers . . . . . . . . . . . . B-3
ClubTrack Plus® Treadmill (P/N 00382) . . . . . . . . . . . B-4
ClubTrack Plus® Controller (P/N 00382) . . . . . . . . . . B-5
HR ClubTrack PlusTM with Heart Rate Control (P/N 00425) . B-5
Part Numbers

Final Assemblies . . . . . . . . . . . . . . . . . . . . . . C-1

Operator and Service Manuals . . . . . . . . . . . . . . . C-1
Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Contents - vii
 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Accessories for Heart Rate Monitoring . . . . . . . . . . . C-5
Field Functional Tests

Complete Field Functional Test . . . . . . . . . . . . . . . D-1

Test the Controller Displays . . . . . . . . . . . . . . D-1
Test the Multi 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 No. 1 . . . . . . . . . . . . . . . . . . . . . . . D-6
Field Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . D-8
Field Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . D-9
Field Test No. 4 . . . . . . . . . . . . . . . . . . . . . . D-11
Field Test No. 5 . . . . . . . . . . . . . . . . . . . . . . D-11
Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . E-1

Index

Contents - viii
 1
Overview

ClubTrack Quinton’s ClubTrack series of treadmills are motorized treadmills
with built-in controllers and are designed for fitness exercise. The
series includes the ClubTrack, P/N 00377; HR ClubTrack with
Heart Rate Monitoring, P/N 00402; ClubTrack Plus, P/N 00382;
and the HR ClubTrack 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.


MedTrack The MedTrack rehabilitation treadmills are designed for
rehabilitation exercise. Two models are available: the CR60 for
cardio-pulmonary rehabilitation (P/N 00380) and the SR60 for
sports rehabilitation (P/N 00390). Both feature a built-in controller.

See the Appendix of the applicable operator manual for

installation requirements.

Front of Hood

Rear

Sample Treadmill

Overview 1-1
Configuration Plate

ON
I
O
OFF

Treadmills distributed for use outside

Circuit Breaker
the USA and Canada have detachable
Power Cord
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 ON for
the treadmill to run.

A Turn off the circuit breaker before connecting or disconnecting

the treadmill 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 pressing a soft-touch key on the
panel. Visual indicators and displays show the operational status
and exercise results.

Overview 1-2
Controllers

GRADE SPEED

POWER UNITS

CLEAR SELECT
UP FASTER

DOWN SLOWER

Quinton STOP BELT

START BELT
COOL
DOWN
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 Controller Assy 34297

GRADE SPEED
POWER UNITS

START
CLEAR UP SELECT COURSE FASTER
INPUT
DOWN SLOWER
NEXT RESUME
STAGE COURSE

STOP BELT ENTER

START BELT COOL STOP BELT
Quinton STAGE
DOWN
FITNESS EQUIPMENT

PCBA 33519-002
Keypanel 33505
ClubTrack Plus
Controller Assy 34505

Overview 1-3
 GRADE
SPEED
MPH
POWER KM/H
UNITS
F1

F2
UP FASTER
F3

DOWN SLOWER
PREVIOUS
MENU MENU

QUINTON STOP BELT STOP BELT

FITNESS EQUIPMENT START BELT COOL DOWN

PCBA 35452
Keypanel 35260
HR ClubTrack Plus Contro ller with Heart Rate Control
Controller Assy 35258

Overview 1-4
 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.

Power Communications

Treadmill Subassemblies

Theory of Operation 2-1

 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.

Deck and Roller Assembly

The deck and roller assembly 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.

Controller Assembly
The controller assembly consists of a keypanel and PCBA mounted
in an enclosure. The enclosure, which has a removable rear panel,
mounts to the uprights.

Controller Subassemblies

Keypanel
The keypanel assembly consists of a membrane key or switch
panel and a PCBA. The keypanel and PCBA are connected through
a flexible cable that is part of the keypanel. A keypanel connector
mates to a PCBA connector.

Theory of Operation 2-2

 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. The HR CLubTrack Plus also displays data on
an LCD screen.

Additional Functions
The controller assembly also:

• performs an electronic self-test when the treadmill is turned on

• provides a special mode for manufacturing and service testing
• includes circuitry for the magnetic access switch.

Controller to Treadmill Interface

The controller communicates 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 drive board. The
controller uses 12 VDC power from the treadmill drive board as the
power source for all circuitry and for the LED displays.

HR ClubTrack Plus Interface

An RJ-45 interface connector on the rear of the HR ClubTrack Plus
treadmill permits connecting the treadmill to a computer for
exercise monitoring. The interface complies with the industry
standard CSAFE communications protocol. Consult Quinton’s web
site www.quinton.com, Fitness Products, for an internet link to the
CSAFE specifications.

Headframe Assembly
The headframe assembly consists of the following components:

• Input power module

• Drive board assembly

• Transformer assembly

• Drive motor assembly

• Grade motor assembly

• Grade system consisting of a pinion shaft, rack gears, feedback

potentiometer, and limit switches.

Theory of Operation 2-3

 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. The frequency of the three-phase signal sent to the drive
motor determines the drive motor rotational speed. The motor
current draw is a function of the torque load placed on the motor
through the deck assembly by the user.

The drive board uses 110 VAC power to generate a half wave
rectified signal used to drive the grade motor. Two solid state
relays drive the grade motor: one in the direction of increasing
grade, the other in the direction of decreasing grade.

Drive Motor Assembly

The drive motor, which is driven by the drive board, delivers
torque and 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 Motor Assembly and System

The grade motor drives the grade pinion shaft, using a chain and a
set of speed reduction sprockets. The grade pinion shaft in turn
drives a set of rack gears, which raise and lower the front of the
treadmill.

A grade potentiometer is used to sense the actual treadmill grade

for the grade system feedback. Limit switches limit the travel of
the rack gears in the event of potentiometer failure or incorrect
calibration.

Deck and Roller Assembly

The deck and roller assembly provides the running surface for the
user. This surface consists of a movable, flexible walk belt
supported by a semi-rigid platform. The platform is supported by a
steel-welded frame.

A poly-V-belt, coupled through a pulley to the drive motor, drives

the front roller. The front roller uses friction to drive the walk belt.
A rear roller, acting as an idler pulley, tensions the walk belt. Both
rollers are mounted to the steel support structure.

Theory of Operation 2-4

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. At
the receiver, the burst is transformed into a digital signal that is
monitored by the controller microprocessor. 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 soon as it detects the user’s heart beat.
Transmission frequency is approximately 5kHz.

Receiver
The receiver PCBA is encased in a shock-absorbing module.
Electrical connections to the controller PCBA comprise three wires
and a removable connector.

• Reception range is approximately 3 ft (1m).

• Proximity to electric motors, monitors, power supplies, T.V.,

etc. can cause directional and attenuating interference.

Microprocessor
The microprocessor calculates the heart rate and displays it in the
multifunction display.

Theory of Operation 2-5

 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.

Tools
These tools may be needed:
• Phillips screwdrivers
• ½-inch hex socket wrench
• 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
treadmill circuit breaker, then unplug the treadmill from the
power source before removing the hood. Use extreme
caution at all times when the hood is removed.
• Secure loose clothing, jewelry, and long hair before working
near treadmill parts.
• Never place your fingers near rotating parts.
• Do not start the walking belt when someone is on the
treadmill.

Troubleshootin g 3-1
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.

Circuit breaker on treadmill set to Set treadmill circuit breaker to ON.

OFF

Building circuit breaker tripped Contact building maintenance to reset circuit breaker. If
circuit breaker trips again,

1. Check outlet voltage. If necessary, verify that the power

at the outlet and at the breaker is the correct rating for
the treadmil l.

2. Verify that the power cord is not caught in the rack gear.

3. Replace the configuration plate (faulty in-rush limiter).

Power cord damaged Remove cord from outlet and replace

Blown fuse in treadmill If any of the transformer primary fuses,

F3 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 ensure that no parts are
jammed (e.g. rack gear in grade change assembly). If F1
or F2 are blown, check the 21 Volt power supply.

Control cable between VSD* and Check for bent or broken pins. Replace control cable.
controller faulty

VSD failure Replace VSD if necessary.

Controller failure Replace controller circuit board.

Configuration plate connectio n Check configuration plate connections; reattach or crimp

faulty as required . If problem persists, replace configuration plate.

Treadmill stops during run; Stop Look for loose ground wires. Reconnect and secure if loose.
Belt has not been pressed. No
error message appears

LCD screen test failure Replace LCD, repeat test. If test fails again, replace PCBA.

HR ClubTrack Plus LCD does not If the LEDs are on and the treadmill is functioning normally,
come on check the LCD connector. If problem persists, replace the
controller PCBA.

External RS232 port failure Perform loop-back test. If test fails, replace PCBA.

* VSD (variable speed drive): circuit board assembly that controls the motor

Troubleshooting 3-2
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.

microprocessor chip failure

E002 VSD microprocessor Replace VSD.

EPROM/SRAM failure

E004 VSD A/D failure Replace VSD.

E101 Controller PCBA Replace controller.

microprocessor failure

E102 Controller PCBA EPROM failure Replace controller.

E103 Controller PCBA interrupt Replace controller.

failure

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 HR ClubTrack Plus, press the NV PRO-
GRAM LOAD TEST key. Proceed to step 4.)

3. Press Clear .

4. Reconfigure controller, pg 4-30 (HR Plus, adjust

the contrast after reconfiguring.)

If error E105 persists, replace controller.

E106 ClubTrack Plus Controller Replace controller.

display RAM failure

E201 Grade error 1. Enter service mode.

2. Calibrate POT.

3. If error persists, replace POT.

4. If error persists, replace VSD.

E202 Speed error. A software check Clear the error by pressing Clear or Power .
of redundant speed variables Attempt to operate the treadmill again. If error
has indicated a disagreeme nt persists, replace the VSD board.
and the microprocessor will
shut down the treadmill.

continued

Troubleshootin g 3-3
 Error Codes (continued)

Code Indication Recommended Action

E203 Motor overload caused by one

of the following:

1. Runner heavier than 1. Restrict use to people within the weight/ speed
weight/speed envelope. 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. Electrical short on the board 4. Examine board for shorts. Examine board for
near the power electronics blackened componen ts or discoloration.

5. Power electronic compone nt 5. Replace board if damaged.

failure

6. Motor blocked by obstruction 6. Remove obstruction.

E204 VSD and controller not Verify cable connections at both ends. Check for
communicating bent or broken pins; replace if required . If error
persists, replace VSD or controller as necessary.

E205 Software tachometer fault Clear the error by pressing Clear or Power .
Attempt to operate the treadmill again. If error
persists, replace VSD board.

E206 Controller or VSD performs Verify wire grounding system is intact.

inadvertent reset

EPHI VSD ABS voltage is too high. Refer to EPHI error code flow chart elsewhe re in
Line voltage is too high. this chapter.
VSD board failure

EPLO VSD ABS voltage is too low. Refer to EPLO error code flow chart elsewhe re in
Line voltage is too low. this chapter.
Transformer connection is bad.
Transformer failure. VSD board
failure.

Troubleshooting 3-4
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.
A In service mode, the HR ClubTrack Plus screen lists the tests
described below. To perform a test, press the softkey next to
the test name, rather than pressing the indicated key
combinations.

Firmware Revision
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 display.
3. Simultaneously press Stop Belt and Grade Down. The VSD
revision level appears in the Select display.

Controller Keys
To test the keys on the key panel:
1. Enter the service mode. If a key has shorted out, P555 appears
in the Select display.
2. Using the table below, press each key in succession to display the
appropriate code in the Select display (the HR ClubTrack Plus
displays text instead of code). P000 should reappear when you
release each key.
Key Code

No key pressed P000

Shorted Key(s) P555

Clear P001

Up P002

Down P003

Stop Belt P004

Input + P005

P006
Input -
Enter P007

Select P007

Next Stage* P008

Start Belt P009

Troubleshootin g 3-5
 (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. When this is completed, the LEDs light up individually,
starting from the top. The Select LEDs illuminate first,
followed by the Units LEDs.
5. After the LEDs are tested, all the digits in all three displays
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 service mode.
2. Simultaneously press Next Stage, Up, and Down until the test
begins.
Vertical columns on the tri-color display light red, green, then
yellow for one second each. The columns move from left to right
until all display LEDs have been tested.
Horizontal columns light red, green, then yellow for one second
each. The columns move from top to bottom until all LEDs have
been tested.
All LEDs go dark when the test is finished.

Speed/Grade (Open-Loop Mode)

In Service mode, the treadmill operates as in open-loop mode,
which is used to verify treadmill speed or grade. In this mode, the
treadmill displays the actual speed or grade, rather than the target
speed or grade.

Troubleshooting 3-6
 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. Press and hold Faster or Slower to change the speed.

6. When testing is finished, press Clear , or press Power twice to
exit open-loop mode.
Grade
1. Enter the service mode.
2. Press Faster, Up, and Down simultaneously to enter open-loop
grade mode.
3. Press Stop 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
exit open-loop mode.

HR ClubTrack Plus LCD Display Test

™

The LCD display test verifies that the display and its electronics
are functioning correctly. If any of the six tests fails, see Electrical
Problems troubleshooting table, page 3-2.

Select the LCD Display Test to begin the series of six tests. To
progress from one test to the next, select MENU.
1. Display Limits Test
A box appears with a one-pixel border between the outer edge of
the box and the edge of the display. A single horizontal and
vertical line intersects the box. If the box does not appear as
described, the test has failed.
2. All pixels ON
The entire display should appear white. A corrupted pixel would be
black.
3. All pixels OFF

Troubleshootin g 3-7
 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. Garbled characters indicate an
electronics or LCD problem.

HR ClubTrack Plus LCD Contrast

™

Select the Set Screen Contrast key. After adjusting, press MENU to
store the selected value. The setting remains when the treadmill is
turned off. Always adjust the screen contrast after performing the
NV PROGRAM LOAD test—the load 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 further, connect an
external loop-back connector, then select the RS232 Port Test key.
The loop back connects the transmit out to the receive in, allowing
the controller to verify proper operation through the external
connector. As the test progresses, the LCD displays a series of
messages: C—1, C—2, C—3, C—P. CEEE appears if an error
occurs. Remove the loop-back connector after the test is finished.

Testing Pin Signals on the Communications

Cable
Communication cable problems can cause an E204 error message.
Use an ohmmeter to test for the following conditions:
1. Check each wire for continuity from one end of the cable to the
other.
2. Check each wire for a short to another wire.
3. Check each wire for a short to the metal connector housing at
the drive end.

Troubleshooting 3-8
 Signals on Control Cable Pins

Pin No. VSD Pin No. DPU Signal

(J12) (J1)

1 1 T+ (Transmit+)

2 2
T - (Transmit -)
3 3 R+ (Receive+)

4 4
R - (Receive -)
5 5 GND (Ground )

6 6 N/C

7 7 GND (Ground )

8 8 +12 VDC

9 9 +12 VDC

NOTE: J12 is a D-sub connector. J1 is a MASCON connector.

Heart Rate Monitoring Option

The Polar system for heart rate detection and transmission has
been time-tested and shown to be accurate and reliable; however,
there is a small percentage of people for whom the system will not
work. If all the steps in the following table are performed and the
belt 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 Poor electrod e contact 1. Be sure that the logo
is erratic or absent. on the belt is facing
out, that the belt is
tight enough, and that
the electrod es are flat
against the skin.

2. Moisten the electrod es

again.

3. Be sure the receiver is

within range—32 inch
(81 cm).

4. Wash belt.

Heart rate is 1. HRM treadmil ls too 1. Move the treadmills at

erratic or above close together. least 18 inch (46 cm)
200. apart.

2. Interference from 2. Move the treadmill

electromagneti c signals away from the source
(e.g., other belt trans- of interference .
mitters, T.V., motors,
computers, and such).

Troubleshootin g 3-9
 Problem Possible Cause Remedy

No signal on 1. No electrod e contact 1. Reposition chest belt,

controller re-wet electrod es.

2. Faulty chest belt 2. Test signal using

different belt
transmitter or a pulse
simulator; replace old
belt if faulty.

3. Faulty receiver 3. Test the belt

transmitter using a
different receiver. If
transmitter is working
correctly, replace
receiver.

Testing Heart Rate Accuracy

Use a pulse simulator (P/N 34198-008) and a Polar watch receiver
(P/N 34198-009) to test the accuracy of the controller’s heart 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. 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 retest. If the
problem remains, replace the controller assembly (P/N 34297).

Mechanical Problems
Mechanical problems can include noise and vibration caused by
loose or worn parts. Use the following tables to diagnose
mechanical failures.

Walk Belt
Problem Possible Cause Action

Belt stops and an 1. Heavy runner 1. Do not exceed

overcurrent error code increased the weight envelope
appears. resistance on belt. (see Specifications).

2. Runner holding 2. Do not resist belt for

handrail stopped more than two
belt movement for seconds.
more than two
seconds.

3. Worn deck 3. Turn over or replace

deck.

Troubleshooting 3-10
 Problem Possible Cause Action

Walk belt slipping 1. Improper walk belt 1. Adjust walk belt

tension. tension.

2. Incorrect drive belt 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.

Drive Belt
Problem Possible Cause Action

Squealing sound similar Drive motor belt Adjust drive belt

to an automobile fan (poly-V belt) slipping tension. Replace drive
belt belt if necessary.
— OR —
Walk belt slows when
user’s foot strikes the
deck

Treadmill Noise
Noise Possible Cause Action

Knocking or thumpin g. Front or rear roller Isolate* and replace

Rate increases or (pulley) assembly roller assembly
decreases with walking bearings
belt speed.

Squealing (similar to Drive belt loose Adjust belt tension.

loose automobile fan Replace belt if
belt) necessary.

Popping during grade Faulty elevation chain Adjust alignment of

change alignment sprockets.

* The rate of bearing noise can help determine which bearing is at

fault. The number of knocks per minute varies with treadmill speed

because the roller speeds change as the belt speed changes. Use a

stethoscope with a tube-like end, or a piece of hose about two feet

long, to isolate bearing noise. Hold one end of the hose near the

suspected bearing and the other end near your ear. Compare several

bearings to determine which is the faulty one.

Flow Charts
Use the following flow charts for step-by-step troubleshooting.

Troubleshootin g 3-11
 Error Code Flow Chart: EPHI and EPLO
EPHI EPLO

BUS voltage BUS voltage

is too high too low

Check line Check line

voltage. voltage.

Have customer
get building Yes
Yes maintenance Too low?
Too high ?
to correct
voltage problem.
CAUTION!
No
Disconnect
No power and wait
Yes No for high voltage
Is DS3 On?
indicator to go off.
Replace VSD

Trans-
No former output Connect meter,
< 24.6 VAC THEN power up.
Check transformer
output: J7 pin 9
Yes and 10.

Replace
transformer

BUS Voltage

Troubleshooting 3-12
 Error Code Flow Chart: E001

E001 E002 E206

VSD VSD Micropro- E201 Inadvertant
Microprocessor cessor EPROM/ Grade Error Reset
chip failure RAM failure

Verify grounding
Enter
system is wired
Replace VSD PCBA Service
correctly and is
Mode
intact

E205
E202 Software Calibrate
Speed Error tachometer Pot
fault

Replace grade
Pot and
Error Yes
recalibrate
Persists
Press Power
or Clear
No
Error Yes
Replace
Persists VSD
Error Yes Replace
Persists VSD
Complete No
No

VSD Board

Troubleshootin g 3-13
 Error Code Flow Chart: E204

E204

Communications Check Ds2 on

Error VSD board.

CAUTION!
Verify Disconnect
communication power and wait
cable connection
Ds2 On? No for high voltage
at each end. indicator to go off.
(Micro 5V)

Verify cable pins Yes

Clip a volt meter
Error Yes are not bent or onto F1 and F2
Persists? broken or cable Replace fuse holder base
damaged. controller. closest to J3. THEN
turn on power. Measure
22 VAC secondary.
No

Damaged No Less than Yes

Finished. cable? 17.0 VAC?

No
Yes Error Replace
Yes
persists? transformer.
Replace VSD.
Replace cable.
No

Finished

Communications Link

Troubleshooting 3-14
 Error Code Flow Chart: E203

E203 Error
Overcurrent

CAUTION!
Disconnect
Restrict use to power and wait
Runner
Is motor Yes outside weight/ Yes people within for high voltage
turning? speed envelope specified weight/ indicator to go
speed envelope.
out.
No No
Check for Are Reconnect Check
all motor leads No disconnected resistance
obstructions in
motor pulleys connected? leads. between motor
or belt leads.
Yes
Excessive deck Resistance No
Yes wear indicated. Replace VSD
Worn deck? >100ohms PCBA
Replace deck.

Yes

No
Replace motor.

Motor Overcurrent

Troubleshootin g 3-15
 Cycle power. CAUTION!
Drive motor LED should be Disconnect
does not turn on momentarily power and wait
then off. for high voltage
indicator to go off.

Error Procede to
Yes No
code Error Code On then off? Replace VSD Check
present? Flow Chart resistance
between motor
No Yes leads.

Perform key- Press Start

panel test No Resistance
>100 ohms

Yes
Replace Check motor
Yes Yes leads for good
Key test fail controller Is DS1 on?
assembly connections Replace motor

No No

Check DS1 LED Replace VSD Does No

on VSD board motor turn?
Complete
Yes

Drive Motor

Troubleshooting 3-16
 Treadmill CAUTION! CAUTION!
will not Disconnect Disconnect
elevate power and wait power and wait
for high voltage for high voltage
indicator to go off. indicator to go off.

Proceed to Yes Error code

error code present? Remove grade motor Check limit
flow chart. connector at J2 on switch continuity
No VSD PCB. Place meter between J1 pin
across J2 pin 2 and 4, 1 and 3, then
Perform THEN connect pin 4 and 6.
keypanel treadmill power.
test.
Press the Up, Yes
then the Down Zero ohms? Replace VSD
key on the
Replace controller.
controller Yes
Key test fail No
assembly.
Adjust limit
No DC switches and
No retest.
voltage approx.
Check and free Yes Rack gear 50 VDC?
rack gear. jammed?
Yes
No
Replace fuse F3, 4, Replace grade
and retest. Yes 5, or 6 fuse motor.
blown? No

Grade Problems

Troubleshootin g 3-17
 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. This includes:
• variable speed drive (VSD)
• enhanced display processor control unit (EDPU) used with the
ClubTrack and MedTrack Rehab
• motivational control unit (MCU) used with ClubTrack Plus
• heart rate monitor (HRM) used with HR ClubTrack
This section is designed only for Quinton-authorized service
personnel with proper training. There are no user-serviceable parts
in the treadmills. Any attempt by non-Quinton-trained personnel
to service the treadmill may void the warranty. For service
information, call 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 series treadmills.

Cautions/Warnings
Electrical
• High voltage is present beneath the treadmill hood while the
treadmill is connected to a power source. Residual high
voltage remains for a few minutes after power is removed. To
prevent high-voltage electrical shock:
• unplug the power cord and use caution every time you
remove the hood.
• 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.
• Turn off the circuit breaker on the treadmill before
connecting or disconnecting the treadmill to the wall outlet.
• The controller does not turn off electrical current to the
treadmill.

Repair/Replacement and Calibration 4-1

 • 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.
• Before running the treadmill, check for worn parts which
could break loose during service or operation.
• Keep fingers away from rotating parts.
• To avoid eye contaminants, clean away dust and debris from
moving parts before servicing.
• Beware of sharp edges when replacing worn parts.
• Do not start the walk belt when 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 and flat blade screwdrivers
• Hex socket wrenches: 5 32 -in, 916 -in, 7 16 -in, 1 2 -in, 516 -in
• 11
32 -inch nut driver
• Heyco® strain relief pliers for replacing hard-wired power cord
• 1
2 -inch crowfoot open-end wrench for removing drive motor
• Torque wrench for rack wheel replacement, 46± 4ft-lbs
• Frequency counter
• Tachometer
• Wooden blocks (2" x 4" x 6" long)
• Belt tension calipers P/N 30113-001 (optional)
• Masking tape or heavy pencil
A Although some procedures are used for several applications
(removing the hood, for example), each procedure is explained
only once. Reference procedures under their headings for
subsequent applications.

A All references to front, rear, left, and right are given as though
you were facing the controller while walking on the deck.

Repair/Replacement and Calibration 4-2

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.

Removing Treadmill Hood

1. For your convenience in working, elevate the treadmill 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 around
any electrical or mechanical component under the hood, wait at least
two minutes from the time you unplug the power cord.
International units: Disconnect the power cord from the
configuration plate.
3. Use a Phillips screwdriver to remove the four screws from the
configuration plate.
4. Remove the three ¼-20 Phillips-head screws located under the
label panel on the front of the hood.

Screw - #10-32 x 0.375L (30579-016)

Lock Washer - ext. star #10 (01182-001)

Configuration Plate

¼-20 x 0.50L Screw (10835-205)

Lock Washer Ext. Star ¼ (01182-005)

Repair/Replacement and Calibration 4-3

 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.

Push to
#10 screws remove.
(10835-325)

8. Gently tap the hood a half 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
the treadmill.
A Recommended: Vacuum hood area before replacing hood and
applying power. Be careful near VSD card cage. Do not damage
VSD board.

10. To replace the hood, follow steps 3-9 in reverse order.

Field Functional Test

To verify that the treadmill is operating properly, perform Field
Test No. 1. See Appendix D, Field Functional Tests, for specific
instructions.
Repair/Replacement and Calibration 4-4
 0.625 spacer (30895-001)0.625 spacer (30895-001)

Instruction Panel
0.625 spacer ClubTrack Plus only
(30895-001) (30910-00X)
0.375 spacer
(30895-002)
10-24 x 1.50L
(10830-335)
10-24 x 1.25 black
(10830-315)
Controller
Hood Cover
(32748-001)

Upright

Metal siderail, LH
(32709-003) ClubTrack and MedTrack SR60
(32709-004) MedTrack CR60 Front
Siderail Cover, LH
(19488-002)

Walk Belt
(33509-002)
VSD Card Cage
(32975-002)
Hood
(32744-001)
Siderail Cover, RH
(19489-002)
Metal siderail, RH
(32707-003) ClubTrack and MedTrack SR60
End caps (32707-004) MedTrack CR60
LH (33309-001)
RH (33180-001) Sample treadmill with hood cover removed

Repair/Replacement and Calibration 4-5

 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. (They are located in the
center of the headframe. The ground is marked with a ground
symbol.)
4. Unplug the wires from the VSD board (North American units:
3 wires (115v) or 2 wires (230v)), International units: 2 wires).
Note the wire colors and connection points.
5. Remove the two ¼-20 hex-head screws holding the
configuration plate to the headframe. Do not let the plate fall
into the VSD PCBA.
6. Replace the configuration plate module following Steps 2
through 5 in reverse order.

30579-016 screw
Limit Switch (19082-001) 01192-001
lockwasher
Configuration Plate
North American - 32776-001(115v)
- 32776-005 (230v)
International - 32776-002

¼-20 UNCX 0.50L (10827-205) Step 5 Step 3

Ext. Star Washer (01182-005) 10835-205
screw,¼-20x½
¼-20 x 0.50L (10827-205)
Lock Washer ¼ Ext. Star (01182-005)

Field Functional Test

To verify that the treadmill is operating properly, perform Field
Test No. 2. See Appendix D, Field Functional Tests for specific
instructions.

Repair/Replacement and Calibration 4-6

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.
7. Feed the new cord into the configuration plate and reverse the
procedure by following Steps 4 through 1.
• Twist the power cord leads before connecting.
• Connect the white wire to the bottom connector.

Detachable Cords
(International units): Unplug the power cord from the connector
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 specific
instructions.

Replacing the VSD Board/Card Cage Assembly

The VSD board is installed within the card cage located in front of
the drive motor. The board alone is not field replaceable; you must
remove the card cage/board assembly and replace it with another
card cage module.
1. Turn off the controller and the treadmill circuit breaker, then
unplug the power cord from the power outlet.
2. Remove the 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. Disconnect the controller cable and the groundwire from the
VSD board.
Repair/Replacement and Calibration 4-7
 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. Unplug the non-isolated transformer wires.
8. Unplug the grade potentiometer wires. Clip the plastic ties
around the cage only, not around the headframe.
9. Unplug the limit switch wires.
10. Unplug the drive motor wires.
11. Unplug the configuration plate wires.
12. Remove the two Phillips screws that hold the switch module
plate to the headframe and remove the plate.

Screw 10827-212 with

split washer 10511-007 Hold down plate
Sil pad 33174-002 32963-001
PCBA Card cage
(32975-002),
VSD not shown
VSD Module
Switch Plate Screws
VSD Module Hardware Qty
Config Plate Screws
32963-001 Mounting Plate 1
33174-002
10827-212
Sil Pad Insulator
Screw 10-24x0.50
1
2
Card Cage Screws
10511-007 Split Ring 2
01164-003 Flat Washer 2

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 installing
the new card cage.
16. Reassemble in reverse order.
Use caution when reassembling the hold-down plate for the switching
module. Alternate torquing the screws just until the split lock washer is
compressed. Over-torquing the screws will damage the module.

Field Functional Test

To verify that the treadmill is operating properly, perform Field
Test No. 2. See Appendix D, Field Functional Tests for specific
instructions.

Repair/Replacement and Calibration 4-8

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
Tensioner Large Nut (Step 7) - part
(32784-001) of tensioner
3 -16 x 2.50L Bolt (Step 4)
8
(10820-207)
Split LW (10511-011)
Flat Washer (01164-006)

Poly-V Drive Belt

(32387-001) ClubTrack and SR60
(32387-002) MedTrack CR60

2. Remove the hood as previously described.

3. Use a 916 -inch hex wrench to remove the 3 8 -inch bolt from the
tensioner. Remove and discard the old tensioner.
4. Be sure the belt is centered on the 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 1516 -inch open-end wrench or a large adjustable
wrench to turn the large nut on the tensioner counter-
clockwise; put tension on the poly-V belt until the two lines on
the tensioner line up. Tighten the 3 8 -inch bolt to 19 foot-
pounds torque.
7. Replace the hood.

Field Functional Test

To verify that the treadmill is operating properly, perform the
following functional tests:

Repair/Replacement and Calibration 4-9

 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. Count the number of belt revolutions in 2 minutes. This
should be 155 ± 3 revolutions.

MedTrack® CR60
5. Increase the walk belt speed to 7.2 mph.
6. Count the number of belt revolutions in 2 minutes. This
should be 112 ± 3 revolutions.
If any of the measurements are not accurate, refer to Replacing
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 minimum, walk on the treadmill.
2. Grasp the handrail and resist the motion of the walk belt. If
slippage is detected, determine if the walk belt or poly-V drive
belt is the cause. Correct as necessary.
3. Stop the walk belt.

Shut Down the Treadmill

Turn off the circuit breaker, disconnect the power cord from the
outlet, and place the treadmill back in service.

Replacing the Poly-V Drive Belt

1. Remove the hood as previously described.
The drive belt tensioner is spring loaded. Do not let it snap closed after
removing the drive belt.

2. Loosen the belt tensioner by turning the 3 8 -inch mounting bolt

counter-clockwise, then pivot the tensioner away from the belt.
3. Remove the drive belt from the drive motor pulley.

Repair/Replacement and Calibration 4-10

 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.)

Installing the Front Shaft Retainer

1. Install retainer with bolts moderately tight (180 in/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 described in Replacing the Tensioner.
5. Set the walk belt tension and tracking.

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.

Replacing the Drive Motor

Replace the drive motor when the motor is inoperative: see Drive
Motor flow chart in Chapter 3, Troubleshooting.

Shaft Retainer
15689-002
Front Pulley Assy
33507-002
33507-001 CR60 Transformer Drive motor
32706-001 (32783-002)
Motor junction
box
Flywheel

Tensioner
(32784-001)

Repair/Replacement and Calibration 4-11

 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. Note the arrangement of the isolation mounts.
(You may need to use a ½-inch crowfoot, open-end wrench to
remove the inner bolt near the card cage.)
7. Pull the motor off the headframe.
8. Loosen the two set screws on the flywheel/drive pulley and
remove. Use a gear puller to pull the flywheel off the motor
shaft.

Flywheel Assembly
32446-001 - ClubTrack and SR60
32446-003 - CR60
¼-20 x 0.25L Set Screws
(10833-145)
Key 01100-002

9. Reinstall the 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 installing new motor mounting nuts.
Tighten the motor mounting nuts until the lock washer flattens, then turn
the nut ½ turn. Do not overtighten the nut.

The new motor and flywheel assembly must be aligned with

the front roller drive pulley. Use a straight-edged ruler placed
on the outside of the front roller drive pulley to align the
outside face of the motor drive pulley to within 0.020 inch.
Tighten the set screws.
11. Replace the poly-V belt as previously described.
12. Replace the hood assembly as previously described.

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.

Repair/Replacement and Calibration 4-12

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. Cut the plastic cable ties
that secure the transformer wiring.
4. Remove the Phillips-head screws that hold the transformer to
the headframe.
Transformer (32706-001)

Four Phillips screws

Two-sided Wiring One-sided Wiring secure the transformer.

5. Discard the old transformer. Replace with new one in reverse

order.
A Wire routing depends upon the transformer you are installing
(see figures above).

6. Replace the hood assembly as previously described.

Field Functional Test

To verify that the treadmill is operating properly, perform Field
Test No. 2. See Appendix D, Field Functional Tests, for specific
instructions.

Repair/Replacement and Calibration 4-13

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. Remove 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. Restore power to the treadmill and test the new grade motor.
High voltage is present when the treadmill is plugged into a power source.
Secure loose hair, clothing, and jewelry before working near rotating
machinery.
Verify that:
a. it operates over the full range of 0-15%.
b. there is no binding when it moves up or down.

Grade Motor
(33316-002)

Grade Motor Bolts

¼-20 x 1.25L (10820-105)
Flat Washer (01164-004)
Kep Nut ¼-20, far side (30578-005)

Repair/Replacement and Calibration 4-14

 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. (If the link is inaccessable, you will have to remove
the motor.)
3. Slide out the link.
4. Install the new chain, aligning it correctly on the sprockets.

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.

Repair/Replacement and Calibration 4-15

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. 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 the grade pot, wires, and setscrews are in place,
calibrate the pot (see Calibration Procedures, page 4-33).

Grade Pot Wires

At the end of each grade pot wire is a pin with a small metal
flange. The flange has a corresponding slot on the connector
housing.

Repair/Replacement and Calibration 4-16

 1. Insert each pin into the connector housing until it clicks
slightly. The flanges will be visible through the slots in the
housing.
Red wire: slot 4

BRN OR WHT
Black wire: slot 5

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. See Appendix D, Field Functional Tests, for specific
instructions.

Removing the Rack Gears

1. If the treadmill will change grade, set the grade to 12% (6-7°).
2. Lower the front of the 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 is jammed (no play in it), replace as described
in Replacing a Jammed Rack Gear, page 4-19.
6. Restore power to the treadmill and decrease grade until the
wheels are approximately half inch off the floor.
7. Remove the two 916 - inch hex-head bolts holding the wheels to
the rack gears. Note the arrangement of washers used as
spacers.
8. Loosen the setscrew that holds the grade potentiometer (pot)
gear and remove the gear.
9. Rotate the grade pot until a positive number appears in the
grade display window. (Step 11 will not work until the number
is positive.)

Repair/Replacement and Calibration 4-17

 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.
A While in open loop mode, the treadmill takes about two
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 display. Decrease
grade until rack gears start bouncing on the pinion shaft.
12. Turn off the treadmill circuit breaker, then unplug the
treadmill.
13. Lift rack gears straight out top.

Rack Gear
(032524-002) Rack Gear

3/8 x 16 x 2.50L
Bolts (10820-207)

Reassembling the Rack Gears

A Install new rack gears simultaneously so that they will be parallel.

1. Restore power to the treadmill.

2. Enter open-loop grade mode as described above.
3. Insert the racks gears into the headframe.

Repair/Replacement and Calibration 4-18

 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. Run the rack gears down until there is enough room to replace
wheels.
8. Replace the two bolts that hold the wheels to the rack gears.
Be sure to:
a. replace washers used as spacers in the correct arrangement.
b. Install wheel bolts in the proper holes.

Use top hole for

SR60, ClubTrack,
ClubTrack Plus, and
HR treadmills.

Use bottom
hole for CR60.
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 gears with wheel bearing grease.
12. Remove the blocks that support the headframe.
13. Reinstall the grade pot gear.
14. Calibrate the grade potentiometer.

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 a Jammed Rack Gear

1. Turn off the treadmill circuit breaker and unplug treadmill.
2. Remove the hood as previously described.
3. Securely block the headframe with wooden blocks to take the
weight off the wheels.

Repair/Replacement and Calibration 4-19

 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. Carefully lower the upright assembly onto the walk deck.
c. Disconnect the controller cable and the ground wire from
the VSD board.
d. Use a 316 - inch Allen wrench to remove both pivot bolts
from the two upright assemblies, then remove the
assembly.
7. Remove the treadmill walk belt and deck as previously
described.
8. Use a 916 - inch socket wrench with a 6 inch extension to
remove the 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 closest to that gear.

9. Remove the grade pot gear. Remove the four bolts that hold
the rack gear cover plate in place and move it out of the way.
10. Slide the rack gear out sideways.
11. Inspect the gear on the pinion shaft. If it is damaged, replace
both the rack gear and the pinion shaft as described below.
12. Bolt the rack gear cover plate back into place.
13. Reassemble the siderails, upright assembly, and walk belt.
14. Restore power and decrease the grade to run the other rack
gear out the top as previously described.
15. Reassemble the rack gear as described above.

Repair/Replacement and Calibration 4-20

 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.

Replacing the Pinion Shaft

1. Remove the right siderail, then remove the rack gear as
previously described in Replacing a Jammed Rack Gear.

Pinion Shaft
(13044-001)

2. Restore treadmill power, then use the grade motor to turn the
pinion shaft until the setscrew on the grade sprocket is visible.
3. Turn off the power and treadmill circuit breaker, then unplug
the treadmill.
4. Loosen the setscrews from the grade sprocket.
5. Remove the grade motor chain as described previously.
6. Slide the pinion shaft out.
7. Slide the new pinion shaft into place: be sure to reinstall the
grade sprocket while installing the pinion shaft.
8. Replace the rack gear cover plate.

Repair/Replacement and Calibration 4-21

 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. 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.

Adjusting the Grade Limit Switches

Grade limit switches prevent the treadmill from exceeding the
preset maximum grade. 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, are mounted on brackets
attached to the front of the headframe.
A Grade limit switch settings are preset at the factory and normally
do not require adjustment. They should be adjusted if the rack
gear is changed.

1. Turn off the treadmill circuit breaker, then unplug the power
cord from the power source. Remove the hood as previously
described.
2. Loosen, but do not remove, the two Phillips screws that secure
each grade limit switch to its bracket.
3. Pivot the switch on the upper screw toward then away from
the rack gear. You should hear a click as the switch opens or
closes.
4. Set the switch wheel on a flat part of the rack gear, then pivot
the switch toward the rack gear just until it stops. Tighten
both screws.
5. If required, repeat Steps 2-4 for the other grade limit switch.
6. Replace the treadmill hood.
Repair/Replacement and Calibration 4-22
 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

5/16-18 x 0.75L (10819-246)

Flat Washer (01164-005)
Lock Washer (10511-010)
Siderail Retainer (15689-002)
cover
Phillips screws holding removed
deck to siderails (10 PL)
¼-20 x 1.25L (10836-105)

Walk belt removed for clarity

Rear screws (2 PL)
¼-20 x 2.25L (10836-185)
Rear roller Front roller
(19138-002) (32386-002) ClubTrack, ClubTrack Plus, HR
ClubTrack, and MedTrack SR60
Adjustment bolt (32386-001) MedTrack CR60
5/16-18 x 3.0L (10820-366)
Flat Washer (19409-006) Side rail cover
End cap

Replacing the Rollers

1. Turn off the treadmill circuit breaker and unplug the power
cord. Remove the hood as previously described.
2. Remove the poly-V belt as described previously.
3. Lift the drive roller assembly out from under the walk belt.
4. Pull the walk belt towards the rear of the deck, then slide the
rear roller assembly out from between 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. Adjust the walk belt tension and tracking.

Repair/Replacement and Calibration 4-23

 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. Turn off the power,
unplug the power cord, and remove the hood as previously
described.
2. Remove the front and rear roller assemblies (see previous).
3. Remove the two Phillips screws from the siderails. These
screws attach the hood 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. Grasp the left siderail cover at the rear of the treadmill, then
pull it up and away from the treadmill to roll the cover off.
Repeat for the right cover.
5. Remove the 12 screws that hold the deck to the siderails.
6. Remove the deck and belt.
7. Install a new belt with the logo side up, and reassemble the
treadmill following Steps 1-6 in reverse order.
A When you install a new belt, verify that the closed end of the
splice on the walk belt hits the roller first as the belt rotates.

8. Adjust the belt tracking and tension.

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.

Repair/Replacement and Calibration 4-24

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.

S L
L S L
S
L S L

S = Short Mounts (32235-002)

L = Long Mounts (32235-001)
Aluminum spacer
(32240-001)

3. Unscrew the mounts from each siderail and replace.

4. Replace the deck as previously described.
(Triple Flex 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.

Replacing the Deck

A The deck is reversible. You can turn it over if one side wears out.

Follow Steps 1-7 in the previous section, Replacing the Walk

Belt, to remove and replace the deck.

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.

Repair/Replacement and Calibration 4-25

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.
A Do not stretch the walk belt at this point.

2. Position one caliper on each side of the belt, approximately

18 inches from the rear roller assembly.
3. Grasp the belt with one caliper clamp.
4. Pull the slack out of the belt with your fingers, then grasp the
belt with the second clamp.
5. Repeat Steps 3 and 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 that the pointer
is exactly on the line increment of the dial for each setting.
Do not overtighten the adjustment screws. Overtightening may damage
the walk belt and roller assemblies.

8. Remove both gauges.

9. Adjust the walk belt tracking.

Method 2 (Calipers not available)

A Both adjustment screws must be completely slack before
starting this procedure.

Use this method only if two belt adjustment calipers are not
available. An accurate measuring device is required.
1. Turn both tension adjustment screws clockwise until most of
the slack is removed from the belt. Do not stretch the walk belt.
2. Place two pieces of masking tape or two light pencil marks on
the right edge of the belt exactly 50.000 inch apart.
3. Repeat Step 2 on the left edge of the belt.
Repair/Replacement and Calibration 4-26
 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.
Do not stand on the belt when adjusting the tracking.

1. Adjust the walk belt tension as described on the previous page.

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 adjustment screw
only:
a. If the belt moves to the right, turn the screw ¼ turn
clockwise.
b. If the belt moves to the left, turn the screw ¼ turn
counter-clockwise.
3. Run the treadmill for at least one minute to observe the belt
tracking. Adjustments may take some time to become apparent.
4. Repeat Steps 3 and 4 as required.
Do not overtighten the adjustment screw. Overtightening may damage
the walk belt and assemblies.

5. Increase the speed to 8 mph, then repeat Steps 3 and 4 as

required.
6. Press Stop Belt to stop the treadmill, then press Power to turn
it off.

Repair/Replacement and Calibration 4-27

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. Turn the treadmill power off and disconnect the power cord
from the power source.
2. Remove optional siderails if present.
While performing Steps 2-7, hold the enclosure securely, so that it does
not fall while you are removing the screws and the handrail. Be careful
not to scratch the uprights.
3. Use a 18 -inch Allen wrench to remove the six socket screws
from the rear cover of the enclosure.

Socket screw on enclosure, Interface Connector,

10-24 x 0.50L (10829-405) HR ClubTrack Plus
Flat Washer (19409-003) only

4. Use a 316 -inch Allen wrench to remove the two socket screws
near the handrail
5. Slide the cover down the uprights to expose the PCBA.
6. Disconnect the controller cable, located on the left side of the
PCBA.
7. Remove the hex nut that holds the ground wires to the
chassis, then remove the wire.
8. Cut the cable tie that holds the cable to the controller.
9. Use a 5 32 -inch Allen wrench to remove the four socket-head
screws that attach the controller assembly to each upright.
10. Lift the entire controller assembly clear of the uprights.
11. Reassemble following Steps 2-9 in reverse order.

Repair/Replacement and Calibration 4-28

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. Slide the rear cover down the uprights.
6. Remove the hex nut that attaches the PCBA groundwire, then
remove the wire.
7. Unplug the control 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 to the LCD display. Disengage
the connector from the cable by sliding the outer connector
housing away from the PCB. The housing will slide
approximately 1/8 inch, then stop. Once the housing is in
this position, the cable should extract without any
resistance.
b. Disconnect the fluorescent tube wires from the PCBA.
8. Remove the 12 Phillips screws that hold the PCBA to the key
panel.

9. Lower the PCBA, then unplug the ribbon cable connecting it to

the key panel.
10. Remove the PCBA from the enclosure.
11. Replace the PCBA and reassemble following Steps 3-8 in
reverse order.

Repair/Replacement and Calibration 4-29

 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. See Appendix D, Field Functional Tests, for specific
instructions.

Replacing the HR Receiver Assembly

1. Follow Steps 1 through 5 in Replacing the PCBA.
2. Unplug the receiver assembly from the controller assembly.

Connector for
HR ClubTrack Plus
000425 Connector for
HR ClubTrack 00402
Orient HR receiver as shown.

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 controller assembly.

Field Functional Test

To test for proper heart rate monitoring operation, follow the
instructions in Testing Heart Rate Accuracy, Chapter 3
Troubleshooting.

Configuring the Controller

When you replace a controller, you must configure it to work with
the specific treadmill.
Perform the following Steps to configure the treadmill.
1. Enter the service mode by simultaneously pressing Stop Belt,
Slower , and Faster .
2. Choose the appropriate configuration number from the
following:

Repair/Replacement and Calibration 4-30

 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.
(For the HR ClubTrack Plus, select the Set Screen Contrast
screen and use the contrast up and down buttons to select the
optimum contrast. Select Enter to save the value.)
5. Exit the service mode by simultaneously 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
instructions.

Removing the Keypanel

To remove the keypanel:
1. Remove the PCBA following the above procedure.
2. Remove the 10 hex nuts that hold the keypanel to the
enclosure.
3. Lift the keypanel off the enclosure.

Replacing the Controller Cable

1. Disconnect the power and remove the hood as previously
described.
2. Remove the controller assembly as previously described
3. Cut any cable ties that fasten the controller cable to the
headframe.
4. Detach the cable ground wire at the VSD board.
5. Pull the cable up through the left upright to remove it.
6. Install a new cable following Steps 1-5 in reverse order.

Repair/Replacement and Calibration 4-31

 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).
A The cumulative time and distance are stored in the controller.
Both values are zero if a new controller is installed. Loading a
factory default program will reset the time and distance to zero.

Distance
To determine the total distance on each treadmill:
1. Press Power to turn on the treadmill controller.
2. Simultaneously press Stop and Slower.
3. Multiply the number that appears in the multifunction 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 total time of treadmill use:
1. Press Power to turn on the treadmill controller.
2. Simultaneously press Stop and Faster.
3. Multiply the number that appears in the center display by 10
to obtain the total number of hours of operation.
4. Record the total time and the date for your records.
5. Press Clear to reset the display for operation.

For HR ClubTrack Plus Treadmills only

A In the HR ClubTrack Plus, total time, total distance, and current
distance are calculated and saved in the HRC; therefore, any
controller replacement restarts the maintenance counters. Total
time and distance are saved into non-volatile memory every
time the stop belt function is activated.

To view cumulated time and distance, enter custom mode and

select Maintenance Information. The screen shows the cumulated
time and distance.

Repair/Replacement and Calibration 4-32

 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. Simultaneously press and hold the +, —, and Power keys
until the 8s on the display go off, then release the keys.
The control remains inactive, allowing unrestricted access, until
you place the key over the logo again.

Calibration Procedures

Grade Potentiometer (Grade Pot)

Calibrate the grade pot whenever 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
pot shaft.
3. Restore power to the treadmill. Maintain caution when
working near moving parts.
A In order to enter open loop mode, grade must be positive.

4. 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.
A While in open loop mode, the treadmill takes approximately
two seconds to react to a command.

Repair/Replacement and Calibration 4-33

 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. Verify that the treadmill operates through its full grade range
(0-15%) and that 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 speed of the belt can be checked for accuracy. The display and
control are digitally controlled and cannot be adjusted. See Step E
of the Complete Field Functional Test in Appendix D, Functional
Field Tests.

Grade Calibration
The treadmill grade is controlled through the grade pot and grade
pot installation procedure and cannot be adjusted. See Step D of
the Complete Field Functional Test in Appendix D, Functional Field
Tests.

Repair/Replacement and Calibration 4-34

 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.

Recommended Service
With normal upkeep, no routine service is 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 belt; be sure it is not rubbing

against the frame. The belt should be centered on the deck
within 0.25 inch; adjust if necessary.

• Check optional siderails to be sure they are fastened securely.

• Remove potential hazards from the treadmill area.

Cleaning the Exterior

Follow these steps to clean the treadmill after servicing or as
required:

1. Elevate the treadmill to maximum height and vacuum the floor

under it to prevent excess dust and dirt from interfering with
operation.

Preventive Maintenance 5-1

 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.

Vacuuming Under the Treadmill Hood

Accumulation of dust and dirt beneath the hood restricts the air
flow needed to disipate heat from the drive motor and VSD board.
To prevent damage to components, periodically vacuum the
mechanical drive and the area behind the VSD board.

Frequency
Usage and environment determine how much dust accumulates
and how frequently you need to vacuum the components. Inspect
the internal 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 removing the hood. Before working near
components, wait at least two minutes from the time you unplugged the
power cord. Be sure the red LEDs on the VSD board are off.

Use extreme caution to avoid physical damage to the internal

components. Avoid static discharge, which can damage the electronic
components.

1. Remove the hood as previously described (pg 4-3).

2. Vacuum the areas behind the VSD cage (deck side). Do not
vacuum the VSD board.

3. Replace the hood.

Replacement Schedules
Replace belts if they are frayed or show excessive wear.

Heart Rate Monitoring Option

Cleaning
dry
Clean the chest belt regularly with mild soap and water, then
thoroughly—residual sweat and moisture keep the transmitter
active and drain the battery in the transmitter. Do not use

Preventive Maintenance 5-2

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.

Preventive Maintenance 5-3

 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.

• To avoid potential safety and electrical problems, use parts

and accessories that meet Quinton specifications.

• This equipment is classified Class I, Type B, ordinary

equipment. Not protected against fluid ingress. Rated for
continuous operation.

• 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 the circuit.

• Failure to follow these guidelines can produce a serious or

possibly fatal electrical shock hazard or other serious
injury. Consult a qualified electrician as required.

A Continuous A-weighted sound measurements taken over the

speed range of an unloaded ClubTrack treadmill are less than
70dB(A).

For systems to be used in the U.S.: The American standard for

chassis leakage current of electromedical apparatus when
measured by interruption of the power ground (earth)
conductor is 300mA. The current ANSI standard, ANSI/AAMI
ES1-1993, contains the limits. The standard is also shown in the

i lkg
10KΩ ± 1%
0.015µF
1KΩ ± 5%
± 1%
100Ω
V

i lkg
± 1%

AAMI Standard test load (1mV=1uA)

Safety Requirements A-1

 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.

Attention: Earth ground (protective)

Consult
accompanying
docume nts

Off (power Type B equipment provides

disconne cted adequate protection against
from mains) electric shock, particularly
regarding allowable leakage
current; reliability of the protective
earth connection (when present)

On (power Type BF equipment contains an

connecte d to F-type isolated patient applied
mains) part providin g a high degree of
protection against electric shock

Alternating Type BF equipment with

current defibrillation protection

High voltage Type CF equipment: contains an

F-type isolated patient appliedpart
and provides a degree of protection
against electric shock higher than
that for type BF equipment re-
garding allowable leakage currents

Earth ground Type CF equipment with

(functional ) defibrillation protection

Replace fuse Fuse

only as
marked

Mains Power Equipotentiality

Warning
T Timed fuse (slo-blo)

HZ Hertz
V Volts

A Ampere s
VA Volt Amperes

Safety Requirements A-2

 B
Specifications

ClubTrack®(00377, 00402) and MedTrack® Rehabilitation

Treadmills (00380, 00390)
PERFORMANC E

Maximum Rated Load ClubTrack & MedTrack SR: 320 lb (145 kg)
MedTrack CR: 400 lb (181.4 kg)
Belt Speed Range: ± 0.2 mph ClubTrack & MedTrack SR: 1.0 to 12 mph (1.6 to 19.3 km/h)
(continuously adjustable) MedTrack CR: 0.6 to 7.2 mph (1.0 to 11.6 km/h)
Rate of speed change Acceleration: ClubTrack & MedTrack SR: 1.0 to 12 mph in 35 secs
MedTrack CR: 0.6 to 7.2 mph in 35 secs
Grade range ± 0.5% 0 to 15%
Rate of grade change Club Track & MedTrack SR: 0 to 15% in 60 secs max with 320 lb user
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 31 in. x 87.25 in. x 53 in. (78.7 cm x 221.6 cm x 134.6 cm)
width x length x height For MedTrack CR 60, add 0.5 in. (1.27 cm) to ht
Walking surface height from 6.0 in. (15.24 cm) For MedTrack CR 60, add 0.5 in. (1.27 cm)
floor
Handrail height from walking 39 in. (99 cm)
surface
ENVIRONMENT AL

Temperature Operating: 50 to 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, 445 to 775 mm Hg absolute
Shipping & storage: 8.22 to 15.0 psia, 425 to 775 mm Hg absolute

Specifications B-1
POWER REQUIREMENT S

Dash Number Voltage/H z Current Min. Branch

Draw in Circuit Amps
Amps

ClubTrack - P/N 00377

-001 99 - 132V, 60Hz 20* 20

-002 through -006 198 - 250V, 50/60Hz 10 10
-007 90 - 132V, 50/60 Hz 20 20
-008 180 - 250V, 50/60Hz 10 10
-009 198 - 250V, 60Hz 10* 15
MedTrack CR - P/N 00380
MedTrack SR - P/N 00390

-001 99 - 132V, 60Hz 20* 20

-002 through -006 198 - 250V, 50/60Hz 10 10
-007 90 - 132V, 50/60 Hz 20 20
-008 180 - 250V, 50/60 Hz 10 10
-009 198 - 250V, 60Hz 10* 15
HR ClubTrack - P/N 00402

-001 99 - 132V, 60 Hz 20* 20

-002 through -006 198 - 250V, 50/60 Hz 10 10
-007 90 - 110V, 50/60 Hz 20 20
-008 180 - 250V, 50/60 Hz 10 10
-009 198 - 250V, 60Hz 10* 15
*Full-load current 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

SPEED 3-digit display
Units Miles per hour (mph) or kilometers per hour (km/h)
Range ClubTrack and MedTrack SR: 0 to 12 mph (0 to 19.3 km/h)
MedTrack CR: 0 to 7.2 mph (0 to 11.6 km/h)
Increment 0.1 mph
Rate of change Two increments (or decrements) per second for the first three
seconds, five per second thereafter until you either release the key or
reach the high/low limit.
Accuracy Within ± 0.2 mph (0.3 km/h) of actual speed during unchanging
operation, 1 mph (1.k km/h) during speed decrease. Shows target, not
actual, speed during speed changes.
GRADE 3-digit display
Units percent
Range 0 to 15%
Increment 0.5%
Specifications B-2
Rate of change Two increments (or decrements) per second for the first three
seconds, five per second thereafter until you either release the key or
reach the high/low limit.
Accuracy Within ± 0.5% actual grade during unchanging operation
4-digit display. Displays exercise parameters, weight, and error
messages
Multi-function Display

Elapsed time or countdown Units: min:sec

timer Range: 00:00 to 99:59
Increment: 00:01
Elapsed distance Units: miles or kilometers
Range: 0 99.9 miles or kilometers
Increment: 0.001 from 0 to 9.999 mi or km,
0.01 from 10.00 to 99.99 mi or km
Pace Units: minutes:second per mile or minutes:second per kilometer
ClubTrack range: 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
“-.-”
Calories Total calories expended
Units: calories
Range: 0.001 to 999.9
Increment: 0.001 from 0 to 9.999;
0.01 from 10 to 99.99;
0.1 from 100 to 999.9
Caloric rate Caloric rate expenditure
Units: calories/min
Range: 0.001 999.9
Increment: 0.001 from 0 to 9.999;
0.01 from 10 99.99;
0.1 from 100 to 999.9
METS Units: METS
Range: 1.000 to 31.62
Increment: 0.001 from 1 to 9.999; 0.01 from 10.00 to 31.62
Heart rate (option) Units: beats per minute
Range: 50-225
Increment: 1
Scan Cycles through parameters, displaying each sequentially for 3 sec
Weight Default: 150 lb to 68 kg
Minimum: 30 lb or 13 kg
Maximum: 400 lb (181 kg)
Increment: 1 lb or 1 kg

Specifications B-3
ClubTrack Plus® Treadmills (P/N 00382, 00425)
PERFORMANC E

Maximum rated load 320 lb (145 kg)

Belt speed range (continuously 1.0 to 12 mph (1.6 to 19.3 k/h)
adjustable)
Grade range 0 to 15%
PHYSICAL

Weight 400 lb (181.4 kg)

Nominal walking surface 20 in. x 60 in. (51 cm x 150 cm)
Treadmill dimensions 31 in. x 87.25 in. x 53 in. (78.7 cm x 221.6 cm x 134.6 cm)
width x length x height
Walking surface height from 6.0 in. 15.24 cm)
floor
Handrail height from walking 39 in. (99 cm)
surface
ENVIRONMENT AL

Temperature Operating: 50 to 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
Shipping & storage: 8.22 to 15.0 psia, 425 to 775 mm Hg absolute
POWER REQUIREMENT S

Part number Voltage/Hz Current Draw in Min Branch Circuit

00382- Amps Amps

-001 99 - 132V, 60 Hz 20* 20

-002 through -006 198 - 250V, 50/60 Hz 10 10
-007 90 - 132V, 50/60 Hz 20 20
-008 180 - 250V, 50/60 Hz 10 10
-009 198 - 250V, 60Hz 10* 15
*Full-load current is computed as described in section 430-24 of the National Electrical Code.
FUSE RATINGS

F1 and F2 250VAC, 4A T, 5 x 20 mm (nominal)

F3, F4, F5, F6 250VAC, 2A T, 5 x 20 mm (nominal)

Specifications B-4
ClubTrack Plus®Controller (P/N 00382)
SPEED (3-digit display)
Units Miles per hour (mph) or kilometers per hour (km/h)
Range 1 to 12 mph, 1.6 to 19.3 km/h
Increment 0.1 mph
Accuracy Within ± 0.2 mph (0.32 km/h) of actual speed during unchanging
operation, 1 mph (1.6 km/h) during speed decrease. Shows target, not
actual, speed during speed changes.
GRADE 3-digit display
Units percent
Range 0 to 15%
Increment 0.5%
Accuracy Within ± 0.5% actual grade during unchanging operation
Four-digit display. Displays exercise parameters, weight, digital timer,
and error messages
MULTI-FUNCTION DISPLAY

Elapsed time or countdown Units: min:sec

timer Range: 00:00 to 99:59
Increment: 00:01
Exercise time 0:00 to 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 99.99 miles or kilometers
Pace Units: minutes:seconds per mile or minutes:seconds per kilometer
Range: 5:00 to 60:00 minutes:seconds per mile
(3:07 to 37.16 min:sec/km)
Increment: 00:01
Zero speed; when walk belt speed is zero, the pace display indicates
“-.-”
Calories Total calories expended or caloric rate expenditure
Units: calories or calories/min
Range: 0.001 to 999.9
Increment: 0.001 from 0 to 9.999; 0.01 from 10 to 99.99; 0.1 from
100 to 999.9
Caloric rate 0.001 to 999.9 cal/min
METS 1.000 to 31.62
Increment: 0.001 from 1 to 9.999; 0.01 from 10.00 to 31.62
Weight Default: 150 lb or 68 kg
Minimum: 30 lb or 13 kg
Maximum: 400 lb or 181 kg
Increment: 1 lb or 1 kg

Specifications B-5
HR ClubTrack Plus™ with Heart Rate Control (P/N 00425)
SPEED (3-digit display)
Units Miles per hour (mph) or kilometers per hour (km/h)
Range 0 to 12 mph, 0 to 19.3 km/h
Increment 0.1 mph, 0.16 km/h
Accuracy Within ± 0.2 mph (0.32 km/h) of actual speed during unchanging operation,
1 mph (1.6 km/h) during speed decrease. Shows target, not actual, speed
during speed changes.
GRADE 3-digit display
Units percent
Range 0 to 15%
Increment 0.5%
Accuracy Within ± 0.5% actual grade during unchanging operation
4.75 in. x 3.61 in. area, 320 x 240 pixels resolution. Displays user prompts,
graphs, weight, time, exercise parameters and stages, and error messages
LCD DISPLAY

Time Units: min:sec

Range: 00:00 to 99:59
Increment: 00:01
Elapsed distance Units: miles or kilometers
Range: 0 to 99.9 miles or kilometers
Increment: 0.001 from 0 to 9.999 mi or km;
0.01 from 10.00 to 99.99 mi 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 display indicates “-.-”
Calories Total calories expended or caloric rate expenditure Units: calories or
calories/min
Range: 0.001 to 999.9
Increment: 0.001 from 0 to 9.999;
0.01 from 10 to 99.99;
0.1 from 100 to 999.9
Caloric rate 0.001 to 999.9 cal/min
METS Range: 0.001 to 999.9
Increment: 0.001 from 1 to 9.999;
01 from 10.00 to 99.99
0.1 from 100 to 999.9
Heart rate Units: beats per minute (BPM)
Range: 50-200, Increment: 1 BPM
Enter Weight Default: 150 lb or 68 kg
Minimum: 30 lb or 13 kg
Maximum: 400 lb or 181 kg
Increment: 1 lb or 1 kg
Enter Target Heart Default: 140 beats per minute (BPM)
Rate Minimum: 80 BPM
Maximum: 200 BPM
Increment: 1 BPM
Enter Exercise Time Default: 20 min
Minimum: 7 min
Maximum: —:— (no limit or owner-set maximum) Increment: 1 min
Serial interface RS-232 interface, complies with CSAFE standards for external commuications.

Specifications B-6
Percent vs Angle Relationship for Treadmill Grade

Rise
θ
Run
Rise Rise
Grade = tan θ =
Run Run
Grade = tan θ θ = arctan(Grade)

(Note: 15% Grade Grade = 0.15)

Grade Angle (°) Grade Angle (°) Grade Angle (°)

0.0% 0.00 5.0% 2.86 10.0% 5.71
0.5% 0.29 5.5% 3.15 10.5% 5.99
1.0% 0.57 6.0% 3.43 11.0% 6.28
1.5% 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 8.0% 4.57 13.0% 7.41
3.5% 2.00 8.5% 4.86 13.5% 7.69
4.0% 2.29 9.0% 5.14 14.0% 7.97
4.5% 2.58 9.5% 5.43 14.5% 8.25
5.0% 2.86 10.0% 5.71 15.0% 8.53

Specifications B-7
 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. 009
198 - 250V, 60 Hz, 10A
English U.K. 002
198 -250V, 50/60 Hz, 10A
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, 50/60 Hz, 10A 006
Japanese, 90 - 132V, 50/60 Hz, 20A 007
Japanese, 180 - 250V, 50/60 Hz, 10A 008

Operator and Service Manuals

Part No. Description

00377-84x ClubTrack /HR ClubTrack User’s Guide

00382-84x ClubTrack Plus User’s Guide
00425-84x HR ClubTrack Plus User’s Guide
00380-84x MedTrack Rehabilitation Treadmills
Operator Manual (Covers both CR60
and SR60)
00377-83x Service Manual (English language only)
(x signifies the number of the latest revision.)

Part Numbers C-1

Spares ELECTRIC AL

Power Cord
North America 30610-004
Japan 100V 30610-004
U.K 30736-012
Germany 30736-015
France 30736-015
Spain 30736-015
Italy 30736-013
Japan 200V 30736-020
Strain Relief 01227-006
Configuration Plate
North America 32776-001
International 32776-002
PCBA Assy, Drive 32975-002
DRIVE

Drive Motor Assy 32783-002

Drive Motor Isolation Kit 33503-001
Flywheel Assembly 32446-001 (-003 CR60)
Drive Belt 32387-001 (-002 CR60)
Tensioner Assembly 32784-001
Transformer Assembly 32706-001
GRADE

Grade Motor 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 33508-002
Walkbelt 33509-002
Triple Flex Maintenance Kit 33511-001
Siderail Cover, right 19488-002
Siderail Cover, left 19489-002
End Cap, Front Left 19306-001
End Cap, Front Right 19306-002
End Cap, Rear Left 19057-002
End Cap, Rear Right 19058-002
Left Handrail Kit 30005-004
Right Handrail Kit 30005-005
Left and Right Handrail Kit 30005-006
Weldment Side Rail, right 32707-003 (-004 CR60)
Weldment Side Rail, left 32709-003 (-004 CR60)
HARDWARE

Spare Hardware 33372-001

Magnet 19296-001

Part Numbers C-2

Controllers
ClubTrack® P/N 00377
PCBA 33518-001
Keypanel
English 33504-001
German 33504-003
French 33504-005
Italian 33504-007
Spanish 33504-009
Japanese 33504-011
Controller Assy (PCBA & keypanel)
English 034506-001
German 034506-003
French 034506-005
Italian 034506-007
Spanish 034506-009
Japanese 034506-011
HR ClubTrack™ with Heart Rate Monitoring (HRM) P/N 00402
PCBA 34296-001
Keypanel
English 34298-001
German 34298-002
French 34298-003
Italian 34298-004
Spanish 34298-005
Japanese 34298-006
Controller Assy (PCBA, keypanel, & receiver)
English 34297-001
German 34297-002
French 34297-003
Italian 34297-004
Spanish 34297-005
Japanese 34297-006
Receiver Assy 34295-001
HRM Upgrade Kit (Convert ClubTrack to HR ClubTrack with HRM)
English 34299-001
German 34299-002
French 34299-003
Italian 34299-004
Spanish 34299-005
Japanese 34299-006
ClubTrack Plus® Upgrade Kit (Convert ClubTrack to ClubTrack Plus)
English, U.S.A. 34328-001
English, International 34328-002
German 34328-003
French 34328-004
Italian 34328-005
Spanish 34328-006
Japanese 34328-007

Part Numbers C-3

MedTrack® CR60 P/N 00380 & SR60 P/N 00390
PCBA 33518-001
Keypanel
English 33504-002
German 33504-004
French 33504-006
Italian 33504-008
Spanish 3 3504-010
Japanese 33504-012
Controller Assy (PCBA & keypanel)
English 34506-002
German 34506-004
French 34506-006
Italian 34506-008
Spanish 34506-010
Japanese 34506-012
ClubTrack Plus® P/N 00382
PCBA 33519-002
Keypanel
English 33505-001
German 33505-002
French 33505-003
Italian 33505-004
Spanish 33505-005
Japanese 33505-006
Controller Assy (PCBA & keypanel)
English 034505-001
German 034505-002
French 034505-003
Italian 034505-004
Spanish 034505-005
Japanese 034505-006
HR ClubTrack Plus™ with Heart Rate Control P/N 00425
PCBA 35452
Keypanel Assy
English 35260-001
German 35260-002
French 35260-003*
Italian 35260-004*
Spanish 35260-005
Japanese 35260-006*
Controller Assy (PCBA, keypanel, & receiver)
English 35258-001
German 35258-002
French 35258-003*
Italian 35258-004*
Spanish 35258-005
Japanese 35258-006*
Receiver Assy 34295-001
Interface Cable RS-232 34721-001
Liquid Crystal Display (LCD) 35259-001
Fluorescent Tube (Backlight Assy) 35428-001

Part Numbers C-4

HR ClubTrack Plus™ Upgrade Kit (Convert any Hyperdrive™ treadmill to HR ClubTrack Plus)
English, U.S.A. 35371-001
German 35371-002
French 35371-003*
Italian 35371-004*
Spanish 35371-005
Japanese 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 Wrist Monitor 34198-009

A To avoid potential safety and electrical problems, use parts and accessories that
meet Quinton specifications.

Part Numbers C-5

 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. You may perform the complete
test, or only the tests required after repair or replacement of parts
as specified in Chapter 4, Repair/ Replacement and Calibration.
Please read the entire chapter before starting. The appropriate test
must be performed as verification whenever any of the procedures
in Chapter 4 are used.

Complete Field Functional Test

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. 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).
• Normal display is shown (00 150 00).
If the normal sequence does not occur, refer to the following table
for possible causes.

Field Functional Tests D-1

 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.

Hall Effect Sensor

(SW 1) and screw on
key panel may be
misaligned.

Microprocessor socket Replace controller

may be damaged . PCBA

Microprocessor socket
may be from non-
approved vendor
(McKenzie).

Seven segment displays Limited-access switch Deactivate limited-

flash all 8s and then go is activated. access switch (see user
blank and stay blank. 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, all yellow.
• Seven segment displays blink, then go blank.
• Multi display briefly shows configuration code (0.0 CP.-x 0.0).
• Normal display shown on seven segment display (00 150 00).
• Tri-color display scrolls INPUT WT. +/- message.

HR ClubTrack Plus™
For the HR ClubTrack Plus, the normal sequence is:
• Seven segment displays show all 8s.
• LCD screen is all white.
• Introduction screen appears on LCD.
• Zero speed and the current grade appear on the segmented
displays.

Field Functional Tests D-2

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. To perform a test, press the softkey next to the test
name, rather than pressing the indicated key combinations.

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.
Key Code

No key pressed P000

Shorted key(s) P555

Clear P001

Up P002

Down P003

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 Keypanel 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. Each digit displays
the number 8 and the associated decimal point for one second,
then turns off as the next one lights up.

Field Functional Tests D-3

 • 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. The columns move
from left to right until all display LEDs have been tested.
• Horizontal columns light red, green, then yellow for one
second each. The columns move from top to bottom until
all LEDs have been tested.
• All LEDs go dark when the test is finished.
2. Press Power twice to exit Service mode.

Test the Heart Rate Monitoring (HR treadmills only)

Use a pulse simulator (P/N 34198-008) and a Polar watch receiver
(P/N 34198-009) to test the accuracy of the controller’s heart 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. 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. 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
sideòcal cover at the rear support and at the front grade wheel.
Both measurements should be the same ± 3 8 in. If they are
not, refer to Calibration Procedures in Chapter 4, Repair/
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:

Field Functional Tests D-4

 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. 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. Count the number of belt revolutions in two minutes. This
should be 112 ± 3 revolutions.
If any of the measurements are not accurate, refer to Replacing the
Tensioner and/or Adjusting the Walk Belt in Chapter 4, Repair/
Replacement and Calibration.
7. Ensure that the speed will traverse from minimum to
maximum and back.

F. 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 little forward pressure and continue to rotate for several

Field Functional Tests D-5

 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. If
any slippage is detected, refer to Replacing the Tensioner
and/or Adjusting the Walk Belt in Chapter 4. Repair/Replace-
ment and Calibration.
4. Stop the walk belt.

H. Shut Down the Treadmill

Turn the circuit breaker off, disconnect the power cord from the
outlet, and place the treadmill back in service.

Field Test No. 1

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. 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).
• Normal display is shown (00 150 00).
If the normal sequence does not occur, refer to the following table
for possible causes:

Field Functional Tests D-6

 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.

Hall Effect Sensor (SW 1)

and screw on key panel
may be misaligned.

Microprocessor socket Replace controller PCBA.

may be damaged

Microprocessor socket may

be from non-approved
vendor (McKenzie).

Seven segment Limited-access switch is Deactivate limited- access

displays flash all 8s activated . switch (see user manual)
and then go blank
and stay blank.

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.

HR ClubTrack Plus™
For the HR ClubTrack Plus, the normal sequence is:
• Seven segment displays show all 8s.
• LCD screen is all white.
• Introduction screen appears on LCD.
• Zero speed and the current grade appear on the segmented
displays.

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. Shut Down the Treadmill

Turn the circuit breaker off, disconnect the power cord from the
outlet, and place the treadmill back in service.

Field Functional Tests D-7

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. 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).
• Normal display is shown (00 150 00).
If the normal sequence does not occur, refer to the following table
for possible causes.
ClubTrack, HR ClubTrack, MedTrack SR60, and MedTrack 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

• 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.

Hall Effect Sensor

(SW 1) and screw on
key panel may be
misaligned .

Microprocessor socket Replace controller

may be damaged. PCBA

Microprocessor socket
may be from non-
approved vendor
(McKenzie).

Seven segment displays Limited-access switch Deactivate limited-

flash all 8s and then go is activated . access switch (see user
blank and stay blank. manual)

Field Functional Tests D-8

 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.

HR ClubTrack Plus™
For the HR ClubTrack Plus, the normal sequence is:
• Seven segment displays show all 8s.
• LCD screen is all white.
• Introduction screen appears on LCD.
• Zero speed and the current grade appear on the segmented
displays.

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 will traverse from minimum to maximum
and back.

D. Test the Speed

Ensure that the speed traverses from minimum to maximum and
back.

E. Shut Down the Treadmill

Turn the circuit breaker off, disconnect the power cord from the
outlet, and place the treadmill back in service.

Field Test No. 3

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 Speed Operation

1. Place a chalk mark or piece of tape on the walk belt across the
direction of travel.
Field Functional Tests D-9
 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. Count the number of belt revolutions in two minutes. This
should be 112 ± 3 revolutions.
If any of the measurements are not accurate, refer to Replacing the
Tensioner and/or Adjusting the Walk Belt in Chapter 4, Repair/
Replacement and Calibration.
7. Ensure that the speed will traverse from minimum to
maximum and 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 little forward pressure and continue to rotate for several
steps. If additional pressure is required to keep the belt
moving, replace the belt and deck.

C. Test the Walk Belt Operation

1. With the walk belt speed at minimum, 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 minimum, walk on the treadmill.
3. Grasp the handrail and resist the motion of the walk belt. If
any slippage is detected, refer to Replacing the Tensioner
and/or Adjusting the Walk Belt in Chapter 4, Repair/Replace-
ment and Calibration.
4. Stop the walk belt

D. Shut Down the Treadmill

Turn the circuit breaker off, disconnect the power cord from the
outlet, and place the treadmill back in service.

Field Functional Tests D-10

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.
Both measurements should be the same ± 3 8 in. If they are
not, refer to Calibration Procedures in Chapter 4, Repair/
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.
Treadmill Model 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).

B. Shut Down the Treadmill

Turn the circuit breaker off, disconnect the power cord from the
outlet, and place the treadmill back in service.

Field Test No. 5

A The following steps must be performed with the treadmill
completely assembled, except as noted.

Field Functional Tests D-11

 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).
• Normal display is shown (00 150 00).
If the normal sequence does not occur, refer to the following table
for possible causes.
ClubTrack, HR ClubTrack, MedTra ck SR60, and MedTra ck CR60

Problem Possible Cause Solution

Seven segment displays ED (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.

Hall Effect Sensor

(SW 1) and screw on
key panel may be
misaligned.

Microprocessor socket Replace controller

may be damaged . PCBA.

Microprocessor socket
may be from
non-approve d vendor
(McKenzie).

Seven segment displays Limited-access switch Deactivate limited-

flash all 8s and then go is activated. access switch (see user
blank and stay blank. manual)

Field Functional Tests D-12

 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.

HR ClubTrack Plus™
For the HR ClubTrack Plus, the normal sequence is:
• Seven segment displays show all 8s.
• LCD screen is all white.
• Introduction screen appears on LCD.
• Zero speed and the current grade appear on the segmented dis-
plays.

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

To test for proper 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. To perform a test, press the softkey next to the test
name, rather than pressing the indicated key combinations.

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.
Key Code

No key pressed P000

Shorted key(s) P555

Clear P001

Up P002

Down P003

(continue d)

Field Functional Tests D-13

 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. Each digit displays
the number 8 and the associated decimal point for one second,
then turns off as the next one lights up.
• When this is completed, the LEDs light up individually,
starting from the top. The Select LEDs light 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).
• 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 columns on the tri-color display light red, green,
and then yellow for one second each. The columns move
from left to right until all display LEDs have been tested.
• Horizontal columns light red, green, and then yellow for
one second each. The columns move from top to bottom
until all LEDs have been tested.
• All LEDs go dark when the test is finished.
2. Press Power twice to exit Service mode.

Test the Heart Rate Monitoring (HR treadmills only)

Use a pulse simulator (P/N 34198-008) and a Polar watch receiver
(P/N 34198-009) to test the accuracy of the controller’s heart rate
function.
1. Turn on the pulse simulator. The LED on the front of the
simulator will blink in synch with the signal.

Field Functional Tests D-14

 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. Shut Down the Treadmill

Turn the circuit breaker off, disconnect the power cord from the
outlet, and place the treadmill back in service.

Field Functional Tests D-15

 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 3-13
—EPHI and EPLO 3-11
adjusting the walk belt 4-25
assemblies 2-1
assembly drawings D-1 F
field functional tests E-1
B field replaceable modules
firmware revision 3-5
C-1
battery life, heart rate transmitter 5-3
flow charts, error 3-11
C —E001
—E203
3-12
3-14
calibration procedures 4-32
—grade pot 4-32 —E204 3-13
—speed and grade 4-33 —EPHI and EPLO 3-11
calipers
card cage
4-26
4-7 G
chain 4-15 grade limit switches 4-22
chest belt, battery 5-3 grade motor 2-4
chest belt, cleaning 5-2 grade motor, replacing 4-13
chest belt, storage 5-3 grade potentiometer (POT)
circuit breaker 1-3 —calibrating 4-32
classification A-1 —replacing 4-15
cleaning 5-1 —wires 4-16
communications interface 2-3 grade range 3-6
components
compression mounts
1-1
4-24 H
configuration plate 4-5 headfram e 2-3
configuring the controller 4-30 heart rate accuracy, testing 3-8
controller 1-3 heart rate monitoring 3-7
—assembly 4-27 heart rate
—cable, removing 4-30 —key panel 1-3
—enclosure, removing 4-27 —option, p/n 1-1
—keys 3-5 —maintenance 5-2
—keys, testing 3-5 —PCBA 4-28
CSAFE protocol 2-3 —theory 2-4
cumulative use 4-31 hood, removing 4-3

D I
deck assembly 2-4 input power 2-3
deck assembly illustrated 4-23 installation 1-1
drive belt 3-9 interface connector (RJ-45) 2-3

K
drive belt, replacing 4-10
drive board 2-4
drive motor 4-11 keypanel 1-3, 2-2
keypanel, removing 4-30
E
electrical problem s 3-2 L
electronic problem s 3-3 limited access switch 4-31

M
error codes 3-3
error code flow charts 3-11
—E001 3-12 manuals, part numbrs C-1
—E203 3-14 mechanical problem s 3-9

Index 1
microprocessor, theory
models 1-1
2-5 S
safety requirements A-1

N service mode
service, recommended
3-4
5-1
noise 3-10 speed range 3-6

O
symbol definitions A-2

open-loop mode 3-6 T

operation 1-3 tension 4-25
options 1-4 tensioner 4-8
overview 1-1 theory 2-1

P
tools 3-1, 4-2
tracking 4-27
P000 3-4 transformer 4-13
part numbers C-1 transmitter 2-5
PCBA, replacing 4-28 transmitter, battery 5-3
pinion shaft 4-21 tri-color Display 3-6
poly-V belt, replacing 4-10 troubleshooting 3-1, 3-2
power 1-3
power cord 4-6 V
pulse simulator 3-8 VSD board 4-7

R W
rack gears 4-17 walk belt 3-9
rack gears, jammed 4-19 —tension 4-25
receiver, theory 2-5 —replacing 4-23
repair 4-1 warnings A-1
roller assembly 2-4
rollers, replacing 4-23

Index 2