Star Trac TR 4500 - Manuals

Tools and Equipment Equipment Function Philips Head Screwdriver #2 Shroud Motor Control Board Assembly Side Bed Cover and End Caps Auto-Transformer Small Slotted Screwdriver 3/32” Motor Control Potentiometers (MAX SPD) & (IRCOMP) Bungee Cord 28” Suspend Motor Shroud on Display Rail 5/32” Hex All...

Treadmill Overview • DC POWER SUPPLY The MCB provides power to the display assembly. Establishes a reference voltage and potentiameter position from the elevation motor • RUNNING BELT MOTOR DRIVE CONTROL Takes Alternating Current and converts it to Pulse Width Modulation (PWM) to power the Drive Mot...

Preventive Maintenance Chart Maintenance Clean Inspect Lubricate Replace Daily Using a liquidnon-abrasivecleaner, wipedown thefollowing:display board handrails,shroud, heartrate grips. Note: Do not spray directlyonto thedisplayboard or heartgrips. Inspect for wearand tear on ex-terior partsregularly...

Quarterly Waxing The treadmill is designed with an automatic prompt, which will display RE WAXacross the display screen every 2,000 miles or 3,000 kilometers. The procedurebelow explains step-by- step how to apply wax and clear the RE WAX prompt. Note: Apply wax powder whilebelt and deck arestill wa...

Maintenance Mode Maintenance Mode includes all of the items of Manager Mode, plus additional data that is automaticallysaved to properly troubleshoot in case of a problem. To engage Maintenance Mode: 1. Press and hold the “ 0 ”, “ 2 ” & “ START ” keys together. While holding the “ 0 ” & “ ST...

Motor Test Mode Motor Test Mode allows the treadmill to calibrate both elevation and running belt speed. Verifies RPMSensor feedback, Drive Motor and MCB response, and verifies Elevation Motor range (count). Alsoburns in the motor, by way of the controls and displays of the treadmill. ***Caution*** ...

Calibration ***Caution*** : Do not stand on the running belt while performing these test. Automatic Speed Calibration: In this mode minimum and maximum speed is automatically calibrated. Calibration lasts less than 3 minutes; belt will be in motion during this test. Auto-calibration should be done e...

Display Test Mode Display Test Mode allows you to test the light-emitting diodes (LEDs), 15-segment displays, and thewatchdog timer of the Display Control Panel by way of its own controls and displays. It also allowsEPROM version to be displayed. To enter Display Test Mode: ***Caution*** : Do not st...

Heart Rate Test Heart Rate Test Mode tests the heart rate calculation and display capability of the treadmill if it isequipped with contact rings or Polar wireless heart rate chest strap reception capability. To enter HeartRate Test Mode: 1. Press and hold the “ 0 ”, “ 1 ” & “ START ” keys toget...

110v MCB LED Layout The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems. ** CAUTION ** AC LED - Indicates that AC power has been applied to the MCB. It does Several of the follow- not give indication of voltage level, if this LED is not lit and the tread- ing...

110v MCB LED Layout NOTE: Engage Motor MOTOR LED - Indicates the presence of acceptable voltage to the motor. Test Mode and If this LED is not lit one of the following conditions exists: manually push on 1. Verify AC voltage is being applied. the running belt to 2. Verify that MTR1/MTR2 wires are co...

220v MCB LED Layout The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems. ** CAUTION ** AC PWR - Indicates that AC power has been applied to the MCB. It does Several of the follow- not give indication of voltage level, if this LED is not lit and the ing troubl...

220v MCB LED Layout NOTE: Engage Motor RPM SENSOR - Indicates input signal from the RPM Sensor to the MCB. Test Mode and If this LED is not flashing during operation, verify the following manually push on 1. RPM sensor disconnected from connector J3 at the MCB. the running belt to 2. RPM sesnor gap ...

Calibration Troubleshooting Symptom: Will not Calibrate to MAX speed. 1. Verify line voltage for sufficient voltage supply. • If wall voltage is less than 10% than what is required, this will cause speed fluctuation. 2. Verify unit is on a dedicated circuit breaker. • Treadmills sharing the same cir...

Manual Calibration The following procedure allows the treadmill to manually calibrate Minimum and Maximum speeds, only in the case Auto-Calibration is not functioning correctly. Symptom: Will not calibrate to MN or MX speed, in the Auto-Calibration Mode. **CAUTION** 1. Engage TEST MODE. Press and ho...

No Display Power The following steps help troubleshoot in case the display board fails to power up, during or beforeregular operation. 110v UNIT 1. Lift and suspend the motor shroud. **CAUTION** The following steps 2. Verify if LED AC is lit. AC LED indicates that AC power is being applied to are pe...

No Display Power The following steps help troubleshoot in case the display board fails to power up, during or beforeregular operation. 220v UNIT 1. Lift and suspend the motor shroud. **CAUTION** The following steps 2. Verify if LED AC is lit. AC LED indicates that AC power is being applied to are pe...

Elevation Motor NOTE: Activationof the thermalprotection break-er does notcause damage tothe elevationactuator or othertreadmill compon-ents. The following procedure explains the elevation system Thermal Protection andlimitations. Symptom: Elevation system shuts-off when used consistently. 1. The St...

Elevation Troubleshooting ** CAUTION ** Do not stand onthe running beltwhile perform-ing these steps. NOTE:These ran-ges were chosento optimize theoutput voltage tothe elevationmotor within anacceptableoperating range,while still usingthe presentmanufacturingtolerances of thetransformermanufacturer....

Speed Troubleshooting Note: This sym- ptom may beeasily fixed byverifying certainvalues in theConfigure Mode. Note: For each value changedthe “ENTER” keymust be pressedto be saved. . Symptom: Treadmill appears/feels faster/slower than other STAR TRAC treadmills. 1. Engage Maintenance Mode by holding...

Speed Troubleshooting Note: This sym- ptom may beeasily fixed byverifying certainvalues in theConfigure Mode. Note: For each value changedthe “ENTER” keymust be pressedto be saved. Note: All 110v units are design-ed to reach amaximum speedof 10.0 MPH.220v units set inmetric will reacha maximum 20.0K...

Speed Troubleshooting ** CAUTION ** Running belt willbe moving at highspeed duringStep 1 & 3. ** CAUTION ** When checkingmotor brusheshave the treadmillturned off andunplugged. Note: Brushes should show asmooth pattern ofwear, cracks orunusual wear willcause motor tojerk, replace ifbrushes if ne...

Heart Rate Troubleshooting ** CAUTION ** Do not stand onthe running beltwhile performingthese steps. Before any troubleshooting is performed, verify that the heart rate grips are being usedand maintained properly. Symptom: Intermittent or erratic heart rate reading. 1. User failing to grip all four ...

Heart Rate Troubleshooting Symptom: No Heart Rate reading. 1. Engage HEART RATE TEST. Turn the power switch “on” while pressing key “5” simultaneously on the display. All the display LEDs will light up when engaged. • Press the HEART key once, EPROM ver- sion will be displayed. HEART key twice, disp...

Heart Rate Troubleshooting 5. Connect Heart Rate Board straight to the display input. • By-pass the Combiner Board, insert the heart rate wires straight to the display. See Diagram #3 & 3a. After connection has beenrepeat step 1. REPLACE: Combiner Board if Heart Rate registers. If no Heart Rate ...

Polar Heart Troubleshooting ** CAUTION **Do not stand onthe running beltwhile perform-ing these step. NOTE : Secure the chest straptransmitter ashigh under thepectoral muscle(breast) as iscomfortable andallow normalbreathing. NOTE: Wet the electrodes (thetwo groovedrectangularareas) thorou-ghly with...

Display Cable The following symptoms indicates a faulty or pinched display cable. Symptom: No display power related. **CAUTION** 1. No display power, treadmill elevation bottoms out during start-up. Do not stand on 2. No display power, MCB LED +11 remains lit on 110v units. MCB LED Display the runni...

Drive Motor The following symptoms indicates a faulty drive motor. Symptom: Tripping the ON/OFF switch breaker. **CAUTION** 1. Disconnect the drive motor belt. Do not stand on 2. Run the drive motor for ten minutes at a high speed (6 MPH/ 10 KPH). If the the running belt ON/OFF switch trips, verify ...

Head / Tail Roller Note: Do notremove all the wasas it is required tolubricate both therunning belt anddeck. You may need to replace the head or tail roller if the following symptoms areobserved. Symptom: Thumping, knocking noise as the running belt goes over theroller. Verify the following: • Delro...

Drive Belt Troubleshooting The drive belt tension may require tightening if a slipping problem occurs on the drivepulley. Symptom: Running belt slips when running or walking. 1. Loosen the four motor mount kep nuts and washer using a 5/16 “ wrench. 2. Adjust the drive belt tension by turning the mot...

Running Belt Troubleshooting Note: For optimal To prevent belt problems from occurring, verify the running belt is properly performance during the adjusted and working smoothly by performing the following steps: lifetime of the treadmill, running belt adjust- 1. Feel the underside center of the runn...

Running Belt Tracking Note: The running belt If the running belt is not centered on the tailroller and is either to far left or may mis-track due to right, adjust tracking using the following steps:: the style of the walkeror runner. 1. Turn treadmill on. Increase speed to 3.0 mph (5.0 kph). Note: T...

Running Belt Tension Note: Prior to making The running belt tension may need to be adjusted over time to keep the any adjustments to the the belt from slipping with each jogging step or at high speeds. Use the running belt tension, following procedure for testing belt tension. verify the drive motor...

Running Deck The following procedure will help determine and properly adjust the deck bumpers. Symptom: Running deck squeaks when running. 1. When properly located, the side bumpers (two on each side) bear against thedelrin rods in the frame rails. The rear bumpers bear against the steel posts atthe...

Isolating Noise NOTE: Verify thatthe treadmill is levelbefore isolating anyspecific component NOTE: Ensure allassembly screwsare tight:1. Handrails.2. Display board.3. Motor shroud. NOTE: When doingthe stethoscopemethod, be carefulof body placement.Ensure all looseitems (hair, clothing, jewelry etc)...

Leveling NOTE: If a levelingfoot does not makecontact with the flooror if it lifts upwardsas weight is appliedto one corner of thedeck, this will causethe running belt tomis-track. To ensure proper tracking of the running belt, treadmill leveling should be verified. Symptoms: • Running belt travels ...

Vibration NOTE: For completeleveling procedure, seethe following page. NOTE: When checkingmotor brushes, thetreadmill must beturned off andunplugged. A treadmill vibrates during use if the floor or leveling feet are uneven or whenassembly bolts are loose. Symptom: Unit vibrates while running. 1. Ver...

Static Shock **CAUTION**When checking motorbrushes, always turnthe treadmill off andunplug. The treadmill may cause a slight shock from the display panel or handrails, due toa faulty ground wire or a worn running belt and deck. Symptom: Slight shock from handrails or when using the display panel. 1....

Display Codes Chart ** CAUTION **Do not stand onthe running belt,while performingthese steps. NOTE: Treadmillshould be turnedoff and un-plugged from thewall when lookingunder the motorshroud. NOTE: ContactSTAR TRACProduct SupportDepartment at1-800-501-1221or through ourweb site at http://www.startra...

Definition: "KEY STUCK" Possible Cause: Damaged or shorted key/keypad. Note 1: This code may occur when a user tried entering "Test Mode" or "Display TestMode" using the wrong key. Look for any indentations on any of the keys. The plus or fast key are used most often and may ...

Definition: "RPM LOSS" Possible Cause: Damaged or misaligned RPM sensor. Note 1 : Press and hold the "0", "1," & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Then press and release the 8 key. Or manually...

Definition: "SUDDEN SPEED CHANGE." Possible Cause: RPM pick-up misaligned. Note 1: Press and hold the "0", "1", & "START" keys down at the same time, then release the "1" key. The display willread: MAINTENANC, then press and release the "8" key. Or...

Definition: "ELEVATION LOST BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: M...

Definition: "ELEVATION RANGE BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: ...

Definition: "ELEVATION STALL BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: ...

Drive Motor Replacement ** CAUTION ** Always turn thepower switch tothe off position.Unplug thetreadmill powercord from thepower outlet. Tools: • Running Belt Drive Motor • Philips-head screwdriver • Bungee cord, approx. 24 inches • Needle nose pliers • 5/16-in socket and torque socket wrench to mea...

Drive Motor Replacement Remove Motor 1. Loosen the 5/16-inch nut that locks the motor alignment screw, then unscrew the screw several turns. 2. Loosen the four 5/16-inch motor mount nuts so that the motor slides freely on the frame. See Diagram A below. 5.2

Drive Motor Replacement 3. Using a 1/8-inch Allen wrench, loosen the two set screws in the motor pulley. 4. Slide the motor towards the rear of the treadmill l to give slack to the motor drive belt. 5. Slip the drive belt off the motor pulley, then remove the pulley and the locking key. 6. Remove th...

Drive Motor Replacement Diagram B. Check and Adjust Belt Tension 1. Place a tension gauge onto the center of the belt and check tension. The gauge should indicate 90 inch-pounds. 2. If you have not tension gauge, press down on top of the belt, midway between pulleys, very hard with your thumb. The b...

Drive Motor Replacement 5. Recheck pulley alignment and belt tension. 6. When alignment and tension are correct, tighten all four motor mount nuts using a socket torque wrench set at 75 inch-pounds. 7. Lock the motor adjustment screw by tightening the locking nut against the frame. 8. Loosen the set...

Elevation Motor Replacement ** CAUTION ** Always turn thepower switch tothe off position.Unplug thetreadmill powercord from thepower outlet. Tools: • Replacement elevation motor • Philips-head screwdriver • Pliers • Tap nuts, ½-inch (2) • Allen wrench, 9/64 in. • Socket wrench with 17-mm socket • Sh...

Elevation Motor Replacement Replacement the Elevation Motor 1. Position the elevation motor in its mount. Be sure to hold the motor’s electrical cable closely against the motor to prevent its being pinched between the motor andthe treadmill frame. 2. Replace and tighten the four screws that hold the...

Elevation Motor Replacement 6. Tighten Allen screws in the drive pulley, taking care to preserve the alignment achieved in the preceding step. 7. Place the drive belt over the idler pulley. 8. Slide the idler pulley tightly against the belt, then finger tighten the mounting screw on the idler pulley...

Side Bed Cover Replacement ** CAUTION ** Always turn thepower switch tothe off position.Unplug thetreadmill powercord from thepower outlet. Tools: • Side bed cover • Philips-head screwdriver • Slot-head screwdriver • 1/8-in Allen wrench • 5/8-in socket and socket wrench with ratchet • Plastic-head h...

Side Bed Cover Replacement 4. Starting at the raised corner of the flange, lift upwards and outwards to free its outer edge from the frame along its length. 5. Lifting the outer edge of the cover, push the cover towards the center of the treadmill to clear the cover’s inner flange from the frame and...

Side Bed Cover Replacement 4. At the front end, pull the outer flange over the frame, then use your hand or a soft mallet to “pop” the outer flange over the frame along its full length. The rear end of thecover should butt against the end cap. See Diagram C . Diagram C 5. If the rear end of the cove...

Autotransformer Replacement The autotransformer may be tapped to accommodate line voltages from 195VAC to 250VAC. Following are procedures for replacing a failed autotransformer. Tools: • Replacement autotransformer • Philips-head screwdriver • Slot screwdriver Procedure: Lift motor shroud The drive...

Autotransformer Replacement Replace the Autotransformer 1. Position the replacement autotransformer over the four holes in the motor plate so that the connector lugs are towards the left-hand side of the treadmill. 2. Drop the four screws removed in the preceding step 5 into the mounting holes of th...

Autotransformer Replacment Reconnect the autotransformer’s black wire to terminal AC1 at the left-rear corner of theMotor Control Board.Connect the blue wire to the lug on the autotransformer. 1. Connect the red wire to the same lug from which it was removed in the previous step. If there is a quest...

Heart Grip Replacement ** CAUTION ** Always turn the power switch tothe off position.Unplug thetreadmill powercord from thepower outlet. Tools: • Handgrip Kit • 1/16 inch Allen wrench • Light nylon cord • Isopropyl alcohol Procedure: Remove the Display Panel 1. Using a 1/16-inch Allen wrench, remove...

Heart Grip Replacement Remove the Handgrips 1. Pull and twist the handgrips free of the rail tubing. If they will not slide off the tubing, use a knife or scissors to cut the rubber along its length, then slide the handgrips offthe tubing. 2. Continue to pull each of the handgrip cables though the g...

Heart Grip Replacement Replace Display Panel 1. Position the display panel over the display panel mount, matching screw holes in the back of the panel with holes in the mount. 2. Using a 1/16-inch Allen wrench, replace and tighten each of the five screws removed in a previous step. Test Treadmill Op...

2 TR 4500 & 3900 Series Elevation Assy ItemNo Part Number Description QtyPer Core Page: 1 260-0235 Motor, Elevation, 110vac 1 N 2 708-0151 Elevation Can 2 N 3 715-0110 Elevation Screw, drilled 2 N 4 130-0250 Pulley, Elevation, elev motor 1 N 5 110-1415 Axle Push Caps 1/2" 2 N 6 708-0645 Axle...

3 TR 4500 & 3900 Series Motor & Electrical Assy ItemNo Part Number Description QtyPer Core Page: 1 800-3016 Mcb, 110v, 18/35/39/45/4000 1 Y 2 715-3132 Mcb, 220v, 18/35/39/45/4000 1 Y 3 800-3259 Filter Network, 110v 1 N 4 800-3258 Filter Network, 220v 1 N 5 260-0220 Motor, 110v, 2.5hp 3500rpm...

4 TR 4500 & 3900 Series Running Belt Assy ItemNo Part Number Description QtyPer Core Page: 1 130-1630 Running Belt, (20"x128.5") 1 Y 2 708-0061 Head Roller 1 Y 3 708-0132 Tail Roller 1 Y 4 130-0121 Drive Belt, (280J10) 1 N 5 130-1629 Drive Belt, (285J10) 1 N 6 130-7009 Pulley, drive moto...