Page 2 - How To Use This Manual
How To Use This Manual • This Service Manual has been written to assist and instruct the repair technician on keycomponents for quick and efficient diagnosis of service problems. • To assist in finding the applicable sections in the Service Manual. Each Section has a table of contents to help locate...
Page 3 - Precautions
Precautions 1. Always make sure that the treadmill is turned off and unplugged before starting any work, unless otherwise noted, or when necessary for voltage testing. 2. Read each section through for NOTES before starting any work. 3. To pull apart electrical connectors, pull on the connector itsel...
Page 4 - Product Support Asistance; PRODUCT SUPPORT DEPARTMENT; Technical Assistance
Product Support Asistance PRODUCT SUPPORT DEPARTMENT STAR TRAC Product Support Department sets the industry standard in Customer Service and Technical Assistance World Wide. Providing superior product support and customer service is at thevery heart of STAR TRAC’s business philosophy. This commitmen...
Page 5 - Tools and Equipment
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...
Page 6 - Treadmill Overview
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...
Page 8 - Preventive Maintenance Chart
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...
Page 9 - Quarterly Waxing
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...
Page 13 - Maintenance Mode
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...
Page 18 - Motor Test Mode
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*** ...
Page 19 - Calibration; Automatic Speed Calibration:
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...
Page 20 - Display Test Mode
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...
Page 21 - Heart Rate Test
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...
Page 23 - AC LED
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...
Page 24 - 10v MCB LED Layout; MOTOR LED; UP LED
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...
Page 25 - AC PWR; DISPLAY PWR
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...
Page 26 - 20v MCB LED Layout; RPM SENSOR; MOTOR CONTROL
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 ...
Page 28 - Calibration Troubleshooting; Will not Calibrate to MAX speed.
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...
Page 29 - Symptom:
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...
Page 30 - No Display Power; 10v UNIT
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...
Page 31 - 20v UNIT
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...
Page 32 - Elevation Motor; Elevation system shuts-off when used consistently.
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...
Page 34 - Elevation Troubleshooting; Elevation Motor overheats and blows the MCB fuse.
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....
Page 35 - Speed Troubleshooting; Treadmill appears/feels faster/slower than other; ENGLISH METRIC
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...
Page 36 - Treadmill will not reach maximum speed.
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...
Page 37 - Treadmill jerks or hesitates during operation.
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...
Page 38 - Heart Rate Troubleshooting; Intermittent or erratic heart rate reading.; Clean and wipe heart rate grips after each use, for optimum results.
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 ...
Page 39 - No Heart Rate reading.; Diagram 1
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...
Page 40 - Diagram 6
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 ...
Page 41 - Polar Heart Troubleshooting; Intermittent or erratic polar heart reading.
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...
Page 42 - Display Cable; No display power related.
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...
Page 43 - Drive Motor; Tripping the ON/OFF switch breaker.; Drive Motor making noise.
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 ...
Page 44 - Head / Tail Roller
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...
Page 45 - Drive Belt Troubleshooting; Running belt slips when running or walking.
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...
Page 46 - Running Belt Troubleshooting
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...
Page 47 - Running Belt Tracking
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...
Page 48 - Running Belt Tension
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...
Page 49 - Running Deck; Running deck squeaks when running.
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...
Page 51 - Isolating Noise; Rumbling
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)...
Page 52 - Leveling; Running belt travels to one side.
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 ...
Page 53 - Vibration; Unit vibrates while running.
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...
Page 54 - Static Shock; Slight shock from handrails or when using the display panel.
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....
Page 55 - Display Codes Chart; Display Codes/Symptoms
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...
Page 56 - Code: KEY DN Flowchart
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 ...
Page 58 - Code: NO RPM Flowchart
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...
Page 61 - Code: SP CNG Flowchart
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...
Page 65 - Code: EL LOST Flowchart
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...
Page 66 - Code: EL RNG Flowchart
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: ...
Page 68 - Code: EL STL Flowchart
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: ...
Page 71 - Drive Motor Replacement; Procedure: Lift motor shroud; Disconnecting Motor Wiring
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...
Page 72 - Remove Motor
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
Page 73 - Install Replacement Motor
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...
Page 74 - Check and Adjust Belt Tension
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...
Page 75 - Reconnect Motor Wiring
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...
Page 76 - Elevation Motor Replacement
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...
Page 78 - Replacement the Elevation Motor
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...
Page 79 - Set the Treadmill Upright
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...
Page 80 - Side Bed Cover Replacement
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...
Page 81 - Installing Replacement Side Bed Cover
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...
Page 82 - Diagram C
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...
Page 83 - Autotransformer Replacement
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...
Page 84 - Replace the Autotransformer
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...
Page 85 - Autotransformer Replacment; Replace the Shroud; Test Treadmill Operation
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...
Page 86 - Heart Grip Replacement; Procedure: Remove the Display Panel
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...
Page 88 - Remove the Handgrips; Replace the Handgrips
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...
Page 89 - Replace Display Panel
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...
Page 93 - Elevation Assy
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...
Page 95 - Motor & Electrical Assy
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...
Page 97 - Running Belt Assy
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...
