Star Trac 2000 series, 3000 series User Manual
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STAR TRAC
SERVICE MANUAL
VERSION 1.0
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~Jr=I,BYUNISEN,
INC._
®liIIlC
Copyright 1993, Unisen, Inc. All rights reserved, including those to reproduce this bookorpart
thereof
in
any form without first obtaining written permission from Unisen, Inc.
Every effort has been made to keep the information current; however, periodically changes are made to
the information herein,
and these changes willbeincorporated into new editionsofthis publication. All
product names
and logos are trademarksoftheir respective owners. Printedinthe USA, 01093.
•
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FOR
ADDITIONAL SUPPORT
Customer Service
Unisen, Inc.
14352 Chambers Road
Tustin, California 92680
Telephone: 714
I 669 - 1660
Fax: 714
I 838 - 6286
~.
Hotline Telephone:
Technical Assistance:
Sales Assistance:
800
I 535 - 4634
800
I 503 -
1221
800
I 228 - 6635
NOTE:
For
faster service, please have your
STAR
TRAC
Model and Serial
Numbers available.
••
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ACKNOWLEDGEME
TS
We
wish to extend thanks to the entire STAR TRAC Customer
Service team for their support. And, a special thanks to Dennis Vega
and Sandy Sather for their valuable technical assistance.
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CONTElVl'S
TABLE OF CONTENTS
PAGE
NUMBER
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How
TO
USE
TIllS
MA
AL
7
CHAPTER 0 E:
PREvE
TlVE
MAl
TE
A
CE
9
DAILY
10
WEEKLY
11
BnNEEKLY
12
MONTI-U.Y
13
CHAPTER
Two:
DIAG
OSTIC
TEST 15
ACTIV
AT
G MOTOR
TEsT
MODE
16
ACTIVATIG DlSPLAY
TEsT
MODE
25
CHAPTER THREE: TROUBLESHOOTI G ERROR CODES 27
SPEED
ERRORS 28
ELEVATlO ERRORS 38
FS
ERRORS 52
CPU
ERRORS 55
No DISPLAY POWER 57
CHAPTER
Fo
R:ICREASING
MECHA
leAL
UPTIME 59
Ru
G BELT TROUBLESHOOTING
60
DRIVE MOTOR TROUBLESHOOTING 65
HEAD-
AND TAll..ROLLER TROUBLESHOOTING 68
TREADMILL
VmRA
TIO TROUBLESHOOTING 69
TREADMll...L STATIC AND SHOCKING TROUBLESHOOTING
71
-------------------
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CO!'ffENTS
PAG£
NUMBeR
•
CHAPTER FIVE: REPLACEMENT PROCEDURES
72
DISPLA Y CABLE
74
EMERGENCY STOP SWITCH
78
ELEVATION MOTOR
81
MOTOR BELT
85
ELEVATION SENSOR
87
LIMIT
SWITCH
89
RPM
SENSOR
92
MOTOR CONTROL BoARD
95
FLYWHEEL
98
MOTOR PULLEY
101
HANDRAILS
104
SUK
DECK
106
RUNNING BELT
110
•
ELEVATION CANS
115
INDEX
117
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How
TO
USE
TIns
MANuAL
This service manualisintended to assistinpreventive maintenance, troubleshooting,
and replacing worn parts for the STAR TRAC 2000 and 3000 Series Treadmills.
STAR
TRAC
MODELS
2000P Series
~1~0
STAR TRAC Programmable
2000S Series
STAR TRAC Simple
2000J Series
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\
STAR TRAC Jogger
2000W Series
STAR TRAC Walker
3000P Series STAR TRAC Programmable
3000S Series
STAR TRAC Simple
3000J Series
STARTRAC Jogger
3000W Series ST
AR
TRAC Walker
In
Chapter
One: Preventive Maintenance, you will find the recommended
maintenance guide for your treadmill.
Keep~ng
a regular preventive maintenance
schedule increases the treadmill uptime and runners' enjoyment.
In
Chapter
Two: Diagnostic Test you will learn how to acti ate the Motor Test
Mode and Display Test Mode to prevent problems and service your treadmill.
Correcting problems and troubleshooting error codes are covered
in
Chapter
Three:
Troubleshooting
Error
Codes.
Chapter
Four: Increasing Mechanical ptime provides hints and tips for preventing
and troubleshooting common mechanical problems.
Chapter
Five: Replacement
Procedures
details with text and illustrations how to replace the worn parts.
Chapter Four: Increasing echanical Uptime provides hints and tips for preventing
and troubleshooting common mechanical problems.
Chapter Five: Replacement
Procedures
details with text and illustrations how to replace the worn parts.
DIRECTIO AL
ORlE
TATIO
The
directions usedinthis manual are from the runner's viewpoint.
The
display panel
is the front
of
the treadmill. The right, left and rear are as viewed by the runner.
•
Front
Left
UNISE
CUSTOMER SERVICE
STAR
TRAC
SERVICE
MA
UAL
I - 800 - 503 -
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Right
Back
PAGE 8
•
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CHAPTER
ONE:
PREVENTIVE
MAINTENANCE
•
Performing regular preventive maintenance on all STAR TRAC treadmills is strongly
recommended. Without preventive maintenance, normal wear and tear may cause
cumulative effects, such as misalignment and early replacement
of
parts.Inaddition,
the more the treadmill is
in
use, the stricter you should adheretothe preventive
maintenance schedule.
NOTE:Ifany unusual problems, such as error codes and blown circuit breakers,
occur, please refer to Chapter Three: Troubleshooting Error Codes.
•
UNlSEN
CUSTOMER SERVICE
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TRAC
SERVICE
MANuAL
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800-503-1221
PAGE 9
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DAILY PREVENTIVE MAINTENANCE
You should perform the following maintenance on a daily basis.
• Use a cloth and diluted all-purpose cleaner to remove any dust, dirt,
and other substances from the main
part
of
the treadmill. Wipe the
display panel, console, handrails, and motor cover. Avoid using cleaner
under the running belt.
• To ensure the longevity
of
the running belt, clean under the running
belt with a soft,
dry cloth.
To clean, slide the cloth between the running belt and the deck from
one side
of
the frametothe other side. You may need a rulerorrod to
slide towel under the running belt.
Then, holding the edges
of
the cloth, pull the cloth from the headroller
to the tailroller.
NOTE:
Do
NOT clean the running belt by activating the treadmill. Do
NOT place feet or any weight on the running belt when cleaning the
treadmill.
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TRAC
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PAGE
10
•
You should perform the following maintenanceona weekly basis.
•
•
•
•
•
Check the running belt for alignment and tension.
NOTE: Do NOT automatically tighten the belt daily. For additional
infonnation on how to verify belt alignment
or
correct a belt that has
slipped or mistracked, please refer
to Chapter Four: Increasing
Mechanical Uptime.
Verify power cord is not under the treadmill.Ifthe power cord is
placed under the treadmill, it may become pinched
or
bind up the
elevation screws. This results
in
error codes or treadmill damage.
WEEKL
Y PREVENTIVE MAINTENANCE
Elevate the treadmill and vacuum the floor under the treadmill. Be
careful nottobump the elevation switches as you sweep.
• Inspect the deck and running belt surfaces for unusual wear.
Check the deck for worn areas where the underlying fiber board
or
soft
spots are visible. Inspect the underside center
of
the running belt for a
worn, glazed appearance.
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PAGE
11
•
Walk on the deck surface.Ifany portion feels soft, replace the deck.
NOTE: For information on replacing a worn deck or belt, please refer
to Chapter Five: Replacement Procedures.
•
•
If
you have a 3000 Series, check the subdeck and weardeck screws.
If
loose, tighten them.
BIWEEKLY
PREVENTIVE MAINTENANCE
You should perform the following maintenance biweeklyortwice a month basis.
•
Vacuum around the motor and electronics by removing the shroud
cover and lifting the motor shroud.
Raise the motor shroud and suspend it from the display neck with the
bungie cord, from your STAR TRAC Treadmill Toolkit.
Be sure to
avoid bumping or damaging the RPM disc and sensor, elevation sensor,
limit switches, and wire connections.
NOTE:
To
raise the motor shroud, use the Phillips screwdriver to
remove the screw in the motor shroud. Gently lift the motor shroud
up
the display handrail.
Using
the bungie cord from the STAR TRAC
Toolkit, hold the motor shroud
at the top
of
the display handrail.
•
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PAGE
12
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•
To
replace the motor shroud, remove the bungie cord and
Lower
the
motor shroud until it touches the frame. Press the sides
of
the motor
shroud to the frame and attach the
veLcro
fasteners. Using the Phillips
screwdriver, tighten the screw in the center
of
the motor shroud.
MONTHLY
PREVENTIVE
MAINTENANCE
You should perform the following maintenance once a month.
• Lubricate the elevation screws with a silicon lubricant to prevent rust
accumulation.
• Activate Motor Test Mode and Display Test ModeofDiagnostic Test.
This will diagnose any unforeseen maintenance and error codes.
NOTE: For additionaL information on activating Diagnostic Test,
please refer to Chapter
Two:
Diagnostic test.
••
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TRAC
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MANUAL
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PAGE
13
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CHAPTER Two:
DIAGNOSTIC TEST
The STAR TRAC software program contains a self-diagnostic test mode that precisely
determines the reason for
an
error. This chapter outlines howtoactivate Diagnostic
Test and diagnose the problem.
Diagnostic Test consists
of
the Motor Test Mode and Display Test Mode. You will
use the test mode to check the motor, sensors (if they are working and calibrated),
and switches (if they are active and responding). The Display Test Mode checks the
keyboard response and
Qualityofthe LEDs. The Diagnostic Tests are the best
methods for determining specific failure areas
on
the STAR TRAC treadmill.
Remember,
in
Diagnostic test, you areincommand. Pay attention to the display
panel. The LED lights and readouts show you the exact position and limits
of
the
treadmill.
In
this chapter,
you
will learn:
CONTENTS
ACTIVATING MOTOR TEST MODE
ACTIVATING DISPLAY TEST MODE
PAGE
NUMBER
16
25
•
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MANUAL
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503
- 1221
PAGE 15
ACTIV
ATING
MOTOR TEST MODE
OF
DIAGNOSTIC TEST
Use the Motor Test Modetocheck the motor, sensors (if they are working and
calibrated), and switches (if they are active and responding).
In
addition, you may be
instructed to activate the Motor Test Mode during preventive maintenance
or
troubleshooting.
To activate Motor Test Mode, please follow these instructions.
If
your treadmill does
not respond, please refer
to
Chapter Four: Increasing Mechanical Uptime or
contact STAR TRAC customer service.
•
..
Step One
Tum the power switchtothe OFF position.
Place the treadmill into the Motor Test Mode.
Step Two
•
If
you have a Jogger, Programmable,orSimple with number
keys, simultaneously press key number 8, while turning the
power switch
to
ON.
•
•
If
you have a Walker or Simple with no number keys,
simultaneously press the
- (minus) key, while turning the power
switch
to
ON.
UNISEN CUSTOMER SERVICE
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TRAC
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PAGE 16
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•
Step Three Verify the display panel reads:
Verify the running belt
is
not moving.
•
If
you have a 2000 Series treadmill from 1990orearlier, verify
the display panel reads:
If
the running beltisnot moving, proceed to the next step.
If
the running belt begins moving, then:
•
To
raise the motor shroud, use the Phillips screwdriver
to remove the screw holding the motor shroud to the
frame. Gently raise the motor shroud up the display
handrail.
Using
the bungie cordfrom the STAR TRAC
Toolkit, hold the motor shroud at the top
of
the display
handrail.
I
J
r
•
Step Four
o
o
3
2
0.0
0.0
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TRAC
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PAGE 17
•
Adjust the
VR2
potentiometer, located on the motor
control board by using a small, flat screwdriver to slowly
tum
the screw on the
VR2
potentiometer counter-
clockwise until the running belt quits moving.
•
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•
Step Five Verify the threshold adjustment works correctly by increasing the speed
of
the running belt.
• Press the
+ (Plus) key
or
fast key to change the display readout
under Distance from 3 to 18.
•
If
you haveanolder 2000 Series (1990orearlier), press the fast
key to change the display readout under Distance from 2 to 16.
NOTE:
At
this point, the belt should be moving slowly at approximately
one inch per second. Look
forasmooth.
movementofthe belt without
hesitation orjerking motions.
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TRAC
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PAGE
18
•
•
•
If
The
belt doesn't move or moves too fast, then adjust the
belt speed.
• Adjust the
VR2
potentiometer, located on the
motor control board by using a small, flat
screwdriver.
To
increase the running belt speed, carefully
tum
the screw clockwise.
To
decrease
The
running belt speed, carefully
tum
the
VR2
screw counter-clockwise.
• Verify the running beltismoving at approximately
one inch per second.
• Replace the motor shroud by removing
The
bungie
cord and lowering the motor shroud until
it
TOuches
the frame. Press the sidesofthe motor
shroud to the frame and attach the velcro
fasteners.
Using
the Phillips screwdriver, tighten
the screw
in the centerofthe motor shroud.
•
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TRAC
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PAGE
19
Step Six
CAUTION
Do not stand on the running belt while the treadmill is
in
test mode.
Verify the RPM sensor works correctly as the running belt continues
moving at approximately one inch per second.
•
If
you have a Programmable, check the LED numbers located
under Pre-Designed Programs on the Display Panel Board.
Numbers one/two and five/six should toggle slowly.
•
•
If
you have a Jogger, Walker,orSimple, verify the elapsed
time and distance lights toggle.
If
not, then:
• Check the alignment
or
adjustmentofthe RPM
disc and the RPM sensor
cabLe
connection.
• Adjust the potentiometer, Located on the RPM
sensor.
•
If
aligned but the LEDs do not toggLe,
repLace
the
RPM sensor.
•
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TRAC
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PAGE
20
•
•
Step Seven Verify the RPM sensor is calibrated by pressing the + (Plus) key
or
fast key to raise the display readout from
0.0
to 3.5 (5.6
km
per hour).
•
If
you have a ProgrammableorSimple, verify the numbers 0 to
7, located under Percent Grade, are lit and number 8 is
blinking.
•
If
you have a Jogger, verify the numbers
0.0to3.5,
located
under Percent Grade, are lit and number
4.0
is blinking.
•
If
you have a Walker, verify the numbers 7 and 8, located under
Elapsed Time, are toggling.
If
yes, the RPM sensoriscalibrated.
If
no, then:
• Check for excessive dust on the RPM sensor and
disc.
• Remove the dust from the RPM sensor and disc,
blow air into the RPM disc area.
Or,
with a toothbrush, gently brush one side
of
the RPM disc and then gently brush the other side
of
the disc.
Be
careful youdonot hit the RPM
sensor with the toothbrushorany foreign objects.
• Adjust the potentiometer on the RPM sensor,
as
describedinStep Six.
•
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MANUAL
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PAGE
21
NOTE:Ifyou have a Walker, please skiptoStep
Ten.
Steps Eight and Nine discuss
elevation.
•
Step Eight
Verify the 0% (zero percent) switch at 0% grade and above 0% grade.
NOTE:
The
treadmill does not display the actual elevation during the
Motor Test Mode.
•
If
you have a Programmable, check under Pre-designed
Programs and verify LED number 4 is on and LED number 8 is
off, when the elevation is at 0% grade. Raise the elevation to
above 0% percent grade and verify that the LED number 4 is
off and LED number 8
is
on.
•
If
you have a Jogger, check under Percent grade and verify
LED number 7.S is on, when the elevation is at 0% grade.
Raise the elevation to above
0%
grade and verify the LED
number 7.5 is off.
•
•
If
you have the Simple, check under Percent Grade and verify
the number
15ison at
0%
grade. Raise the elevation to above
0% grade and verify the number
15isoff.
If
not, check the elevation switches cable connection.
NOTE:
If
thereisan
elevation-related problem, you may disable
the elevation system.
This
allows the treadmill to operate
nonnaLLy,
without the elevation operation.
UNISEN CUSTOMER SERVICE
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TRAC
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PAGE 22
•
p
r
l
•
l
•
To
disabLe
the eLevation
mOlor,
turn the power switch off. Then
simuLtaneousLy press the key number 0, while turning the power
switch
to ON.
The
dispLay
readoUl
says ELV OFF. The eLevation
will be disabLed until the power switch is turned off.
Jfyou
have a Simple with no numbers, simultaneously press the
DOWN Arrow key, while turning the power switch
to ON. The
dispLay
readout says ELV
OFF.
The
eLevation is disabLed until
the power switch is turned off.
NOTE:
In
the Diagnostic test, it is possibLe, aLthough unlikeLy, you could override the
system. For exampLe,
if
you press the elevation up arrow key, the treadmill elevates
until you release the up arrow key. On the early 2000 Series treadmill, it is possible
to overdrive the elevation
Limit
switches and eLevation grades.
Be sure
to pay attention to the display panel as you work with the treadmill in
Diagnostic test. The
LED
Lights
and readouts show you the exact position and
Limits
of
the treadmill.
Step Nine
Check the elevation motor speed.
• Press the UP Arrow key while verifying the elevation speed
located under Total Calories
in
this Test Mode. The elevation
motor speed should read approximately 60 revolutions per
second, as the treadmill elevates.
•
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PAGE
23
•
Press the DOWN Arrow
key
while verifying the elevation speed
located under Total Calories
in
this Test Mode. The elevation
motor speed should read approximately 60 revolutions per
second or higher, as the treadmill descends.
If
not, then:
• Adjust
VR3
on the Motor Control Board.
To
increase the speed,
tum
VR3
clockwise.
To
decrease the speed,
tum
VR3
counter-clockwise.
If
yes, proceed to the next step.
If
the display numbers aren't reading, check the elevation
sensor connection.
•
Step
Ten
If
an error code appears,
tum
the power switch to
OFF.
Wait
four seconds, then
tum
the power switch to
ON.
Replace the motor shroud by removing the bungie cord and lowering
the motor shroud until it touches the frame. Press the sides
of
the
motor shroud
to
the frame and attach the velcro fasteners. Using the
Phillips screwdriver, tighten the screw
in
the centerofthe motor
shroud.
•
Step Eleven Exit the Motor Test Mode by pressing the STOP key.
• Tum the power switch
to
OFF. Wait four seconds, then tum the
power switch
to
ON.
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TRAC
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PAGE
24
•
•
ACTIVATING DISPLAY
TEST
MODE
OF DIAGNOSTIC
TEST
Use the Display Test Modetocheck the display panel, key response, and quality
of
the LEDs. In addition, you may be instructed to activate the Display Test Mode
during preventive maintenance
or
troubleshooting.
To activate Display Test Mode, please follow these instructions:
Step One
Step
Two
Tum
the power switch to the OFF position.
Place the treadmill into Display Test Mode.
•
If
you have a Programmable, Walker,orSimple with number
keys, simultaneously press the key number 5, while turning the
power switch to ON.
•
•
If
you have a JoggerorSimple with no number keys,
simultaneously press the
+ (Plus) key, while turning the power
switch to ON.
NOTE:Ifyou cannot access Display Test Mode, you may need to
replace the display panel. For addifional injonnafion on
troubleshooting the display panel, please refer
to Chapter Three:
Troubleshooting
Error
Codes.
•
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TRAC
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PAGE 25
Step Three All the LEOs on the Display Panel should be lit. Press any key, except
the STOP key, to display the EPROM number.
• Please make note
of
this EPROM number.Ifthere are problems
with the display panel, STAR TRAC requires this EPROM
number to ship the correct replacement part.
•
Step Four
Step Five
Check the key response by individually pressing each key on the
display panel. Each key should beep and display a pattern
of
LED
lights on the display panel readout. The 0 key will beep, but no LED
lights will
be displayed.
If
not all the LEDs to form the pattern are lit, you may need to
replace the display panel. For additional information, please
refer
to Chapter Three: Troubleshooting Error Codes.
Exit the Display Test Mode.
• Press the STOP key.
• Tum the power switch to OFF. Wait four seconds, then tum the
power switchtoON.
•
UNlSEN CUSTOMER SERVICE
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PAGE
26
•
•
•
CHAPTER
THREE:
TROUBLESHOOTING ERROR CODES
This chapter outlines the speed, CPU elevation, and FS (fail safe) error codes and
howtosolve
the
error
code
problems.
To correct an error using this troubleshooting guide, locate the typeoferror code,
such as
SPD
ER 2, and follow the instructionsinthe flow charts.Ifthe error persists
continue to the next step and follow the instructions and so on.
In
this chapter, you will learn error codes for:
•
CONTEIVTS
SPEED
(SPD
ER)
ELEVATION
(EL
ER)
FAIL
SAFE
(FS ER)
CPU (CPU ER) ERROR
No
DISPLAY POWER
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PAGE NUMBERS
28
38
52
55
57
PAGE
27
SPEED
(SPD
ER)
ERROR CODES
Speed (SPD ER) error codes indicate that the RPM sensor may be damaged or the
CPU circuit is being interrupted, such
as
a ground problem or loose connection.
The following flow charts demonstrate the corrective steps for speed error codes 0,
1,
2, and 3. Begin these instructions by placing the treadmillinthe Motor Test Mode.
To enter Motor Test Mode, simultaneously press the 8 key, while turning the power
switch to ON.
If
you have a Simple with no number keys, simultaneously press the -
(minus) key, while turning the power switch to ON.
•
The display panel should read:
or
on older models:
o
o
3
2
0.0
0.0
NOTE: Please begin by cleaning dust and obstructions from the RPM disc and RPM
sensor.
•
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PAGE
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•