TREADMILL
SERVICE MANUAL
VOL 2.
1
TABLE OF CONTENTS
Introduction ……………….………..……………………………………………. 3.
How to use the manual …………………………………………
Safety Instructions ……………………………………………… 4.
Product Support …………………………………………………
CHAPTER 1. Preventative Maintenance Chart ……………………………… 5.
Running Belt Adjustment ……………………………………… 6.
Running Belt Waxing …………………………………………… 7.
CHAPTER 3. Diagnostics ………………………………………………………. 8.
Manager Mode …………………………………………………… 9.
Maintenance Mode ……………………………………………… 11.
Motor Test Mode ………………………………………………… 17.
Display Test Mode ………………………………………………. 18.
Speed Calibration ……………………………………………….. 19.
Elevation Calibration …………………………………………… 20.
CHAPTER 4. Troubleshooting ………………………………………………… 21.
Display Code Troubleshooting ……………………………… 22.
MCB Layout (LEDS) ……………………………………………. 26.
Display Board Assembly Wiring …………………………….. 28.
Fan Board Assembly Wiring ..………………………………… 30.
MCB Assembly Wiring …………………………………………. 31.
Drive Motor Wiring ……………………………………………… 34.
Complete Lower Chassis Wiring …………………………….. 36.
CHAPTER 6. Parts Lists ……………………………………………………….. 37.
2
INTRODUCTION
Welcome to the world of STAR TRAC. In your hands is the NEW STAR TRAC PRO
TREADMILL SERVICE MANUAL. This manual includes the PRO, PRO S, and the ELITE
model. Each section is easy to use, providing detailed instructions and quick maintenance
instructions.
We highly recommend that you read the entire manual prior to performing any maintenance
or repair procedure. The information on the following pages will enable you to begin easily,
quickly and safely.
How to use the manual
THIS IS NOT AN OWNER’S MANUAL. This Service Manual is intended for use by qualified
repair technicians as a guide to diagnose and correct service problems.
The Service Manual is divided into six chapters. Each section is provided with it’s own Table
of Contents to assist in locating specific topics and procedures. Titles and major headings
are located at the top of every page.
The Service Manual contains the following sections:
Chapter 1: Introduction - Provides a general overview of the Pro Treadmill, outlines safety
precautions to be observed when performing maintenance or repair.
Chapter 2: Preventive Maintenance Schedules - Outlines periodic preventive maintenance
checks and services; provides detailed procedures for specific maintenance tasks.
Chapter 3: Diagnostics - Describes how to access and use built-in diagnostic and
customizing features and capabilities.
Chapter 4: Troubleshooting - Provides information designed to help diagnose and correct
equipment problems. Troubleshooting information is arranged in a Symptom - Probable
Cause - Suggested Remedy format.
Chapter 5: Parts Replacement - Provides step-by-step illustrated procedures to remove
and install authorized infield replacement parts.
Section 6: Parts Breakdown - Contains an illustrated listing of all parts and assemblies
contained in the Pro Treadmill Series .
3
Safety Instructions
The following Safety Instructions apply whenever performing any maintenance or parts
replacement procedures.
1. Read each procedure COMPLETELY before starting any work. Give particular attention
to all NOTES, CAUTIONS and/or WARNINGS.
2. If the optional external wall powered power pack is used with the unit, MAKE SURE the
power pack is unplugged from the wall before handling any electrical components.
3. When disconnecting cable connectors, ALWAYS pull on the connector head, NEVER
the wires.
Product Support
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 the very heart of STAR TRAC’s business philosophy. This commitment to
service has been a major contributor to STAR TRAC’s success and growth in the worldwide
fitness equipment industry.
Technical Assistance
• When purchasing a part or requesting technical assistance, please contact our Product
Support Department: CALL TOLL-FREE: 1-800-535-4634 or 800-503-1221 US and
CANADA or 714-669-1660, please have the following information available:
1. STAR TRAC model.
2. STAR TRAC serial number.
3. Problem statement/symptom.
After Hours Voicemail Direct
• CALL TOLL-FREE: 1-800-486-4736
1. STAR TRAC model.
2. STAR TRAC serial number.
3. Problem statement/symptom.
4. Return phone number and contact name.
Fax Requests
• Domestic and international: FAX 714-669-0739
1. STAR TRAC model.
2. STAR TRAC serial number.
3. Problem statement/symptom.
4. Return phone fax number and contact name.
5. Purchase order or reference number.
6. Part description and quantity.
7. Ship to/bill to.
4
CHAPTER 1: Preventative Maintenance
Performing regular scheduled preventive maintenance is essential in keeping your PRO
TREADMILL in top operating condition. Without preventive maintenance, normal wear and
tear may cause cumulative effects, such as misalignment and early replacement of parts.
This section provides a list of factory-recommended preventive maintenance requirements,
along with detailed procedures for performing each task.
MAINTENANCE CHART
• D = Daily
• W =
• M = Monthly
• W = WAX
(depending on the amount of use, Monthly procedures may need to be performed more
frequently).
Weekly
INTERVAL PROCEDURE
DWM
►
Using a liquid non-abrasive cleaner: Formula 409™ or FANTASTIK™
Wipe down the following: display board, handrails, shroud, heart rate grips.
Note: Do not spray directly onto the display board or grips.
Inspect for wear and tear on exterior parts regularly, especially under the running belt.
Inspect the running belt for alignment and tension. (See page 6. Adjustments for
instructions.)
Inspect the line cord plug and cord for possible damage or loose connection.
►
W Periodic running belt re-waxing virtually eliminates belt down time, and maximizes the
Elevate the treadmill and vacuum under the unit. Note: Unplug the unit when
Vacuuming.
Verify running belt alignment and tension. Inspect the area under the treadmill for
Obstructions.
►
Lift the motor shroud and vacuum around the motor and electronics.
Clean and lubricate the elevation screws. Note: This must be done unplugged and
turned off.
►
Inspect the display and handrail screws for loosening. Inspect the display panel
Keys for wear.
life of the running belt. (See page 7. for Re-waxing instructions)
5
Running Belt Adjustments
The running belt and its headroller, drive belt, tailroller, and running deck are designed to be
self-centering, slip-free, and smooth-operating without the need for frequent adjustments.
Running belt sideward movement, slipping, or grinding after extended use,
or thumping during initial use, may be corrected by the following procedures:
Change Sideward Movement to TRACKING: If the running belt is not centered on the
tailroller and is either too far left or right, adjust tracking using the following steps:
1. Turn the treadmill on. Increase treadmill speed to 3.0 mph (5.0 kph).
2. Adjust tracking by adjusting the tailroller Allen screws (located at the back sides
of the tailroller) with a 1/4" Allen wrench in 1/4-turn increments.
If the running belt is tracking to the left, adjust the running belt to track to the right
Tighten the left tailroller Allen screw by turning clockwise, or loosen the right tailroller
bolt by turning counter-clockwise.
If the running belt is tracking to the right, adjust the running belt to track to the left.
Tighten the right tailroller Allen screw by turning clockwise or loosen the left tailroller
bolt by turning counter-clockwise.
3. After the running belt appears to be tracking properly, increase the treadmill speed
to 10.0 mph (16.0 kph) and verify that the belt stays centered.
Slipping-Running Belt: Remove the motor shroud and operate the treadmill slowly at 1 to 2
mph (2 to 3 kph). While observing the headroller, walk on the belt and try to slow it down by
gently applying pressure with your feet while holding the handrails. If only the running belt,
and not the headroller, slows down, tighten the running belt by turning both the right and left
tailroller adjustment bolts clockwise 1/4-turn. Repeat this adjustment unt il the running belt no
longer slips, ensuring that you turn both tailroller bolts an equal number of turns. Re-install
the motor shroud. If the headroller and the running belt both slow down, tight-en
the drive belt as described under “Slipping-Drive Belt”, below.
Slipping-Driver Belt: Adjust the treadmill incline to 5% to provide clearance underneath.
Set the ON/OFF switch to the OFF position and unplug the treadmill. Remove the motor
shroud. With a 1/2" socket wrench, loosen the four motor bolts. Use the socket wrench to
adjust the tension bolt in the middle of the motor bracket 1/4-turn clockwise, stretching the
drive belt. Tighten the motor bolts and re-install the motor shroud. Plug the treadmill in, turn
it on, and test for slipping as described under “Slipping-Running Belt”, above. Repeat this
step as necessary.
Thumping: Turn the treadmill off. Turn the right and left tailroller adjustment bolts counterclockwise with the 1/4" Allen wrench until the running belt is loose. Note the number of times
each bolt is turned. Remove excess accumulated running deck wax from the tailroller with a
credit card, a putty knife, or other flexible plastic implement. Tighten the running belt by
turning the adjustment bolts clockwise the same number of turns as they were loosened.
Turn the treadmill on and check for sideward movement and/or slipping of the running belt.
Tighten the tailroller adjustment bolts further, if necessary, in 1/4-turn increments.
6
Re-Waxing Belt
Periodic running belt re-waxing virtually eliminates belt down time, and maximizes the life of
the belt. Whenever the present distance is 2000 miles (or 3000 km) more than the LAST
DECK (last deck service), the start-up display will scroll REWAX BELT. This is a reminder to
have your maintenance or service provider perform the 5-minute belt re-waxing procedure at
your convenience. (Immediate service is not required). Wax is included in the treadmill.
TOOLS & MATERIALS
Bottle of Wax Powder (1)
Clean Towel (1)
Paint Stick or Ruler (1)
Diluted All-purpose Cleaner (409), or Bristle Brush
PROCEDURE:
Apply wax powder while belt & deck are still warm (5 minutes minimum use) for
optimum benefit.
1. CAUTION: TURN TREADMILL POWER OFF AND UNPLUG THE POWER CORD
BEFORE REWAXING THE BELT.
2. CLEAN DECK & BELT:
A. Using the paint stick or ruler, slide a towel under the middle of the belt from one side
of the frame to the other.
B. Hold the edges of the towel; pull to the tailroller; pull to the headroller; then pull the
belt down to wipe the remaining belt.
TIP: Fold the dirty towel and shake into trash.
3. LIFT BELT: Lift the left side (facing display) of the belt, about 12 inches down from the
motor shroud. Hold the belt up to elevate the belt from the deck.
4. SPREAD WAX: Flip the nozzle on the cap of the wax bottle. Point the nozzle at the deck.
Be sure that the bottle is tilted at a downward angle. Squeeze the wax bottle twice between
the running belt and the deck. TIP: Gently shake the bottle between each squeeze.
5. Repeat steps 3 and 4, about 18 inches from the end of the deck.
6. Repeat steps 3 through 5, on the right side of the belt/deck.
7. WALK: Plug in the treadmill. Turn the treadmill ON/OFF switch to the ON position. Start
the treadmill at 1 mph and walk on all sections of the belt and deck for 1 minute to ensure
the wax has been evenly distributed and worked-in properly.
8. CLEANUP: Turn the treadmill power OFF . Remove any excess wax with diluted cleaner
(409) and towel. TIP: Blow away extra wax first (like dust), then wipe.
9. DISPLAY UPDATE: Update the LAST DECK service mileage to remove the REWAX
BELT message.
A. Power ON the treadmill.
B. Enter MAINTENANCE SETTINGS (see Chapter 8).
C. Press the INCLINE DOWN key until the Information Window reads LAST DECK.
D. Use the 0 ~ 9 keys to enter the present treadmill distance.
E. Press the START key to enter and update the display.
F. Press the STOP key to exit MAINTENANCE SETTIN
7
CHAPTER 2: Diagnostics
The STAR TRAC Pro Series Treadmill contains diagnostic and customized modes. In these
modes you are able to check accumulated data about the past usage of the treadmill, test its
motor and display controls and investigate display code messages.
• Manager Mode (customize)
• Maintenance Mode (diagnostics)
• Motor Test Mode (d ia g nostics)
• Display Test Mode (diagnostics)
• Heart Rate Test Mode (diagnostics)
8
Manager Mode
After having used your Star Trac Pro treadmill for several workouts, you may wish to
specially customize your treadmill by changing some of its settings.
To engage Manager Mode:
1. Press and hold the “ 0 ”, “ 1 ” & “ START ” keys together. While holding the “ 0 ” &
“ START ” keys down, release the “ 1 ” key only.
2. The display will beep and display Manager Mode momentarily, then UNITS will be
displayed.
Once the treadmill is in Manager Mode, you may use the following keys:
INCLINE KEY: Displays the next or previous parameter.
SPEED KEYS: Allows the variable to be changed within the parameter.
ENTER KEY: Saves the value if changed in the EPROM (software).
Note: ENTER KEY must be pressed, for each value changed.
STOP KEY: Exists Manager Mode and restarts the treadmill with a “warm
start.”
0 – 9 KEYS: Enters new parameter values. If UNITS parameter is displayed,
key 5 starts DISPLAY TEST and key 8 starts MOTO R TEST.
HEART KEY: When pressed will automatically display manufactures default
value.
Note: ENTER KEY must be pressed, to save the default values if changed.
FOREST KEY: When pressed in MOTOR TEST mode will automatically
engage running belt calibration process.
Note: Do not press stop key or stand on running belt while the unit is in the
process of calibration.
9
Manager Mode
The following parameters may be changed using the previous keys:
Parameters Lowest
Value
UNITS
MN SPD
MX SPD
EL OPT
TIME
OP HRS
DIST
--- --- English Metric English English= units of lbs.,
0.1 2.5 English=0.5 Metric=1.0 0.5 Minimum speed in
5.0 20.0 English=10.0 Metric=20.0 10.0 Maximum speed in
--- --- ON OFF ON Turns the elevation
5 99 99 Maximum time in
0 0 --- --- 6,553.5 Total operating hours
0 0 --- --- 65,635 Total treadmill miles
Highest
Value
Option 1 Option 2 Default
Value
Meaning
miles, hours, minutes
Metric= units of kg.,
km, hours, minutes.
MPH or KM/HR
MPH or KM/HR
system ON or OFF.
minutes allowed for
program, including
warm-up/cool-down.
(Units=English)
or kilometers
(Units=Metric)
WEIGHT
SER NO
LANG
ENTRY
0 399 --- --- 155 Defaults (to user),
typical weight in lbs/kg
depending on what
setting (UNITS =
English or Metric
0 0 --- --- 65,535 Treadmill serial
number.
--- --- --- --- English Language in English,
Dutch, German,
Portuguese, Spanish,
Swedish, or Italian.
--- --- Units Tenths Units This variable changes
the starting speed in
Units or Tenths
10
Maintenance Mode
Maintenance Mode includes all of the items of Manager Mode, plus additional data that is
automatically saved 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 ” &
“ START ” keys down, release the “ 2 ” key only.
2. The display will beep and display MAINTENANCE momentarily, then UNITS will be
displayed.
Once the treadmill is in Maintenance Mode, you may use the following keys:
INCLINE KEY: Displays the next or previous parameter.
SPEED KEYS: Allows the variable to be changed within the parameter.
ENTER KEY: Saves the value if changed in the EPROM (software).
Note: ENTER KEY must be pressed, for each value changed.
STOP KEY: Exists Manager Mode and restarts the treadmill with a “warm
start.”
0 – 9 KEYS: Enters new parameter values. If UNITS parameter is displayed,
key 5 starts DISPLAY TEST and key 8 starts MOTO R TEST.
ALPINE KEY: When pressed will automatically display manufactures default
value.
Note: START KEY must be pressed, to save the default values if changed.
FOREST KEY: When pressed in MOTOR TEST mode will automatically
engage running belt calibration process.
Note: Do not press stop key or stand on running belt while unit is calibrating.
11
Maintenance Mode
The following parameters may be changed using the previous keys:
Parameters Lowest
Value Highes
UNITS
MN SPD
MX SPD
ELEVATION
TIME
OP HRS
--- --- English Metric English English= units of lbs.,
0.1 2.5 English=0.5 Metric=1.0 0.5 Minimum speed in
5.0 20. 0 English=10.0 Metric=20.0 12.5 Maximum speed in
--- --- ON OFF ON Turns the elevation
5 99 99 Maximum time in
0 0 --- --- 0 Total operating hours
t
Value
Option 1 Option 2 Default
Value
Meaning
miles, hours, minutes
Metric= units of kg.,
km, hours, minutes.
MPH or KM/HR
MPH or KM/HR
system ON or OFF.
minutes allowed for
program, including
warm-up/cool-down.
DISTANCE
WEIGHT
SER NO
LANGUAGE
ENTRY
0 0 --- --- 0 Total treadmill miles
(Units=English)
or kilometers
(Units=Metric)
0 399 --- --- 155 Defaults (to user),
typical weight in lbs/kg
depending on what
setting (UNITS =
English or Metric).
0 0 --- --- 0 Last five digits of
Treadmill serial
number.
--- --- --- --- English Language in English,
French, Dutch,
German, Portuguese,
Spanish, Swedish,
Italian, or Katakana.
--- --- Units Tenths Units This variable changes
the starting speed in
Units or Tenths
12
Loading...