Star Trac Pro CrossTrainer Elite CrossTrainer, Pro CrossTrainer, Elite CrossTrainer Service Manual

Pro CrossTrainer

Elite CrossTrainer

Service Manual

CrossTrainer Service Manual

Table of Contents

Table of Contents ..............................................................................................................................................................1

Preventive Maintenance....................................................................................................................................................2

Settings - Maintenance Mode..........................................................................................................................................3

Diagnostics - Display Codes ........................................................................................................................................... 5

Diagnostics - LED Test ....................................................................................................................................................6

Diagnostics - Keypad Test............................................................................................................................................... 7

Diagnostics - Heart Rate Test, Measurements .............................................................................................................. 8

Diagnostics - UB Calibration...........................................................................................................................................9

Trouble Shooting - Incorrect Model Setting ................................................................................................................10

Trouble Shooting - Noises : Pinging .............................................................................................................................11

Trouble Shooting - Noises : Bearings ........................................................................................................................... 14

Trouble Shooting - Excess Lateral UB Arm Movement...............................................................................................17

Part Installation Procedure - Shrouds..........................................................................................................................18

Part Installation Procedure - Keypad ...........................................................................................................................21

Part Installation Procedure - LCB, Batt. And UB Board ............................................................................................. 23

Part Installation Procedure – Upper Crank Arm........................................................................................................... 27

CrossTrainer Parts List................................................................................................................................................... 30

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Preventive Maintenance

To keep your Star Trac CrossTrainer in top condition, Star Trac strongly recommends performing
regular daily, weekly and monthly preventive maintenance routines outlined below.

Daily Maintenance

x Remove excessive accumulations of dust, dirt and other substances by using a clean, soft

cloth and a non-abrasive liquid cleaner, such as Formula 409™ or FANTASTIK™. Wipe down
the exterior of the display panel, upper body arms, pedals, shrouds and heart rate grips.

Note: Do not spray directly on the display or heart rate grips.
Spray on the cloth first.

Weekly Maintenance

Perform the following services each week:

x Vacuum the floor under and around the CrossTrainer. Move the unit to another spot, if

necessary, to vacuum thoroughly.

x Inspect the screws (i.e. display panel mounting screws) for security, and retighten if

necessary.

x Inspect the display panel keypads for wear.

Monthly Maintenance

Perform the following services each month, or as needed:

x Check that the pedals and shrouds are secure.
x Check the upper body arms for looseness. Tighten screws when necessary.
x Check for smooth and quiet operation of all moving parts.

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Settings - Maintenance Mode

The Maintenance Mode allows you to query and modify the basic settings of the Star Trac
CrossTrainer.

Engaging Maintenance Mode

1. Press and hold the , and keys together.

2. A beep will sound and the “MAINTENANCE MODE” will display momentarily in the information
window.

3. Release all keys. “SERIAL NO XXXXX” will display in the information window.

Modifying the Maintenance Mode

The following keys are used to modify Maintenance Settings:

Upper and Lower Data Information Window SCROLL keys: Display the next and
previous settings.

Increase and Decrease Level Keys: Adjust the value of the displayed setting up
and down respectively, in increments of 1 unit.

OK Key: Updates (saves) the value of the display setting in the Flash memory, and exits
Maintenance Mode.

Maintenance Mode Settings

The items that you may display and change:
Default values set in ()

Serial Number

Date
Display Vers 1
Display Vers 2

LCB Vers

Units

Time

Weight

CrossTrainer serial number (0)
Manufactures date for the CrossTrainer (07/03)
Display software version (N/A)
Display software version (N/A)
LCB software version (N/A)
English = units of pounds, miles, feet inches; (English)
Metric = units of kilograms, kilometers, centimeters
Maximum time in minutes allowed for program, excluding warm-up and cool­down (20)
Default (to user), typical weight in lb (UNITS=English) or kg (UNITS = Metric)
(155 lbs, 70 KG)

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Settings - Maintenance Mode (cont.)

Language

Model

LCB Ver2

CSAFE

Auto Status

Wall Power

IRDA

OPER Hours

Quick Start

Manual

TB Begin

TB Inter

TB Diff

Auto Pilot

IHR Pro

CHR Pro

CW Pro

Alpine

Rndm Prog

UB Revs

Comm Lost

Key Down

Batt Low

Repl Batt

LED Test

Keypad Test

Heart Rate Test

Measurements

UB Calibration

Language is English, Dutch, French, German, Spanish, Swedish, Italian or
Katakana (English)
PB-UB = Pro Bike Upright, PB-RB = Pro Bike Recumbent, Pro CT = Pro
CrossTrainer, Elite CT = Elite CrossTrainer, Stepper = Pro Stepper
LCB hardware version (N/A)
Turns on/off CSAFE functionality (Off)
Turns on/off the unsolicited status of the CSAFE feature (Off)
Turns the wall power setting on/off (Off)
Turns on/off infrared port functionality (Off)
Total operating hours (0)
Number of times the Quick Start program was run since last reset (0)
Number of times the Manual program was run since last reset (0)
Number of times the Total Body – Beginner program was run since the last
reset (0)
Number of times the Total Body – Intermediate program was run since the last
reset (0)
Number of times the Total Body – Difficult program was run since the last reset
(0)
Number of times the Auto Pilot program was run since the last reset (0)
Number of times the Interval Heart Rate Control program was run since the last
reset (0)
Number of times the Constant Heart Rate Control program was run since last
reset (0)
Number of times the Constant Watt Control program was run since the last reset
(0)
Number of times the Alpine program was run since last reset (0)
Number of times the Random Hill program was run since last reset (0)
1/40 the number times the UB motor pot has turned
Number of times a Comm Lost condition has occurred. See Display Codes
Number of times a Key Down condition has occurred. See Display Codes
Number of times a low battery condition has occurred. See Display Codes
Number of times the need for battery replacement has occurred. See Display
Codes
Access to integral LED test function
Access to integral keypad test function
Access to integral heart rate system test function
Access to integral measurements function
Access to integral upper body system calibration function

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Diagnostics - Display Codes

Display Codes

Star Trac CrossTrainers perform a self-test at the beginning of every workout. If a problem is
detected, a message displays before or after the workout, depending on the nature of the problem.

Key Down – One or more keys on the display panel are stuck in the “on” position for at least 10
seconds. This can occur if a user presses keys before the system is turned on.

Comm Lost – Communication between the Load Control Board (LCB) and the display are lost. This
can occur if the display cable is not connected securely at install.

Batt Low – Upper body actuator is commanded to work and the battery voltage is less than 5.7 volts.

Repl Batt – Upper body actuator is commanded to work and the battery voltage is less than 5.3 volts.

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Diagnostics - LED Test

LED Test

The LED Test can be used to verify that all LED (lights) are functioning on the display assembly.

To engage the LED Test

1. Enter the Maintenance Mode (see Settings – Maintenance Mode).

2. Press

3. Press

4. Check for any burned out lights.

5. To exit the LED Test, press

If any of the LED’s do not illuminate, they may not be functioning and the display electronics should
be replaced.

until LED Test is displayed in the information window.

to enter the LED Test. All lights on the display should be on.

.

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Diagnostics - Keypad Test

Keypad Test

The Keypad Test can be used to verify that all keys are functioning on the display assembly.

To engage the Keypad Test

1. Enter the Maintenance Mode (see Settings – Maintenance Mode).

2. Press

3. Press

4. Press each key on the display. Each time you press a key, the information window will display
which key has been pressed.

5. To exit the keypad test, press

If any of the keys do not respond, they may not be functioning and the display keypad must be
replaced.

until Keypad Test is displayed in the information window.

to enter the Keypad Test.

.

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Diagnostics - Heart Rate Test, Measurements

Heart Rate Test

Heart Rate can be checked using the Heart Rate Test.

To verify heart rate operation:

1. Enter the Maintenance Mode (see Settings – Maintenance Mode).

2. Press

3. Press

4. The display will read TELEMETRY.

5. To exit the heart rate test, press

until Heart Rate Test is displayed in the information window.

to enter Heart Rate Test.

a. If checking contact heart rate it will read “CONTACT” and the heart rate number.
b. If checking Polar, the display will read “TELEMETRY” and the heart rate number.

.

Measurements Mode

Measurements can be done to verify the voltage of the battery, and the UB motor’s position voltage
feedback*.

To verify the battery voltage:

1. Enter the Maintenance Mode (see Settings – Maintenance Mode).

2. Press

until Measurements is displayed in the information window.

3. Press to enter Measurements.

4. The display will read “BATT VLT = “and the voltage of the battery.

5. Press “1” to switch to upper-body motor voltage display.

6. The display will read “UB VOLTS =” and the voltage denoting the position of the UB motor.

7. To view motor voltage again, press “0”.

8. To exit the measurements, press

*Elite model only.

.

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Diagnostics - UB Calibration

UB (Upper Body) Calibration (Elite Only)

The UB Calibration will set the minimum and maximum range of the upper body arms in which they
can move within. You can do a Manual Calibration or an Auto Calibration. Auto Calibration is
recommended.

To calibrate the Upper Body:

1. Enter the Maintenance Mode (see Settings – Maintenance Mode).

2. Press

3. Press to enter UB Calibration Mode.

Manual Calibration

1. For Manual Calibration press 1.

2. Press the
save.

3. Press the until the upper body actuator stops, and then press the to save.

Auto Calibration

For Auto Calibration press 2. The display will automatically raise the arms up, then bring them back
down to calibrate the positions.

until UB Calibration is displayed in the information window.

until the upper body arms stop moving (None Position), and then press to

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Trouble Shooting - Incorrect Model Setting

The display electronics on the CrossTrainer can be configured to operate with many different models
of Star Trac products. For them to operate properly, the correct model must be set in the
Maintenance mode.

If the correct model is not set, the following may happen:

x When the unit is powered up, the display will read “Pro Bike” (or Pro Stepper) in the level

profile window.

x The display will read “Start Pedaling” or “Start Stepping” instead of “Start Striding”.
x Also, some programs will not work when the keys are pressed. i.e. When pressing the Total

Body program key, Warm Up program will start.

If you experience any of these symptoms, engage the Maintenance mode to correct the Model
setting.

Engaging Maintenance Mode

1. Press and hold the , and keys together.

2. A beep will sound and the “MAINTENANCE MODE” will display momentarily in the information
window.

3. Release all keys. “SERIAL NO XXXXX” will display in the information window.

4. Press the

5. Press the

x Pro CT = CrossTrainer Pro which has fixed upper body mechanism.
x Elite CT = CrossTrainer Elite which has the adjustable upper body mechanism.

6. Press

7. Test for functionality.

until the display reads “Model”.

until the correct setting shows.

to save the setting and exit the maintenance mode.

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Trouble Shooting - Noises : Pinging

While striding on the Star Trac CrossTrainer, a pinging (metal on metal) noise is heard.

Possible Causes:

x The pin has come loose on the upper crank arm.
x Not enough clearance between the lower crank disk and the bolt on the end of the pedal arm.

Check the Upper Crank arm/Pin

1. Check the gap between the crank arm and leg assemblies (right and left). There should be no

more than 1/8 inch (4 mm) gap.

2. If there is more than 1/8 inch (4 mm) gap, replace the crank arm (721-0109). The pin has come

loose and shifted. This causes the pedal arm to misalign and rub the lower crank disk.

If the gap between the crank arm and leg assemblies is correct then check the gap between the
lower crank disk and the end of the pedal arm.

Checking Crank Disk and Pedal Arm Gap

1. Remove the center shroud cover.

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Trouble Shooting - Noises : Pinging (cont.)

2. Have someone ride the unit and verify where the contact between the pedal arm and the disk

is occurring.

3. If the head of the bolt in the forward end of the pedal arm is hitting the disk, you may be able to

adjust the position of the bolt by twisting the arm to eliminate the noise.

4. Use the largest adjustable end wrench (crescent wrench) to twist the base of the pedal arm.

x Place a piece of paper over the pedal arm, to prevent scratching it with the wrench, just in

front of the foot pedal but before the upward bend.

x Slide the wrench over the paper and all the way down on the pedal arm. Be sure the handle

of the wrench points toward the middle of the machine.

5. Carefully push down on the handle of the wrench to twist the pedal arm, moving the top of the

pedal arm and the bolt head away from the disk. You may need to use a breaker bar on the
handle of the wrench to get more leverage.

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