Star Trac TREADMILL, PRO, PRO S, Elite Service Manual

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 [phone]

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

Maintenance Mode

Parameters Lowest

Value

HR CONTROL

HEART RATE

METS

WATTS

PAUSE

SCALE

INFRARED

COM

CSAFE

FAN

--- --- ON OFF ON OFF= Heart Control

--- --- POLAR

--- --- ON OFF OFF OFF= METS disable

--- ---- ON OFF OFF OFF = WATTS

30 60 30

--- --- ON O FF On Off = disable weight

--- --- ON OFF OFF Off = disable infrared

--- --- ON OFF Off Off = disable

--- --- O n Off On Of f = disable display

Highest
Value

Option 1 Option 2 Default

Value

Both POLAR, CONTACT or

45 Seconds of pause

CONTACT

BOTH

45
60

POLAR

CONTACT

BOTH

30
45
60

Meaning

disable

ON= Heart Control

enabled

BOTH (Polar &

Contact)

ON= METS enable

disable
ON = WATTS enable

time during work out

program.

scales

On = enable weight

scales

hardware

ON = enable infrared

hardware

entertainment

hardware

On = enable

entertainment

hardware

(Cardio Theater /

Fitlinks)

fans

On = enable display

fans

AUTO STOP

Entertainment

--- --- O n Off On Off = disable load

--- --- O n Off Off Off = disable enter-

detection
On = enable load
detection

tainment display key
On = enable enter­tainment display key

13

Maintenance Mode

Parameters Lowest

Value

ACCEL TIME

DECEL TIME

LOCK OUT

LOCKOUT ID

RAIL STOP

10 REV

CNT/RV

MN PWM

1/2 PWM

MX PWM

DATE

25 60 --- --- 25 Time, in seconds, to

20 60 --- --- 20 Time, in seconds, to

--- --- ON OFF OFF OFF = disabled

10000 65535 12345 Treadmill Lockout ID

--- --- ON OFF OFF OFF = Disables Euro

22.0 74.0 30.7 = For

1 31 31 =

2 100 --- --- 60 Minimum PWM

150 300 --- --- 260 1/2 Maximum PWM

380 512 --- --- 440 Maximum PWM

--- --- --- --- 0 Manufacturing date.

Highest

Value

Option 1 Option 2 Default

Value

110v units

Magnetic

RPM Sensor

35.6 = For
220v unit

31 =

Magnetic

RPM Sensor

30.7 Inches of belt traveled

125 Number of counts per

Meaning

reach max speed.

reach 0 mph (0km/hr)

ON = enabled

handrail stop.
ON = Enables Euro
handrail stop

for 10 revolutions,

1.6” pulley:27.5

1.7” pulley: 29.1

1.8” pulley:30.7 (110v)

2.1” pulley:35.8(220v)

RPM Revolution.

automatically done.

automatically done.

automatically done.

NO RAIL

STOP

KEY DN

SPEED CHG

EL STL

0 255 --- --- 0 # of times the Stop

0 255 --- --- 0 # of times, one of the

0 255 --- --- 0 # of times a sudden

0 255 --- --- 0 # of times an elevation

Switch/ Stop key was

down or disconnected

on power-up since last

reset.

keys was down or

depressed on power-

up since last reset.

change in speed was

detected.

stall was detected.

14

Maintenance Mode

Parameters

EL RANGE

EL LOST

NO MOTOR

NO

SENSOR

ELEV

ZERO

ELEV MAX

LAST

DECK

LAST BELT

LAST

MOTOR

MASTER

PIN

Lowest

Value

175 242 --- --- 240 Voltage to elevation

25 170 --- --- 57 = 120V

--- --- 13579 13579 13579 Master pin personal

Highest

Value

0 255 -- - --- 0 # of times elevation

0 255 -- - --- 0 # of times elevation

0 255 --- --- 0 # of times No Motor

0 255 --- --- 0 # of times No Sensor

0 65565 --- --- 0 # of miles when the

0 65535 --- --- 0 # of miles when the

0 65535 --- --- 0 # of miles when the

Option 1 Option 2 Default

Value

Black motor
25 = 120v
Silver motor
80 = 230V

Meaning

range was detected.
(EL Range will detect
between the Pot read

of 253 and 255).

range was detected.

(EL Lost will detect

when the display has

lost the elevation

motor Pot reading).

was detected.

(display when there’s

no motor current

detected, but there is

belt movement).

was detected.

(No Sensor will

display when there’s

no RPM feedback).

motor to obtain 0%.
Multiply by 0.0196608
to = actual voltage.

Voltage to elevation
motor to obtain 15%.
Multiply by 0.0196608
to = actual voltage

deck was last waxed.

After a 2000 mile (or

3000 KM) difference,

“REWAX BELT” will

scroll in the display

until “LAST DECK”
miles are updated.

last running belt was

replaced.

last motor was

replaced.

trainer configuration.

15

Maintenance Mode

Parameters Lowest

Value

MODEL

MANUAL

FOREST

TRIAL

ALPINE

MYSTERY

5K LAKE

10K BAY

PALM PC

CUSTOM

DHRC

0 255 -- - --- 1 Model number used

0 65,535 --- --- 0 # of times Manual

0 65535 --- --- 0 # of times “Forest

0 65535 --- --- 0 # of times “Trial

0 65535 --- --- 0 # of times “Alpine

0 65535 --- --- 0 # of times “Mystery

0 65535 --- --- 0 # of times “5K Lake

0 65535 --- --- 0 # of times “10K Bay

0 65535 --- --- 0 # of times “Palm PC

0 65535 --- --- 0 # of times “Dynamic

Highest

Value

Option 1 Option 2 Default

Value

Meaning

by CSAFE to

distinguish models

and equipment.

Program was used

since last reset.

Program” was used

since last reset.

Program” was used

since last reset.

Program” was used

since last reset.

Program” was used

since last reset.

Program” was used

since last reset.

Program” was used

since last reset.

Custom Program”

was used since last

reset.

Heart Rate Control

Program” was used

since last reset.

CUSTOM

TRAINER

QUICK-

START

0 65535 --- --- 0 # of times “Custom

0 65535 --- --- 0 # of times “Personal

0 65535 --- --- 0 # of times “Quick-

Program” was used

since last reset.

Trainer Program” was

used since last reset.

Start Program” was

used since last reset.

16

Motor Test Mode

Motor Test Mode allows you to test major components such the RPM Sensor, Motor
response, MCB PWM readings and engages auto-calibration. To engage Motor Test Mode:

***Caution*** : Do not stand on the running belt while performing these test.

WHEN SHOULD MOTOR TEST MODE BE ENGAGED?

Motor Test Mode should be engaged whenever a speed or elevation issue occurs.

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.

3. Then press key “ 8” display will read:

240 3 .0

A. Elevation Motor Range. B. PWM Duty Cycle. C. RPM feedback

Once the treadmill is in TEST Mode, you may use the following keys:

INCLINE KEY: Adjust voltage to incline motor, inclines the treadmill in
increments of 1%. When using the Incline Keys verify the elevation system is
responding correctly by the following:

• As the treadmill elevates up and down verify the corresponding LEDs D31 & D32
light up on the MCB. (See page 22-23 for MCB/LED layout

• Verify that the Elevation Motor Range (see above A column) is changing in
increments of 1% as the treadmill elevates up and down.

Caution: Do not elevate treadmill above 15% = 57 (110v units), 80 (220v units) or
below 0% = 240 (110 & 220v units) mechanical damage may occur.

SPEED KEYS: Adjust the PWM duty cycle and motor speed up and down,
respectively, in increments of 0.1 mph (UNITS=English) or 0.1km/hr (UNITS =
Metric). When using the Speed Keys verify the speed control system is
responding correctly by the following:

• As the treadmill begins to increase speed, verify that the display registers RPM
feedback (see above C column) in increments of 0.1 mph/km.

FOREST KEY: Starts automatic calibration of minimum, 1/2 maximum, &
maximum speed.

.
STOP KEY: Exists MOTOR TEST Mode and restarts the treadmill.

17

Display Test Mode

Display Test Mode allows you to test the light-emitting diodes (LEDs), it also allows software
version to be displayed. To enter Display Test Mode:

***Caution*** : Do not stand on the running belt while performing these test.

WHEN SHOULD DISPLAY TEST BE ENGAGED?

Display Test should be done if any problems occur with either missing LED segments, a key
fails to respond or when a KEY DN (key down) display code is given.

1. Press and hold the “ 0 ”, “ 2 ” & “ START ” keys together. While holding the “ 0 ” & “

START ” keys down, release the “ 2 ” key.

2. The display will beep and display MAINTENANCE SETTINGS.

3. Press and release the “5 key. Observe the display: DISPLAY TEST. Pressing the

will automatically scroll through all the keys and LED segments.

4.Pressing the “1” key once will display the MCU1 software version. Pressing the SPEED

UP key will verify MCU2 software, FIFO1 and FIFO2.

5. Press the to go back to DISPLAY TEST.

6. Pressing the “2” key once will display KEYBOARD TEST. Press any key on the display

at this point and observe the information window. Verify on the display screen that each key
pressed matches the button pressed.

Note: If display screen does not match the button pressed or does not respond to the key
pressed, then we recommend replacing the keypad.

7. Press the to go back to DISPLAY TEST.

8. Pressing the twice will EXIT DISPLAY TEST.

18

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.

***Caution*** : Do not stand on the running belt while performing these test.

WHEN SHOULD AUTO-CALIBRATION BE ENGAGED?

Auto-calibration should be done every time MN, MX SPD & UNITS parameters have been
changed in either MANAGER or MAINTENANCE MODES. Auto-calibration must be
engaged when speed controlling components have been upgraded or replaced such as;
MCB, Display Board, Drive Motor & RPM Sensor.

1. Press and hold the “ 0 ”, “ 2 ” & “ START ” keys together (or the “0” , “2” ). While holding

the “ 0 ” & “ START ” keys down, release the “ 2 “ key. The display will beep and
display MAINTENANCE MODE.

2. Press and release the “8” key. Display will read: 240 3 .0 if treadmill is at 0%.

3. Press key, display will read: CALI treadmill will go into an automatic

speed calibration for less than 3 minutes. Press “STOP” key to exit Motor Test.
NOTE: If Auto-calibration fails to give the correct response refer to Chapter 4.

4. Press key to exit Motor Test.

19

Elevation Calibration

Re-calibrating the 0% or 15% elevation may become necessary if the Elevation Motor
potentiometer goes out of range or looses range.

WHEN SHOULD ELEVATION CALIBRATION BE ENGAGED?

Elevation Calibration should be engaged in combination with the Motor Test Mode when
dealing with elevation issues and display codes such as EL RANGE and EL LOST

NOTE: Do not elevate treadmill above 15% = 57 (110v units), 80 (220v units) or below
0% = 240 (110 & 220v units) mechanical damage may occur.

1. Press and hold the “ 0 ”, “ 2 ” & “ START ” keys together. While holding the “ 0 ”

& “ START ” keys down, release the “ 2 ”. The display will beep and display

MAINTENANCE MODE.

2. Press and release the “8” key. Display will read: 240 3 .0 if the treadmill is at 0%

Note: If the treadmill is not at 0%, then press the elevation keys until the

unit is leveled at 0%.

3. Once the unit is leveled and the display is reading 240 3 .0 press the “0” key once, the

letter Z will be displayed for 0% setting. Press the key to save.

4. Pressing the INCLINE UP key until unit reaches desired maximum elevation (15%) “0”

Press the “ 0 “ key a second time the letter M will be displayed for 15% setting. Press
the key to save the above elevation.

NOTE: 110V units maximum elevation is 57 and 80 for 220v units.

5. Press key to exit Motor Test.

NOTE: Verify that the Elevation Motor Range (see above A column) is changing in

increments of 1% as the treadmill elevates up and down. Erratic increment changes would
indicate the display cable may be faulty.

20

CHAPTER 3: Troubleshooting

Should the STAR TRAC PRO TREADMILL experience a problem or a display code appear,
the following chapter will help determine the precise reason for the problem.

Included are troubleshooting and display code charts.

• Display Code Troubleshooting

• MCB LED Layout

• Main Drive Assembly Wiring

• Display Board Assembly Wiring

• Fan Board Assembly Wiring

21

Display Code Troubleshooting Chart

Display Code Description of code Possible Cause Solution

No Rail Stop

# of times the Stop Switch/

Stop key was down or

disconnected on power-up

since last reset.

1. Disconnected Stop
Switch on the
handrail or in the
upper display
board.

A. Car efully pop-

out the handrail
stop switch from
the handrail and
check connec­Tion.

B. Verify that the

Stop Switch is
not damaged or
that it is sticking.

C. Remove left

handrail and
check Stop
Switch within the
handrail.

D. Carefully remove

the display
board and check
connection. See
page 28.

E. Replace Stop

Switch Assembly

KEY DN

SPEED CHG

# of times, one of the keys

was down or depressed on

power-up since last reset.

# of times a sudden change

in speed was detected.

2. Stop Key on the
Display Board
faulty.

1. One or more
key(s) on the
display panel are
faulty or stuck.

1. Sudden speed
change was
detected from the
RPM Sensor.

A. Engage Display

Test and check
STOP KEY. See
page 18.

A. Engage Display

Test and check
key pad re­response. See

page 18.

A. Engage Motor

Test Mode, see
page 17 and
verify speed
response. No
response would
indicate RPM
Sensor re­placement.

22

B. Verify that the

RPM Sensor
LED on the MCB
is responding,
see page 26. If
LED does not
respond replace
MCB.

EL STL

# of times an elevation stall

was detected.

2. Speed is irregular at

high or low speeds.

1. Elevation system
has malfunctioned.

A. Engage

Manager Mode
and verify that
the MIN SPD, ½
SPD and MAX
SPD are set
correctly. See
page 9.

B. Engage Speed

Calibration, see
page 19. If
speed calibration
can not be
obtained,
replace the
MCB.

C. Turn unit off and

verify that the
motor brushes
are secured
within the motor.

A. Engage Motor

Test Mode, see
page 17 and
verify elevation
response and
corresponding
LEDs on the
MCB operate
correctly, see
page 26. No
LED or Elevation
Motor response
would indicate
MCB re­placement.

B. If elevation

motor appears to
grind or overheat
would indicate
Elevation Motor
replacement.

23

2. Foreign
obstruction not
allowing the
elevation system
to elevate.

A. Ver if y that no

foreign
obstruction is
blocking the
elevation screws
or elevation belt
from elevating.

EL RANGE

# of times elevation range

was detected.

3. Elevation screws
binding.

4. Elevation system
loose causing
bind.

1. Elevation motor

readings are outside
the range.

A. Elevation screws

that have not
been cleaned or
lubricated as
outlined in the
maintenance
chart, see page
5 will cause the
elevation system
to bind.

A. Verify that the

elevation idler is
not loose or
damaged.

A. Engage

Elevation
Calibration, see
page 20 and
verify that the
elevation motor
readings are
within range.

EL LOST

# of times elevation lost was

detected.

1. Elevation motor
readings are
outside the range
or reading is lost

A. Com bine Motor

Test Mode, see
page 17 with
Elevation
Calibration, see
page 20 and
verify that the
elevation motor
readings are

within range.
B. Verify that the
Elevation Motor
Range is
changing in
increments of
1% as the
treadmill elev­ ates up and
down. Erratic

24

increments
would indicate
the display cable
or elevation
motor is faulty.

NO SENSOR

# of times no sensor was

detected.

1. Sudden speed
change was
detected from the
RPM Sensor or no
loss of speed
feedback has
been detected.

2. Cable loose or
interference. See
note below for
troubleshooting
instructions.

A. Engage Motor

Test Mode, see
page 17 and
verify speed
response. No
response would
indicate RPM
Sensor re­placement.

B. Verify that the

RPM Sensor
LED on the MCB
is responding,
see page 26. If
LED does not
respond replace
MCB.

D. Engage

Manager Mode
and verify that
the MIN SPD, ½
SPD and MAX
SPD are set
correctly. See
page 9.

E. Engage Speed

Calibration, see
page 19. If
speed calibration
can not be
obtained,
replace the
MCB.

NOTE: verify that all cables are secured and tie wrapped away from the RPM sensor. The magnet

on the display cable will bounce as the unit is in operation and may hit the connector for the RPM
sensor causing it to loose contact for a second and the no sensor code will appear. See diagram:

25

MCB (motor control board) Layout

)

I-LIMIT (D16

MTR SHRT (D40)

+18V (D33)

MTR AC (D18)

MOTOR (D10)

AC

PWM (D12)

V_CON (D34)

SPD SENSR (D30)MTR ENABLE (D24)

DOWN (D31)

UP (D32)

The above LED’s are designed to help you determine at a quick glance if power is being
applied to specific components such as; display, motor and RPM sensor. Combining this with
Motor Test Mode will eliminate possible causes that may result to downtime.

The following page provides the definition for each LED.

26

MCB (motor control board) Layout

Designation

D10 MOTOR AC power is ‘on’, Motor is hooked up and relay is

D12 PWM PWM command / signal is present.
D16 I-LIMIT LED should blink once when AC voltage is first applied to

D18 MTR AC AC power is ‘on’, relay is energized and rectified AC line

D24 MTR ENABLE Relay is ‘on’ (i.e. energized).
D30 SPD SENSR Blinks when speed is detected. Blinking rate or ‘on’ rate

Description

energized. This LED will stay lit for a few minutes after
AC voltage is removed or relay turned off.

Motor Controller board and should stay off at normal
operation. When I-LIMIT (Over current) condition is hit,
this LED will turn on. The MCB will shut down the drive to
the motor when over current (Fault) condition is
maintained for more than 5 seconds to protect the motor
and MOSFET. This LED will stay on until the treadmill is
reset or STOP button is hit.

voltage is present.

depends on the speed detected.

Message When LED Is On

D31 DOWN Elevation Down command is present.
D32 UP Elevation Up command is present.
D33 +18 V Always ‘on’ when MCB supply voltage is present.
D34 V_CON Always ‘on’ when Console supply voltage is present.
D38 AC Stays ‘on’ when AC line voltage (110VAC/220VAC) is

present.

D40 MTR SHRT Turns ‘on’ when the motor is SHORTED.
TP1 Test Pin 1 Current sense feedback test-pin for troubleshooti ng .
TP2 Test Pin 2 Brush sense feedback test-pin for troubleshooting.
TP3 Test Pin 3 Power ground test-pin for troubleshooting.

P7 N/A Activates the relays for troubleshooting.
P8 N/A Bypasses the speed input for troubleshooting.

27

Display Board Assembly Wiring

-

28

Display Board Assembly Wiring (continued)

Complete wiring view of the back of a Pro Tread display

29

Fan Board Assembly Wiring

715-3444 cable J3A

Lower Chassis

715-3419 cable P4A

F

n P

B P

r 1-

44

715-3459 Fan Board Voltage Key, 110V

30

MCB (motor control board) Assembly Wiring

RPM Sensor

Ground

Main I/O Interface cable
from upper display
J1/J1A plugged in here.

Elevation Interface

31

MCB (motor control board) Assembly Wiring

p

715-3423

er

y

P9 Fan Board.

4

MCB
Assembl

gnd

P1 EMI/Harmonic Filt

P2

Fan Board 715-3423

P4

J3

32

MCB (motor control board) Assembly Wiring

MCB

3

J1/J1A Display Cable

Main I/O Interface from Display to MCB

33

Drive Motor Wiring

n

Locking Wire Saddle

Motor Network Filter
assembly 715-3466

Grounds

Drive Motor with ferrite

Fan Board Assembly
715-3423

Elevatio

34

Input from MCB (P4) 715-3426

Drive Motor Wiring

RPM Sensor

Elevation Motor

Fan PCB

AC Line to MCB

Output to Motor

Electrical Wiring & Cable Routing

EMI Filter 440-0257

35

Complete Lower Chassis Wiring

Fan Board

Motor

MCB

Elevation Motor

AC Breaker Switch

EMI Filter

Motor Network Filter

36