Star Trac Treadmill TR 4500 User Manual

Section 1:

Introduction

Welcome to the world of STAR TRAC. In your hands is the STAR TRAC TR 4500 Service Manual. This manual is designed to be easy to use, providing detailed instructions on how to service and maintain the TR 4500.

We highly recommend that you read all the applicable sections of the service manual prior to serving the treadmill. The information on the following pages will enable you to begin easily, quickly, and safely.

		Contents
1.1	How to use the Service Manual	1.4	Tools and Test Equipment
1.2	Precautions	1.5	Treadmill Overview.
1.3	Product Support Assistance

1.0

How To Use This Manual

•This Service Manual has been written to assist and instruct the repair technician on key components for quick and efficient diagnosis of service problems.

•To assist in finding the applicable sections in the Service Manual. Each Section has a table of contents to help locate specific symptoms and topics. Titles and major headings are located at the top of every page.

•This manual is to be used strictly as a Maintenance manual for service and repair, not as an owner’s manual.

•An illustrated Parts List is located at the back of this manual for identifying parts with part numbers.

•Troubleshooting tables and Error Code Flowcharts are included for certain sections to help diagnose the system problem and find the root cause.

1.1

Precautions

1. Always make sure that the treadmill is turned off and unplugged before starting any work, unless otherwise noted, or when necessary for voltage testing.

2. Read each section through for NOTES before starting any work.

3. To pull apart electrical connectors, pull on the connector itself, not the wires.

4. When replacing fuses, be sure the new fuses is the correct amperage rating. Do Not exceed the fuse amp rating. If necessary use a fuse of lower rating until the proper fuse may be attained.

5. When checking continuity at the wire connector, insert the test probe carefully to prevent the terminals from bending.

1.2

Product Support Asistance

PRODUCT SUPPORT DEPARTMENT

STAR TRAC Product Support Department sets the industry standard in Customer Service and Technical Assistance World Wide. Providing superior product support and customer service is at 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

• When placing the call, 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

•When placing the call, please have the following information available: 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]

•When placing the fax, please supply the following information: 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.

Product Support Documentation Access

•Web page http://www.startrac.com/support/

•Docufacts CALL TOLL FREE 1-800-429-3228 ext. 640 US and Canada or 714-253-3878 for a list Product Support Procedures and Bulletins.

1.3

Tools and Equipment

Equipment		Function
Philips Head Screwdriver #2		Shroud
		Motor Control Board Assembly
		Side Bed Cover and End Caps
		Auto-Transformer
Small Slotted Screwdriver 3/32”		Motor Control Potentiometers (MAX SPD) & (IRCOMP)
Bungee Cord 28”		Suspend Motor Shroud on Display Rail
5/32” Hex Allen key		Handrail assembly
5/64” Hex Allen key		Display Board set screws
1/8”	Hex Allen key	Display Assembly
1/4”	Hex Allen key	Running Belt
		Head Roller
		Tail Roller
5/16” Wrench or Nut Driver		Drive Motor Bolts
9/64” Allen Wrench		Elevation Motor
17-mm Socket Wrench

Multi-meter	Voltage Checks
	Continuity / OHM ΩChecks

1.4

Treadmill Overview

•DC POWER SUPPLY

The MCB provides power to the display assembly. Establishes a reference voltage and potentiameter position from the elevation motor

•RUNNING BELT MOTOR DRIVE CONTROL

Takes Alternating Current and converts it to Pulse Width Modulation (PWM) to power the Drive Motor.

Motor voltage feedback and control-speed-commands determine the level of PWM power delivered to the motor.

Motor Control circuits include fault sensing and safety functions.

•TACHOMETER SIGNAL CONDITIONING

The signal from the RPM sensor is fed to signal conditioning circuits on the MCB, where the signal is converted to a digital output that is utilized by the Display Assembly to indicate belt speed.

•ELEVATION MOTOR CONTROL

The elevation circuit on the MCB receives elevation direction and enable information from the Display Assembly, using these signals to provide control to the Elevation Motor. Elevation position information, in turn, is fed to the Display Assembly to indicate percent of incline.

1.5

Section 2:

Preventive Maintenance

Schedules

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. This may result in downtime. For this reason, we highly recommend following the manufacturer’s maintenance schedules.

Contents:

2.1Preventative Maintenace Chart

2.2Waxing Procedure

2.0

Preventive Maintenance Chart

Maintenance	Clean	Inspect	Lubricate	Replace
Daily	Using a liquid	Inspect for wear
	non-abrasive	and tear on ex-
	cleaner, wipe	terior parts
	down the	regularly,
	following:	especially under
	display board	the running belt.
	handrails,	Inspect the line-
	shroud, heart	cord plug and
	rate grips.	cord for possible
	Note: Do not	damage or loose
	spray directly	connection.
	onto the
	display
	board or heart
	grips.
Weekly	Elevate the	Verify running
	treadmill and	belt alignment
	vacuum under	and tension.
	the unit.	Inspect the area
	Note: Unplug	under the
	the unit when	treadmill for
	vacuuming.	obstructions.
Monthly	Lift the motor	Inspect the	Using a silicone
	shroud and	display and	spray lubricate
	vacuum	handrail screws	the elevation
	around the	for loosening.	screws, while
	motor and	Inspect the	the unit is
	electronics.	display panel	elevated.
	Clean and lub-	keys for wear.	Note: This must
	ricate the elev-		be done with the
	tion screws.		unit
	Note: This		unplugged and
	must be done		turned off.
	with the unit
	unplugged and
	turned off.
Quarterly			Wax the running
			belt and deck
			using Unisen
			powder wax.

2.1

Quarterly Waxing

Note: Apply wax powder while

belt and deck are still warm (from 5 to 15 minutes of use) for optimum benefit. The following steps are done with the treadmill off.

Note: Blow away extra wax first from around the siderails and deck before wiping.

Note: The RE WAX prompt may be cleared either in “Settings or Configure Mode”.

The treadmill is designed with an automatic prompt, which will display RE WAX across the display screen every 2,000 miles or 3,000 kilometers. The procedure below explains step-by- step how to apply wax and clear the RE WAX prompt.

Time Required:

5 minutes

Tools Required:

1 Wax Powder Bag (Unisen) Teaspoon

1 Clean Towel

Paint Stick or Yard Stick

Diluted All-purpose Cleaner (409) Bristle Brush

PROCEDURE

STEP 1: Cleaning the deck and belt:

•Using the stick or ruler, slide a towel under the middle of the running belt from one side of the frame to the other.

•Hold the edges of the towel, pull from head-roller down to the tailroller, then pull the belt down to wipe the remaining of the belt. TIP: Careful when removing the towel, it will be dirty. Fold the dirty towel and shake into trash.

STEP 2: Re-waxing the deck and belt:

•Lift the left side (facing the display) of the belt, about 12 inches down from the motor shroud (see above figure). Hold the belt up such that the width of the belt is elevated from the deck.

•Gently place one level teaspoon of wax powder on the deck about two inches from the edge, and blow the wax steadily under the belt, so that the wax powder is spread evenly across the deck (see above figure). Gently place a second level teaspoon of wax 18 inches down the belt.

•Repeat the above step to the right side of the belt and deck.

STEP 3: Walking the wax in:

•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.

STEP 4: Clean-up:

•Remove any excess wax with diluted cleaner (409) and towel, or bristle brush.

STEP 5: Clear RE WAX prompt:

•Engage Settings or Configure Modes. Press and hold the “0”, “1” or(2) & “START” keys down, release the “1” or (2) key only. Display will beep and display SETTINGS or CONFIGURE momentarily (depending if the 1 or 2 key was released), then UNITS will be displayed.

•Press the Incline Down Key (elevation) until LSTDCK is displayed. Press and release the HEART Key, this will automatically transfer the accumulated miles/kilometers into the LSTDCK, press the ENTER Key to save.

2.2

Section 3:

Diagnostics

The STAR TRAC 4500 Treadmill series contains diagnostic and customizing 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. For these reasons, your treadmill is equipped with a ;

•	Manager Mode (customize)	• Display Test Mode (diagnostics)
•	Maintenance Mode (diagnostics)	• Heart Rate Test Mode (diagnostics)
•	Motor Test Mode (diagnostics)
	Contents:	3.8	Engaging Motor Test Mode
3.1	Engaging Manager Mode
3.2	Engaging Maintenance Mode	3.9	Calibration
3.3	Description of parameters	3.10 Engaging Display Test Mode
			Heart rate test

3.0

Manager Mode

After having used you Star Trac 4500 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 MOTOR TEST.

HEART KEY: When pressed will automatically display manufactures default value.

Note: ENTER KEY must be pressed, to save the default values if changed.

3.1

Manager Mode

The following parameters may be changed using the previous keys:

Parameters	Lowest	Highest	Option 1	Option 2	Default	Meaning
	Value	Value			Value
UNITS	---	---	English	Metric	English	English= units of lbs.,
						miles, hours, minutes
						Metric= units of kg.,
						km, hours, minutes.
MN SPD	0.1	2.5	English=0.5	Metric=1.0	0.5	Minimum speed in
						MPH or KM/HR
MX SPD	5.0	20.0	English=10.0	Metric=20.0	10.0	Maximum speed in
						MPH or KM/HR
EL OPT	---	---	ON	OFF	ON	Turns the elevation
						system ON or OFF.
TIME	5	99			99	Maximum time in
						minutes allowed for
						program, including
						warm-up/cool-down.
OP HRS	0	0	---	---	6,553.5	Total operating hours
DIST	0	0	---	---	65,635	Total treadmill miles
						(Units=English)
						or kilometers
						(Units=Metric)
WEIGHT	0	399	---	---	155	Defaults (to user),
						typical weight in lbs/kg
						depending on what
						setting (UNITS=
						English or Metric
SER NO	0	0	---	---	65,535	Treadmill serial
						number.
LANG	---	---	---	---	English	Language in English,
						Dutch, German,
						Portuguese, Spanish,
						Swedish, or Italian.
ENTRY	---	---	Units	Tenths	Units	This variable changes
						the starting speed in
						Units or Tenths

3.2

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 MOTOR TEST.

HEART KEY: When pressed will automatically display manufactures default value.

Note: ENTER KEY must be pressed, to save the default values if changed.

3.3

Maintenance Mode

The following parameters may be changed using the previous keys:

Parameters	Lowest	Highest	Option 1	Option 2	Default	Meaning
	Value	Value			Value
UNITS	---	---	English	Metric	English	English= units of lbs.,
						miles, hours, minutes
						Metric= units of kg.,
						km, hours, minutes.
MN SPD	0.1	2.5	English=0.5	Metric=1.0	0.5	Minimum speed in
						MPH or KM/HR
MX SPD	5.0	20.0	English=10.0	Metric=20.0	10.0	Maximum speed in
						MPH or KM/HR
EL OPT	---	---	ON	OFF	ON	Turns the elevation
						system ON or OFF.
TIME	5	99			99	Maximum time in
						minutes allowed for
						program, including
						warm-up/cool-down.
OP HRS	0	0	---	---	0	Total operating hours
DIST	0	0	---	---	0	Total treadmill miles
						(Units=English)
						or kilometers
						(Units=Metric)
WEIGHT	0	399	---	---	155	Defaults (to user),
						typical weight in lbs/kg
						depending on what
						setting (UNITS=
						English or Metric
SER NO	0	0	---	---	0	Treadmill serial
						number.
LANG	---	---	---	---	English	Language in English,
						Dutch, German,
						Portuguese, Spanish,
						Swedish, or Italian.
ENTRY	---	---	Units	Tenths	Units	This variable changes
						the starting speed in
						Units or Tenths

3.4

Maintenance Mode

Parameters	Lowest	Highest	Option 1	Option 2	Default	Meaning
	Value	Value			Value
HRT CON	---	---	ON	OFF	OFF	OFF= Heart Control
						disable
						ON= Heart Control
						enabled
HRT	---	---	CNT DN	CNT DN	CNT DN	CNT DN= Manual
			POLAR	POLAR		countdown heart rate
			CONTACT	CONTACT		POLAR, CONTACT or
			BOTH	BOTH		BOTH (Polar &
						Contact)
10 REV	22.0	74.0	30.7 = For	35.8 = For	29.1	Inches of running belt
			110v units.	220v units		travel for 10 flywheel
						revolutions, measured
						in inches.
						1.8” pulley:30.7 (110v)
						2.1”pulley:35.8(220v)
CNT/REV	1	255	31 =	125 =	31	Number of counts per
			Magnetic	Optical		RPM Sensor
			RPM Sensor	Sensor		revolution.
MN PWM	2	50	---	---	30	Minimum PWM to
						obtain minimum
						speed, automatically
						done.
1/2 PWM	25	170	---	---	130	1/2 Maximum PWM to
						obtain 1/2 maximum
						speed, automatically
						done.
MX PWM	86	255	---	---	230	Maximum PWM to
						obtain maximum
						speed, automatically
						done.
DATE	1.00	12.99	---	---	1.96	Treadmill
						manufacturing date.
NO STO	0	255	---	---	0	Number of times the
						Stop Switch was down
						or disconnected on
						power-up since last
						reset.

3.5

Maintenance Mode

Parameters	Lowest	Highest	Option 1	Option 2	Default	Meaning
	Value	Value			Value
KEY DN	0	255	---	---	0	Number of times the
						Stop Switch was down
						or disconnected on
						power-up since last
						reset.
NO RPM	0	255	---	---	0	Number of times the
						display did not detect
						a RMP signal.
SP CNG	0	255	---	---	0	Number of times a
						sudden change in
						speed was detected
EL STL	0	255	---	---	0	Number of times an
						elevation stall was
						detected.
EL RNG	0	255	---	---	0	Number of counts per
						RPM Sensor
						revolution.
EL LOST	0	255	---	---	0	Number of times no
						elevation was
						detected.
ELZERO	0	255	---	---	240	Represents the incline
						number for 0%.
EL MAX	0	255	---	---	57	Represents the incline
						number for 15%.
LSTERR	0	25	---	---	0	Indicates what display
						code appeared last.
						18 = NO STO
						19 = KEYDN
						20 = NO RPM
						21 = SP CNG
						22 = EL STL
						23 = EL RNG
						24 = EL LOST
LSTELV	0	255	---	---	0	Displays the target
						elevation prior to the
						display code.
LSTPOT	0	255	---	---	0	Displays the incline
						number prior to the
						display code.

3.6

Maintenance Mode

Parameters	Lowest	Highest	Option 1	Option 2	Default	Meaning
	Value	Value			Value
LSTRES	0	2	---	---	0	Displays
						1 = Unit was resetting
						to 0%.
						0 = Unit finished
						resetting to 0% prior
						to the display code.
LSTSSP	0	255	---	---	0	Displays the speed
						prior to the display
						code.
LSTPWM	0	255	---	---	0	Displays the PWM
						number prior to the
						display code.
LSTMSP	0	255	---	---	0	Display the actual
						measured speed prior
						to the display code.
LST TM	0	65355	---	---	0	Displays the elapsed
						time, in seconds, prior
						to the display code.
LSTDCK	0	65355	---	---	0	Number of miles when
						the deck was last
						waxed. After a 2000
						mile (or 3000 KM)
						difference, “REWAX
						BELT” will scroll in the
						display until “LST
						DCK” miles are
						updated.
LSTBLT	0	65355	---	---	---	Number of miles when
						the last belt was
						replaced.

3.7

Motor Test Mode

Motor Test Mode allows the treadmill to calibrate both elevation and running belt speed. Verifies RPM Sensor feedback, Drive Motor and MCB response, and verifies Elevation Motor range (count). Also burns in the motor, by way of the controls and displays of the treadmill.

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

Engage Test Mode:

1. Press and hold the “ 0 ”, “ 1 ” & “ START ” keys together (or the “0” , “2” ). While holding the “ 0 ” & “ START ” keys down, release the “ 1 ” (or 2) key only. The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will be displayed.

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

Alternative mode to enter Motor Test Mode:

1. Turn the power switch on while pressing the “ 8” key simultaneously on the display.

240	3	.0
A. Elevation Motor Range.	B. PWM Duty Cycle.	C. RPM Sensor 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 light up on the MCB.

•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 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.

START KEY: Starts burn-in mode. (continuous operation of running belt and incline using program 8 at maximum speed. Press STOP KEY to stop burn-in.

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

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

3.8

Calibration

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

Automatic Speed Calibration:

In this mode minimum and maximum speed is automatically calibrated. Calibration lasts less than 3 minutes; belt will be in motion during this test.

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

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

2.

3.

& “ START ” keys down, release the “ 1 ” (or 2) key. The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will be displayed.

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

240 3 .0

Press “HEART” key, display will read: CAL 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 Section 4.

3.9

Display Test Mode

Display Test Mode allows you to test the light-emitting diodes (LEDs), 15-segment displays, and the watchdog timer of the Display Control Panel by way of its own controls and displays. It also allows EPROM version to be displayed. To enter Display Test Mode:

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

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

&“ START ” keys down, release the “ 1 ” (or 2) key.

2.The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will

be

displayed.

3. Press and release the “5 key. Observe all the LEDs light up.

4. Pressing any key once will display the EPROM version.

Alternative mode to enter Motor Test Mode:

1. Turn the power switch on while pressing the “5” key simultaneously on the display. Observe all the LEDs light up.

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

INCLINE KEYS: Lights % grade LED’s one at a time, also segments of 15-segment screen one at a time.

PROGRAM SELECT KEY: Lights the six LEDs bordering the 15-segment display.

HEART KEY: Displays “HEART HEART” on the 15-segment display.

START KEY: Displays “START START” on the 15-segment display.

0 – 9 KEYS: Lights corresponding LEDs in the Number/Program Select Keys, (except for key 9), alongside the Pre-Designed Program profiles.

STOP KEY: Displays “WD TEST” on the 15-segment display. Activates the watchdog timer, resetting the processor and returning the program back to Start Mode.

3.10

Heart Rate Test

Heart Rate Test Mode tests the heart rate calculation and display capability of the treadmill if it is equipped with contact rings or Polar wireless heart rate chest strap reception capability. To enter Heart Rate Test Mode:

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

&“ START ” keys down, release the “ 1 ” (or 2) key.

2.The display will beep and display MANAGER (or MAINTENANCE) momentarily, then UNITS will

be

displayed.

3. Press and release the “5 key. Observe all the LEDs light up.

4. Press the key 3X’s, display will read SEEKING HR across the display.

5. Grasp the stainless steel contact rings or place the Polar wireless heart rate chest strap around your chest (treadmill must be equiped with both contact and Polar).

6. In the far right display screen a blinking LED segement will flash then the average heart rate will be displayed.

NOTE: If the above Heart Rate Test fails to give the correct reading or response, refer to Section 4.

3.11

Section 4:

Troubleshooting

Should the STAR TRAC 4500 Treadmill experience a problem or a display code appear, the following procedures will help determine the precise reason for the problem. Included are flow charts breaking down each individual display code with problem statements and solutions.

			Contents
4.1	110v MCB Layout		4.24	Running Deck Symptoms
4.3	220v MCB Layout		4.26	Isolating Noise
4.5	Calibration Symptoms		4.27	Leveling
4.7	Manual Calibration		4.28	Static Symptoms
4.8	No Display Power 110v		4.29	Vibration
4.9	No Display Power 220v		4.30	Display Codes Chart
4.10		Elevation Motor Symptoms	4.31	KEY DN Flowchart
4.12		Elevation Symptoms	4.32	NO STO Flowchart
4.13		Heart Rate Symptoms	4.33	No RPM Flowchart
4.16		Polar Symptoms	4.37	SP CNG Flowchart
4.17		Display Cable Symptoms	4.41	EL STL Flowchart
4.18		Drive Motor Symptoms	4.45	EL RNG Flowchart
4.19		Head / Tail Roller Symptoms	4.49	EL LOST Flowchart
4.20		Drive Belt Symptoms	4.53	EL NOZ Flowchart
4.21		Running Belt Symptoms

4.0

110v MCB LED Layout

The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems.

** CAUTION ** Several of the following troubleshooting require dealing with live voltage. Have the treadmill turned off and unplugged when checking wire connections.

NOTE: The display console may still power up with the AC LED off.

AC LED - Indicates that AC power has been applied to the MCB. It does not give indication of voltage level, if this LED is not lit and the treadmill does not power up, verify the following:

1.The treadmill is plugged into a wall outlet.

2.The ON/OFF switch is turned to the “ON” position.

3.Verify with a VOLT METER that 110VAC is present at the outlet. Units with step-down transformers need 220VAC.

4.Verify 110v (+/- 10%) AC voltage at AC1 & AC2 wires.

After the above have been verified and the AC LED is still “OFF”, the MCB should be replaced.

+18v LED - Indicates the presence of an acceptable level of voltage to operate the MCB. If this LED is off or dim, the AC voltage level is not acceptable to properly power the MCB. Verify the following:

1.Verify with a VOLT METER that 110VAC is present on on pins AC1 & AC2.

After the above step has been verified and the + 18V LED is still “OFF”, and the display does not power up, replace the MCB.

+11v LED - Indicates there is +11 volts supplied to the display board. If this LED is not lit verify the following:

1.The display cable is damaged or pinched, disconnect the display cable and verify if the LED lights up. If LED lights up replace the cable.

After the above has been verified and the +11 LED is still “OFF”, the MCB should be replaced.

4.1

110v MCB LED Layout

NOTE: Engage Motor Test Mode and manually push on the running belt to verify RPM feedback.

NOTE: If the current limit is reached, the MCB will shut the treadmill down and the I-LIMIT LED will remain on until it resets.

MOTOR LED - Indicates the presence of acceptable voltage to the motor. If this LED is not lit one of the following conditions exists:

1.Verify AC voltage is being applied.

2.Verify that MTR1/MTR2 wires are connected to the MCB. (This should be done with the treadmill unplugged and turned off)

After the above have been verified and the MOTOR LED is still ‘OFF”, the MCB should be replaced.

PWM LED - Indicates that there is a valid control command from the display to the MCB (this LED flashes only when the treadmill is operating) If this LED is not lit verify the following:

1.Verify if the display cable is connected.

2.Verify if the display cable is damaged or pinched. (see page 4.17 in this section for Display Cable

symptoms)

After the above have been verified and the PWM LED is still “OFF” , the MCB should be replaced.

I-LIMIT LED - Indicates that an excessiveload is being placed on the motor. Amp readings of 26 or higher will cause the LED to light. If this LED is lit one of the following conditions exists:

1.Running belt is worn.

2.Belt and deck require lubrication.

3.Drive motor drawing over the 26 amp peak.

After the above has been verified and the I-LIMIT LED is still “ON”, the MCB should be replaced.

UP LED - Indicates that the incline is being commanded up. If this LED is not lit and the elevation motor will not respond, verify the following:

1.Display cable for possible pinch or tear (see page 4.17 in this section for Display Cable symptoms)

2.Replace MCB.

DOWN LED - Indicates that the incline is being commanded up. If this LED is not lit and the elevation motor will not respond, verify the following:

1.Display cable for possible pinch or tear (see page 4.17 in this section for Display Cable symptoms)

2.Replace MCB.

4.2

220v MCB LED Layout

The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems.

** CAUTION ** Several of the following troubleshooting steps require dealing with live voltage. Have the treadmill turned off and unplugged when checking wire connections.

NOTE: The display console may still power up with the AC PWR LED off.

AC PWR - Indicates that AC power has been applied to the MCB. It does not give indication of voltage level, if this LED is not lit and the treadmill does not power up, verify the following:

1.The treadmill is plugged into a wall outlet.

2.The ON/OFF switch is turned to the on position.

3.Verify with a VOLT METER that 110VAC is present at the outlet. Units with step-down transformers need 220VAC.

4.Verify 220v (+/- 10%) AC voltage at AC1 & AC2 wires.

After the above have been verified and the AC LED is still “OFF”, the MCB should be replaced, if the treadmill is not operating.

DISPLAY PWR- Indicates there is +11 volts supplied to the display board. If this LED is not lit verify the following:

1.The display cable is damaged or pinched, disconnect the display cable and verify if the DISPLAY PWR LED lights up. If the LED lights up replace the cable.

After the above has been verified and the DISPLAY PWR LED is still “OFF”, the MCB should be replaced.

4.3

220v MCB LED Layout

NOTE: Engage Motor Test Mode and manually push on the running belt to verify RPM feedback.

RPM SENSOR - Indicates input signal from the RPM Sensor to the MCB. If this LED is not flashing during operation, verify the following

1.RPM sensor disconnected from connector J3 at the MCB.

2.RPM sesnor gap misaligned.

3.RPM sensor faulty

After the above have been verified and the RPM LED is still “OFF”, the MCB should be replaced.

MOTOR CONTROL - Indicates that there is a valid control command from the display to the MCB. If this LED is not lit verify the following:

1.Verify if the display cable is connected.

2.Verify if the display cable is damaged or pinched.

After the above have been verified and the MOTOR CONTROL LED is still “OFF”, the MCB should be replaced.

UP LED - Indicates that the incline is being commanded up. If this LED is not lit and the elevation motor will not respond, verify the following:

1.Display cable for possible pinch or tear ( see page 4.17 in this section for Display Cable symptoms).

2.Replace MCB.

DOWN LED - Indicates that the incline is being commanded down. If this LED is not lit and the elevation motor will not respond, verify the following:

1.Display cable for possible pinch or tear ( see page 4.17 in this section for Display Cable symptoms).

2.Replace MCB.

4.4

Calibration

Troubleshooting

The following steps help troubleshoot in case Auto-Calibration procedures fail to give the correct reading or response.

Symptom:

Auto-Calibration fluctuates.

1. Verify line voltage for sufficient voltage supply.

•If wall voltage is less than 10% than what is required, this will cause speed fluctuation.

2. Verify unit is on a dedicated circuit breaker.

•Treadmills sharing the same circuit line will cause intermittent problems and variation in speed.

3. Verify the following parameters are set correctly

in the Configuration Mode: (Configuration Mode details in Section 3)

•CNT/RV : 31 = Magnetic/Cherry RPM Sensors

•10 REV: 29.1” for 1.7” dia. motor pulley (110v)

•10 REV: 35.8 for 2.1” dia. motor pulley (220v) NOTE: If not sure what your 10 REV settings should be, manually measure your drive motor pulley diameter. Above measurements are done in inches.

4. Verify RPM Sensor alignment.

•Hall Effect/Cherry RPM Sensor is being used,

verify the gap is no more than 1/8 inch. NOTE: See Diagram # 1.

5. Adjust IR COMP potentiometer. NOTE: See Diagram #2, adjustment.

REPLACE: MCB if symptom continues.

4.5

Calibration Troubleshooting

Symptom:

Will not Calibrate to MAX speed.

1. Verify line voltage for sufficient voltage supply.

•If wall voltage is less than 10% than what is required, this will cause speed fluctuation.

2. Verify unit is on a dedicated circuit breaker.

•Treadmills sharing the same circuit line will cause intermittent problems and variation in speed.

3. Verify the following parameters are set correctly

in the Configuration Mode. (Configuration Mode details in Section 3)

•MN SPD: 0.5 MPH or 1.0 KM/PH

•MX SPD: 10.0 MPH (110v) or 20.0 KM/PH (220v)

•CNT/RV : 31 = Magnetic/Cherry RPM Sensors

•10 REV: 29.1” for 1.7” dia. motor pulley (110v)

•10 REV: 35.8” for 2.1” dia. motor pulley (220v) NOTE: To reach 20.0 KM/PH on 220v units, drive motor pulley must be 2.1”. If not sure what your 10 REV settings should be, manually measure the drive motor pulley diameter.

4. Verify RPM Sensor alignment.

•Hall Effect/Cherry RPM Sensor is being used, verify the gap is approximately 3 business

cards or 1 credit card. If adjustment is necessary loosen the flywheel to re-position.

NOTE: See Diagram #1.

REPLACE: RPM Sensor if RPM reading is sensitive or feedback appears erratic.

5. Adjust the MAX SPEED potentiometer. NOTE: See Diagram #2. (220v units only)

GO TO: Section 3.7 Manual Calibration if problem continues.

Diagram #1

Diagram #2

4.6

Manual Calibration

**CAUTION** Do not stand on the running belt while performing these steps.

NOTE: Alternative mode to enter Motor

Test Mode; turn

the power switch “ON” while pressing

the “8” key sim-

ultaneously on the display.

NOTE: The MN SPD should not exceed .5 MPH

or 1KPH. The

1/2 MX SPD should be exactly half of the desired MX SPD. The MX MX SPD must not exceed 10 MPH or 20 KPH (220 units).

NOTE:Speed Command

255 is the maximum the treadmill will reach.

The following procedure allows the treadmill to manually calibrate Minimum and Maximum speeds, only in the case Auto-Calibration is not functioning correctly.

Symptom:

Will not calibrate to MN or MX speed, in the Auto-Calibration Mode.

1. Engage TEST MODE. Press and hold the “ 0 ”, “ 1 ” & “ START ” keys together (or the “0” , “2” ). While holding the “ 0 ” & “ START ” keys down, release the “ 1 ” (or 2) key. The display will beep and display SETTINGS (or CONFIGURE) momentarily, then UNITS will be displayed.

2. Press and release the “8” key. Display will read: XXX 3 .0 XXX is a variable number depending on the elevation position the treadmill is at. 3 indicates Speed Command, 0 indicates RPM. If the treadmill is at 0% the display will read: 240 3 .0

3. Press the “+” key (speed) to the desired MN SPD,1/2 MX, and MX SPD. Write

down the corresponding Speed Command number displayed for each desired setting.

4. Press the “STOP” key. Engage Configuration/Settings Mode as described in STEP 1.

5. Using the “UP ELEVATION” key go to MN PWM parameter and enter the new

MN SPD Speed Command number by using the “+” or “-” keys, then press the “START” (enter) key to save the new setting. Do this for the 1/2 MX and MX SPD.

6. Press the “STOP” key to exit.

4.7

No Display Power

The following steps help troubleshoot in case the display board fails to power up, during or before regular operation.

110v UNIT

	Diagram A			Diagram B

**CAUTION**	1. Lift and suspend the motor shroud.
The following steps 2. Verify if LED AC is lit. AC LED indicates that AC power is being applied to
are performed with	the MCB, does not indicate voltage level. If this LED is lit go to step 3.
the treadmill “ON”.	If LED is not lit verify the following: (see diagram A)

•The treadmill is plugged into the wall.

•The ON/OFF Switch is turned to the “ON” position.

•Verify wire connection AC1/AC2 on the MCB.

•Verify the ON/OFF Switch Breaker wires are connected.

•Verify 110v (+/- 10%) AC voltage at AC1/AC2. if the voltage is 0 or less than 90v, check wall voltage, verify unit is on a dedicated line.

•If wall voltage is correct, verify linecord continuity. (see diagram B) REPLACE: MCB if all the above check OK.

3.Verify if LED +18 is lit. LED +18 indicates the presence of an acceptable level of voltage for MCB operation.

REPLACE: MCB if +18 is not lit.

4. Verify if LED + 11 is lit. LED +11 indicates 11v are being applied to power the display board. If the LED is lit go to step 5.

REPLACE: MCB if +11 is not lit.

5. Verify display cable connection.

• Verify display cable for possible pinch or tear mark. REPLACE: Display board if display cable checks OK.

4.8

No Display Power

The following steps help troubleshoot in case the display board fails to power up, during or before regular operation.

220v UNIT

	Diagram A			Diagram B

				1. Lift and suspend the motor shroud.
	**CAUTION**
	The following steps 2. Verify if LED AC is lit. AC LED indicates that AC power is being applied to
	are performed with			the MCB, does not indicate voltage level. If this LED is lit go to step 3.
	with treadmill “ON”.			If LED is not lit verify the following: (see diagram A)
				• The treadmill is plugged into the wall.
				• The ON/OFF Switch is turned to the “ON” position.
				• Verify wire connection AC1/AC2 on the MCB.
				• Verify the ON/OFF Switch Breaker wires are connected.
				• Verify 220v (+/- 10%) AC voltage at AC1/AC2. if the voltage is 0 or
				less than 200v, check wall voltage, verify unit is on a dedicated line.
				• If wall voltage is correct, verify linecord continuity. (see diagram B)
				REPLACE: MCB if all the above check OK.
				3. Verify if LED DISPLAY POWER is lit. This LED indicates 11v are being
				applied to power the display board. If the LED is lit go to step 4.
				REPLACE: MCB if DISPLAY POWER LED is not lit.
				4. Verify if LED MOTOR CONTROL is lit. This LED indicates there is a valid
				control command from the display to the MCB. Verify the following if LED
				is off:
				• Verify display cable connection.
				• Verify display cable for possible pinch or tear mark.
				REPLACE: Display board if display cable checks OK.
				4.9

Elevation Motor

NOTE: Activation of the thermal protection breaker does not cause damage to the elevation actuator or other treadmill components.

The following procedure explains the elevation system Thermal Protection and limitations.

Symptom:

Elevation system shuts-off when used consistently.

1. The Star Trac Model 4500 elevation system actuator is protected from

overheating by a thermal protection circuit. In the event that the thermal protection breaker is activated, the treadmill’s elevation system is temporarily disabled, and an “EL STL” display codes is displayed.

•A simple resetting of the treadmill restores full operation once the elevation actuator has been allowed to cool for a few minutes.

2.The pre-defined workout programs 1 through 8 as well as other typical workout

regimens include elevation changes that easily fall within the operating limits of the Model 4500’s elevation system actuator. The following information serves as a guide for users that may wish to set a custom program that requires frequent and/or large changes in incline.

•Incline changes greater than 5 percent should not be programmed for intervals less than 1 minute.

•Full range incline changes (from 0 percent to 15 percent, or viceversa) should not be programmed for intervals less than 3 minutes.

4.10