TREADMILL - Sportsmith
Contents
1. gt gt TREADMILL SERVICE MANUAL VOL 2 TABLE CONTENTS 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 Troubleshoolihg 21 Display Code Troubleshooting 22 MCB Layout LEDS 26 Display Board Assembly Wiring 28 F2. Proceed into Keypad test mode Please review owner s manual Engage connector at location 13 labeled Keypad Proceed into Keypad test mode Please review owner s manual Check I O ribbon cables connections upper and lower Replace Pro Keypad Replace console PCB Proceed into Keypad test mode Please review owner s manual 034 V_CON D30 SPD 024 ENABLE C F Pr Q Q W u 031 N DOWN D38 MOTOR AC 018 MIR MCB PGBOARD LEDS
3. Auto Stop was disabled Display console replacement Belt continues to roll Enable Auto Stop set to ON without runner for more than 1 minute Walk on belt at slow speed for 1 minute then step off leaving belt running Auto Stop should now gage within minute Walk on belt at slow speed for 1 minute then step off leaving belt running Auto Stop should now engage within 1 minute New software update Pro Tread Troubleshooting Guide 2 of 2 Weight Scale Numeric values are beyond specifications in respect to the actual weight after calibration success e Weight scale feature was disabled Calibration was not done properly Enable weight Scale system in software Check wiring and recalibrate using known weight distributed squarely on the weight plates Debris under cells Clean debris refer to document 620 7244 for requirements Improper clearance on either side of weight cell 1 of 3 Fan System will not power up in the High or Low speeds Blown line fuses on the Fan board location F2 amp F3 2 of 3 Only one fan operates Improper connection on Fan board both LED s are RED in color Fan may be short circuited In the harness or is bad 3 of 3 Fan system will only power in one speed e No communication between upper Membrane Keypad and Fan board 1 of 2 Pro K
4. M 715 3423 MCB motor control board Assembly Wiring Main I O Interface from Displav to MCB 33 Drive Motor Wiring EIL Lem Motor Network Filter assembly 715 3466 Fan Board Assembly 715 3423 t Grounds 34 Drive Motor Wiring Um m se y 1 I 35 Complete Lower Chassis Wiring 36 Unit does not Power ON plugged in to AC outlet Incorrect or no voltage at power source Pro Treadmill power breaker switch in OFF position Pro Tread Troubleshooting Guide certified electrician verify wall outlet has proper voltage Depress the Pro Treadmill power breaker switch to the ON position I O ribbon cables improperly connected Bad fuses on Motor Control Board Bad Motor Control Board e Check Main I O ribbon cables for proper connection Check fuses F1 amp F4 on Motor controller Board Replace if necessary Replace Motor controller Board if fuses are blown repeatedly Unit trips breaker when plugged into wall Console Displays The Emergency Stop Switchisin Emergency Stop its active state Message No Emergency Bypass Connector installed behind Display Console Incorrect wiring to Emergen
5. See diagram 1 25 MCB motor control board Layout J mITTETM pL pnm peel The above LED s are designed to you determine at 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 Description Message When LED Is On D10 MOTOR AC power is on Motor is hooked up and relay is energized This LED will stay lit for a few minutes after AC voltage is removed or relay turned off D12 PWM PWM command signal is present D16 I LIMIT LED should blink once when AC voltage is first applied to 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 D18 MTR AC AC power is relay is energized and rectified AC line voltage is present D24 MTR ENABLE Relay is i e energized D30 SPD SENSR Blinks when speed is detected Blinking rate o
6. was used since last reset 10K BAY of times 10K Program was used since last reset PALM PC it of times Palm PC CUSTOM Custom Program was used since last reset DHRC of times Dynamic Heart Rate Control Program was used since last reset CUSTOM it of times Custom Program was used since last reset TRAINER it of times Personal Trainer Program was used since last reset it of times Quick Start Program was used since last reset 16 Motor Test 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 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 amp START keys together While holding the 0 amp 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 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 4 increments of 1 When using the Incline Keys verify the elev
7. all related electronic connections and recycle power Replace Pro Kevpad Check all related electronic connections and recycle power Replace heart rate PCB 715 3405 Replace Pro Keypad Replace Main Display Console Pro Tread Troubleshooting Guide Enable Telemetry Heart Rate system in software Manager Maintenance mode menu Please review Owner s Manual Check Salutron Contact Heart Rate PCB for proper connection seating e Replace Telemetry Heart Rate Strap i e Polar strap batteries Verify strap worn properly Check connection of the Heart Rate Receiver behind main console location J18 labeled Polar Interface Replace Telemetry Heart Rate Check all related electronic connections and recycle power Replace Pro Keypad Check all related electronic connections and recycle power Replace heart rate receiver 715 22 3407 Replace Pro Keypad Replace Main Display Console Enable Weight Scale system in software Notify Star Trac for options and availability Connect if installed No Heart Rate in the Numeric window or Heart Chart when straps are worn Telemetry Heart Rate system is disabled Software Improper Salutron Contact Heart Rate PCB connection seating Telemetry Heart Rate Strap i e Polar strap batteries are bad User is not wearing strap cor
8. 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 Manager Mode The following parameters may be changed using the previous keys Parameters Lowest Highest Default Value Value Value UNITS English Metric English English units of Ibs miles hours minutes Metric units of kg km hours minutes 0 1 2 5 English 0 5 Metric 1 0 0 5 Minimum speed in j j MX SPD 5 0 20 0 English 10 0 Metric 20 0 10 0 Maximum speed in bud sl Rail 3 system ON or OFF TIME 5 Maximum time in minutes allowed for program including warm up cool down DIST 65 635 Total treadmill miles Unitsz English or kilometers Units Metric WEIGHT 399 155 Defaults to user typical weight in Ibs kg depending on what setting UNITS English or Metric 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 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 amp START keys together While holding th
9. 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 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 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 amp 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 amp 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 amp 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
10. ENGAGED Auto calibration should be done every time MN MX SPD amp 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 amp RPM Sensor 1 Press and hold the 0 2 amp START keys together or the 0 2 While holding the 0 amp 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 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 v9 v keyto exit Motor Test 19 Elevation Calibration Re calibrating the 096 or 1596 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 096 2 240 110 amp 220v units mechanical damage m
11. N key down display code is given 1 Press and hold the 0 2 amp START keys together While holding the 0 amp 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 D START 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 1 n STOP wW STOP D 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 T Pressthe 77 gt STOP J to go back to DISPLAY TEST 8 Pressing the NJ 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 Do not stand on the running belt while performing these test WHEN SHOULD AUTO CALIBRATION BE
12. PM Sensor LED on the MCB is responding see page 26 If LED does not respond replace MCB Engage Manager Mode and verify that the MIN SPD SPD and MAX SPD are set correctly See page 9 Engage Speed Calibration see page 19 If speed calibration can not be obtained replace the MCB Turn unit off and verify that the motor brushes are secured within the motor 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 re placement If elevation motor appears to grind or overheat would indicate Elevation Motor replacement 23 2 Foreign obstruction not allowing the elevation system to elevate Elevation screws binding 4 Elevation system loose causing bind Verify that no foreign obstruction is blocking the elevation screws or elevation belt from elevating 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 Verify that the elevation idler is not loose or damaged EL RANGE 1 Elevation motor readings are outside the range of times elevation range was detected Engage Elevation Calibration see EL LOST of times elevation lost was detected Elevation motor readings are ou
13. 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 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 Ifthe 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 cust
14. R MX SPD 5 0 20 0 English 10 0 Metric 20 0 12 5 Maximum speed in MPH or KM HR ELEVATION ON OFF ON Turns the elevation system ON or OFF TIME 5 Maximum time in minutes allowed for program including warm up cool down DISTANCE Total treadmill miles Units English or kilometers Units Metric WEIGHT 399 155 Defaults to user typical weight in lbs kg depending on what setting UNITS English or Metric Last five digits of Treadmill serial number LANGUAGE English Language in English French Dutch German Portuguese Spanish Swedish Italian or Katakana ENTRY Units Tenths Units This variable changes the starting speed in Units or Tenths 12 Maintenance Mode Tee pU Value Value Value HR CONTROL ON OFF ON OFF Heart Control disable Heart Control enabled CONTACT CONTACT BOTH Polar amp BOTH BOTH Contact METS ON OFF OFF OFF METS disable ee WATTS OFF WATTS disable WATTS enable Seconds of pause INFRARED COM time during work out program Off disable weight scales On enable weight scales Off disable infrared hardware ON enable infrared hardware Off disable display fans On enable display fans Off disable load detection On enable load detection Off disable enter tainment display key On enable enter tainment display ke uu LIT CSAFE Off disable entertainment hard
15. T NO MOTOR 255 of times No Motor was detected display when there s no motor current detected but there is belt movement of times No Sensor was detected No Sensor will display when there s no RPM feedback Voltage to elevation motor to obtain 096 Multiply by 0 0196608 to actual voltage 57 120V Voltage to elevation Black motor motor to obtain 15 25 120v Multiply by 0 0196608 Silver motor to actual voltage 80 230V of miles when the deck was last waxed After a 2000 mile or 3000 KM difference REWAX will scroll in the display until LAST DECK miles are updated ZERO ELEV MAX bi LAST 65565 DECK 0 ELEV 175 242 25 it of miles when the last running belt was replaced it of miles when the last motor was replaced LAST BELT LAST MOTOR MASTER PIN 13579 13579 13579 Master pin personal trainer configuration 15 Maintenance Mode en Ed al s Value Value Value MODEL 255 1 Model number used by CSAFE to distinguish models and equipment MANUAL 65 535 of times Manual Program was used since last reset FOREST 65535 of times Forest Program was used since last reset TRIAL 65535 of times Trial Program was used since last reset ALPINE 65535 of times Alpine Program was used since last reset MYSTERY 65535 of times Mystery Program was used since last reset 5K LAKE of times 5 Lake Program
16. an Board Assembly Wiring 30 MCB Assembly Wiring 31 Drive Motor Wiring 34 Complete Lower Chassis Wiring 36 CHAPTER 6 37 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
17. ation system is responding correctly by the following Asthe treadmill elevates up and down verify the corresponding LEDs D31 amp 032 light up on the MCB See page 22 23 for MCB LED layout e Verify that the Elevation Motor Range see above A column is changing in increments of 196 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 amp 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 Asthe 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 amp maximum speed sur e dii J STOP KEY Exists MOTOR TEST Mode and restarts the treadmill 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 D
18. ay occur 1 Press and hold the 0 2 amp START keys together While holding the 0 amp 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 096 then press the elevation keys until the unit is leveled at 096 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 096 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 ALPINE y NOTE 110V units maximum elevation is 57 and 80 for 220v units 3 5 v9 key to exit Motor Test NOTE Verify that the Elevation Motor Range see above A column is changing in increments of 196 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 Mai
19. 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 until 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 596 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 counter clockwise 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
20. cy Stop Switch e I O ribbon cabl s improperly connected Faulty Display Board Itis highly recommend that each Pro Tread has the proper Ampere rate gt dedicated AC line Please review owner s manual Turn the Emergency Stop Switch counter clockwise to release Install connector at J25 labeled 715 3482 EMG STOP Replace Emergency Stop Switch Assembly 715 3473 e Check I O ribbon cables for proper connection Verify all wiring and electronic connection before proceeding with next step Replace Console Display Board No Heart Rate in the Numeric window or Heart Chart from handgrips Contact Heart Rate system is disabled in software Heart rate stainless steel grips are not installed properly Note Max Heart rate is 225 beats per minute Enable Contact Heart Rate system in software Manager Maintenance mode menu Please review Owner s Manual e Check heart rate grip assembly Improper wiring of grips or grip cable harness Check heart rate grip wiring connection and cable assembly No Animated Heart when heart rate is being displayed in Numeric window No Active Heart Chart heart rate is being displayed in Numeric window or displaying number of beats per minute outside 90 to 170 success with any of the heart rate Systems Check
21. d display controls and investigate display code messages e Manager Mode customize e Maintenance Mode diagnostics e Motor Test Mode diagnostics Display Test Mode diagnostics e Heart Rate Test Mode diagnostics 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 4 START keys together While holding the 0 amp 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 4 SPEED KEYS Allows the variable to be changed within the parameter i ENTER KEY Saves the value if changed in the EPROM software Note ENTER KEY must be pressed for each value changed soe amp 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 o 9 key 5 starts DISPLAY TEST and key 8 starts MOTOR TEST read 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
22. e 0 amp 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 it SPEED KEYS Allows the variable to be changed within the parameter ENTER KEY Saves the value if changed the EPROM software START Note ENTER KEY must be pressed for each value changed STOP W STOP JSTOP KEY Exists Manager Mode and restarts the treadmill with a warm start 0 9 KEYS Enters new parameter values If UNITS parameter is displayed o 9 key 5 starts DISPLAY TEST and key 8 starts MOTOR TEST ALPINE ALPINE KEY When pressed will automatically display manufactures default 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 Default Value Highes Value t Value UNITS English Metric English English units of Ibs miles hours minutes Metric units of kg km hours minutes 0 1 25 English 0 5 Metric 1 0 0 5 Minimum speed in MPH or KM H
23. eypad will not Loose N cap I O cables Add shim s to obtain clearance Replace cell at a time until problem is solved AC power is not plugged in or Plug into AC outlet or turn power power switch is not on Switch to ON D Verify power wall outlet has proper live voltage Replace fuses Please refer to Certified Electrician e Check for proper connection at JIC for line voltage Check the connection at 13 Look green LED s on fan system board at FAN STATUS FAN1 amp FAN2 e Replace fan power harnesses or replace fan harness or replace fan Fan I O cable is not connected Check harness at connector properly at location labeled Verify proper wiring and electronic connections Recycle power proceed each step below at a time to establish communication e Replace fan I O harness Replace Fan Replace Pro Membrane Keypad Replace Fan Board Verify LED s labeled Low Speed and High Speed are toggle in sync with the upper console keypad Switching actions Check N cap I O cables Illuminate to corresponding e programs Loose main ribbon cables connection 2 of 2 Pro Keypad will not function to corresponding programs Or No Beeps e Improper connection at location J3 connector labeled Keypad Loose ribbon cables connection Check main ribbon cables connection at J3 J3A P3 amp
24. k MAINTENANCE CHART e D Daily W Weekly e Monthly W WAX depending on the amount of use Monthly procedures may need to be performed more frequently INTERVAL PROCEDURE 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 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 Periodic running belt re waxing virtually eliminates belt down time and maximizes the life of the running belt See page 7 for Re waxing instructions Running Belt Adjustments The running belt and its headroller drive belt tailroller and running deck are designed to be self centering slip free and sm
25. n Drive Assembly Wiring Display Board Assembly Wiring Fan Board Assembly Wiring 21 Display Code Troubleshooting Chart No Rail Stop of times the Stop Switch Stop key was down or disconnected on power up since last reset of times one of the keys was down or depressed on power up since last reset SPEED CHG of times a sudden change in speed was detected Stop Key on the One or more Sudden speed Disconnected Stop A Switch on the handrail or in the upper display board Carefully pop out the handrail stop switch from the handrail and check connec Tion Verify that the Stop Switch is not damaged or that it is sticking Remove left handrail and check Stop Switch within the handrail Carefully remove the display board and check connection See page 28 Replace Stop Display Board faulty key s on the display panel are faulty or stuck change was detected from the RPM Sensor Switch Assembly Engage Display Test and check STOP KEY See page 18 Engage Display Test and check key pad re response See page 18 Engage Motor Test Mode see page 17 and verify speed response No response would indicate RPM Sensor re placement 22 of times an elevation stall was detected 2 Speed is irregular at high or low speeds 1 Elevation system has malfunctioned B Verify that the R
26. omer 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 e CALL TOLL FREE 1 800 486 4736 1 STAR TRAC model 2 STAR TRAC serial number 3 Problem statement symptom 4 Return phone number and contact name FAX Requests Domestic and international FAX 714 669 0739 STAR TRAC model STAR TRAC serial number Problem statement symptom Return phone fax number and contact name Purchase order or reference number Part description and quantity Ship to bill to 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 tas
27. ooth 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
28. r on rate depends on the speed detected D31 DOWN Elevation Down command is present D32 UP Elevation Up command is present D33 418 V Always on when MCB supply voltage is present D34 V CON Always when Console supply voltage is present D38 AC Stays on when AC line voltage 110VAC 220VAC is present 040 MTR SHRT Turns on when the motor is SHORTED TP1 Test Pin 1 Current sense feedback test pin for troubleshooting TP2 Test Pin 2 Brush sense feedback test pin for troubleshooting 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 N Can Interface Polar Receiver P 28 Display Board Assembly Wiring continued Complete wiring view of the back of a Pro Tread display 29 Fan Board Assembly Wirine 715 3444 cable J3A Em Wm an Fuse 1 25 SB F2 E m Fan PCB Power 715 3449 RY g c a Fi p gt gt E 1 4 y 715 3459 Fan Board Voltage Key 110V B L 4 f MCB motor control board Assembly Wiring Main I O Interface cable from upper display J1 J1A plugged in here No matching ID reanired 31 MCB motor control board Assembly Wiring DER i Cs T i r P9 Fan Board
29. rectly Improper connection of the Telemetry Heart Rate Receiver to _the main console Bad Telemetry Heart Rate Receiver e Animated Heart when heart amp rate is being displayed in Numeric window No Active Heart Chart heart rate is being displayed in Numeric 3window or displaying number of beats per minute outside 90 to 170 Note Max Heart rate is 225 beats per minute range Above Remedies tried but still no i success with any of the heart rate 1 of 2 Weight Scale system can not calibrate error is displayed Weight Scale system is not enabled software e No weight cell or cells installed or Connected Recalibrate weight system using Nominal weight of 250lbs or similar known weights Connect or re install cell or cells System was not calibrated at all or 7 not calibrated properly Cell not installed correctly Cell has been damaged due to an Replace Cell impact Install switch or check display console connection or switch connection inside left handrail Release Stop switch If problem persists replace Stop switch Stop Switch not installed or installed but not connected No Stop Error e Stop Switch stuck in depressed position
30. the belt from the deck 4 SPREAD 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 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 an
31. tside the range or reading is lost page 20 and verify that the elevation motor readings are within range Combine Motor Test Mode see page 17 with Elevation Calibration see page 20 and verify that the elevation motor readings are within range Verify that the Elevation Motor Range is changing in increments of 196 as the treadmill elev ates up and down Erratic 24 of times no sensor was detected Sudden speed change was detected from the RPM Sensor or no loss of speed feedback has been detected Cable loose or interference See note below for troubleshooting instructions increments would indicate the display cable or elevation motor is faulty Engage Motor Test Mode see page 17 and verify speed response No response would indicate RPM Sensor re placement Verify that the RPM Sensor LED on the MCB is responding see page 26 If LED does not respond replace MCB Engage Manager Mode and verify that the MIN SPD SPD and MAX SPD are set correctly See page 9 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
32. ware enable entertainment hardware Cardio Theater 13 Maintenance Mode Parameters Lowest Highest Default Value Value Value reach max speed DECEL TIME Time in seconds to reach 0 mph 0km hr LOCK OUT OFF disabled ON enabled LOCKOUTID 10000 65535 12345 Treadmill Lockout ID RAIL STOP OFF Disables Euro 1 10 aie 220v unit handrail stop ON Enables Euro handrail stop Inches of belt traveled for 10 revolutions 1 6 pulley 27 5 irs pulley 29 1 1 8 pulley 30 7 110v 2 1 pulley 35 8 220v Number of counts per automaticall done automatically done Maximum PWM automatically done 10 REV CNT RV ma RPM Sensor RPM Sensor MN PWM 1 2 PWM didi p Manufacturing date of times the Stop Switch Stop key was down or disconnected on power up since last reset of times one of the keys was down or depressed on power up since last reset NO RAIL STOP KEY DN SPEED CHG of times a sudden change in speed was detected of times an elevation stall was detected 14 EL STL Maintenance Mode Parameters Value Value Value EL RANGE 255 of times elevation range was detected EL Range will detect between the Pot read of 253 and 255 255 of times elevation range was detected EL Lost will detect when the display has lost the elevation motor Pot reading 0 240 EL LOS
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