Pro Stepper Service Manual
Contents
1. i Pro Stepper Service Manual STAR TRAC LIMITED WARRANTY COMMERCIAL FITNESS PRODUCTS STAR RAC by I NISE INC warrants to the original purchaser that ts Commercial Fitness Products are free of defects in workmanship and materials Fars are covered for a period of two 2 years from date ol purchase Sport Treadmill TR4500 Treadmill and Pro S Treadmil drive motors and motor control boards are covered or a penod of three 3 years Fom date of purchase P OTreadmil and Elite Treadmill drive motors and otor control boards are covered for a period ol five 5 years from dale of purchase Frare welds are warranted for tne life of the product Treadmill wear items such as running bell running deck and me brushes are warranted for six 5 months from cate of purchase see Exclusions below Other wear items such as bicycle seat upholstery and handiebar grips are warranted for one 1 year from date 01 purchase see Exclusions below Du ng the applicable warranty period Star Trac will either repair or replace at its option defec ive panis al no c arge Additiorally Star Trac will cover labor costs for required repairs ct Sport Treadmill IR4500 Treadmill and Pro 5 Treadmill drive marors and malor control boards for a period of three 3 years from date of purchase Star Trac will cover labor costs for equired repars of Pro Treadmill and Elte Treadmi drive motors ana motor con d boards for a period of five 5 years Irom date 0 purchas2. STAR TRAC Pro Stepper Service Manual Table of Contents Display Panel Preventive Maintenance Preventive Maintenance Cont d Settings Maintenance Mode Settings Maintenance Mode cont Diagnostics Display Codes Diagnostics LED Test Diagnostics Keypad Test Diagnostics Heart Rate Test Measurements Trouble Shooting How do I use the Stepper Trouble Shooting FAQ Trouble Shooting Incorrect Model Setting Trouble Shooting Noise Trouble Shooting Noise Clutch Pillow Blocks Trouble Shooting Noise Springs Trouble Shooting Noise Pedals Part Installation Procedure Shrouds Parts Replacement Shroud s Part Installation Procedure Shrouds Part Adjsutment Adjsuting Belt Tension Part Installation Procedure Load Control board Wiring Part Installation Procedure Alternator Wiring Part Assemblies Hardware Kit Part Assemblies Clutch Assembly Part Assemblies Display Assembly Part Assemblies Right Pedal Assembly Part Assemblies Left Pedal Assembly Part Assemblies Chain Link Assembly Part Assemblies Electrical Components Part Assemblies Frame Assembly Right Part Assemblies Frame Assembly Left Part Assemblies Frame Assembly Parts list Part Assemblies Frame Assembly Maintenance Log Warranty SOMIDNARwWNHO 0 O O O ON IO N N N N N N N N BBB mb Po eee ae a ADAN 8 8 00 FREN O 0 NN ON e STAR TRAC Pro
3. STAR Use Pro Stepper Service Manual Part Assemblies Clutch Assembly Kit Part Number 800 3114 Drive Shaft Assembly 180 1537 SPROCKET 13 TEETH 2 DESCRIPTIO MAI 2 PILLOW BLOCK E 2 N PILLEY MAIN DRIVE WELDED SPACER MAIN DRIVE OT LG SPACER MAIN DRIVE 20 THK CLUICH ROLLER 1 2 23 Pro Stepper Service Manual 620 7619 Rev A STAR uz 4129 Pro Stepper Service Manual enni cora LL CES DISPLAY FRONT UBRE PRO IFO CENTER _NIVERSAL SCREW MO 5x81 PHT PACSZ N MAxO 7x10L PHT PH CS EC SSY AR ASSY DISPLAY BOARD POPULA ED 8 SSY CONN FITLINNXICARDIO ARNESS GROUND ELE200 Y CABLE POLA RECENER 65 R PRO S SPLAY BACK PRO BIKE 24 Pro Stepper Service Manual 620 7619 Rev A GIG TRAC Pro Stepper Service Manual Drawing 711 1045 01 Pedal assy Left 25 Pro Stepper Service Manual 620 7619 Rev A Drawing 711 1045 02 Pedal assy Right 26 Pro Stepper Service Manual 620 7619 Rev A gt gt TAR TRAC amp b Stepper Service Manual a As P a imt 2 5 ui e tO oc AT 2 x A Lon SS gt l X N e e DN IG Se Fi los T n e bi ITEM PART NO DESCRIPTION 1 020 6810 WELDMENT CONN CHAIN STEPPER 130 1543 LINK CONN CHAIN 130 1636 BEARING IGLIDE 4MMx4MM 130 1641 CHAIN 40 NPX 5 PIT 14 5L 27 Pro Stepper Service Manual 620 7619 Rev A Dala Pro
4. Stepper Service Manual STAR TRAC finns TY RIOT Ae set ali amm Gite epoca Ban deri a pilas La aan weal aka pts na adad ELZ a meditate Pro Stepper Series 5100 display keypad 1 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual To keep your Star Trac Pro Stepper in top condition Star Trac strongly recommends performing regular daily weekly and monthly preventive maintenance routines outlined below Daily Maintenance Remove excessive accumulations of dust dirt and other substances by using a clean soft cloth and a non abrasive liquid cleaner such as Formula 409M or FANTASTIKTM Wipe down the exterior of the display panel pedals shrouds and heart rate grips Note Do not spray directly on the display or heart rat Sa ma H E E MA Spray on the cloth first then wipe the display Weekly Maintenance Perform the following services each week e Vacuum the floor under and around the Pro Stepper Move the unit to another spot if necessary to vacuum thoroughly Inspect the screws i e display panel mounting screws for security and retighten if necessary Inspect the display panel keypads for wear Monthly Maintenance Perform all the steps in weekly maintenance plus the following services each month or as needed e Check that the pedals and shrouds are secure Check for smooth and quiet operation of all moving parts 2 Pro Stepper Servic
5. repair acility O inspect and estimate the cost to repair such defective paris he cost il ally of shipping defective parks 10 and from su repair facility and Or such estimate s all be nome solely by the original consumer purchase Defective partis must remain available lor inspection unti the claim Is finalized Whenever Clas are settled Star Trac reserves the tight to be subrogated uncer any existing insurance policies the claimant may have Exclusions For Scot readmills TR4500 Treadmills and Pro S Trea rrills running bell waxing is the original purchaser s responsib ity For ali veadmills tracking anc tersi n adjustments a e the original purchaser s responsibility Running be thal have separated cue to heal and belts with chaffed edges or creases caused by folding will nol pe covered This limited warranty does not apply lo cosmetic damage imoerfections thal are within design soecficaticris or thal do rol materially ake functionality cr damage due 10 acts cf Goo accident abuse misuse negligence lack of nomal maintenance abnormal service or hand ng that ciffers from that specified for is model imoroper installaton or cperabon In addition alteration or modification of the product or repair by anyone other than a Star Trac technica representative 0 authonzed service provider will vcid this warranty This warranty is valid only in the continenta united states Disclaimer of Warranties Limitation of Liability Ths warranty is i heu of a
6. ODE will display momentarily in the information window Release all keys SERIAL NO XXXXX will display in the information window Press the until the display reads Model Press the until the correct setting shows Stepper Pro Stepper Press to save the setting and exit the maintenance mode Test for functional ity 12 Pro Stepper Service Manual 620 7619 Rev A ro Stepper Service Manual Noise is one of the hardest things to diagnose because it may only make the noise under certain conditions To find the part that is making the noise will require some patience and trial and error It may also require the help of another person to slowly and safely move the part while another person listens NOTE Always use safe work practices and do not allow clothing hair or fingers to get caught in moving parts Try these methods when trying to locate the noise e Move the product to a quiet location to help in diagnosing the noise when possible e Loosen or tighten screws to make the noise louder or eliminate the noise Often a noise will change its pitch when you do this and that may point you towards the correct part Gently and carefully when possible spray a little lube on the bearing or shaft to see if the noise will get quieter This is very successful when a shaft is spinning within a bearing and making a squealing noise Remove part of the moving assembly to help isolate the noise Try swapping parts
7. Stepper Service Manual Electrical Components 1 Sueno Su Left Stepper La 2 003122 A Mando Raw All no Pullev 1 3 ose tus ai Ub RblSc d 4 Lcb Stepper 5 5 711 3166 Cable Alt And Lcb Stepper 6 711 3167 Cable Resistor Stepper 1 28 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual 620 7619 Rev A 29 pa TAR TRAC Pro Stepper Service Manual SE Pro Stepper Service Manual 620 7619 Rev A 30 DESCR RACKET A ERNATOR ADJUS RACKET RPM SENSORIALTERNATOR 16 130 140 060 140 2810 170 0652 10 263 10 0637 LI um 6 o SZF 52F 116 16 X 2 0 HETS 5 6 18 2 HH HE CSZ ow ny 1101447 1 0 1530 1401720 110 1830 140 1833 110187 HIET WASHER Va SSE FLAT WASHER 36 SAEFL r B 1 YU U L UNIVERSAL LASSYS EP CABL cas 31 Pro Stepper Service Manual 620 761 9 Rev A Pro Stepper Service Manual Drawing 711 3155 Frame Assembly 32 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual star TRAC Model Serial Number Mfg Date Date Problem Adjustment Part Replaced Service performed bv Comments 33 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual 34 Pro Stepper Service Manual 620 76 19 Rev A
8. ach time you press a key the information window will display which key has been pressed A To exit the keypad test press Pagi If any of the keys do not respond they may not be functioning and the display keypad must be replaced 8 Pro Stepper Service Manual 620 7619 Rev A sss Lala Pro Stepper Service Manual Heart Rate Test Heart Rate can be checked using the Heart Rate Test To verify heart rate operation Enter the Maintenance Mode see Settings Maintenance Mode Press until Heart Rate Test is displayed in the information window Press 9 to enter Heart Rate Test The display will read TELEMETRY If checking contact heart rate it will read CONTACT and the heart rate number If checking Polar the display will read TELEMETRY and the heart rate number A 5 To exit the heart rate test press Measurements Mode Measurements can be done to verify the voltage of the battery To verify the battery voltage Enter the Maintenance Mode see Settings Maintenance Mode Press until Measurements is displayed in the information window Press to enter Measurements The display will read BATT VLT and the voltage of the battery a e To exit the measurements press 9 Pro Stepper Service Manual 620 7619 Rev A STAR TRAC Pro Stepper Service Manual Q Why does the stepper not have any resistance when increase the level A When pressing the upA or down Y key
9. d basta Start Pedaling Wrong Model Selected SISMA MOJELA PO Stepper Start Striding Wrong Model Selected Change Model to Pro Stepper forgot where the wires go on the Wires may be in the wrong alternator position 8 Refer to the wiring photo 21 h N The connectors are all Im replacing the LOB mont shapes so it is not Refer to the LOB wiring but am not sure where the connectors plug in possible to plug them in the diagram wrong place 11 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual The display electronics on the Pro Stepper can be configured to operate with many different models of Star Trac products For them to operate properly the correct model must be set in the Maintenance mode If the correct model is not set the following may happen VVhen the unit is powered up the display will read Pro Bike or Pro CrossTrainer or Elite CrossTrainer in the level profile window The display will read Start Pedaling or Start Striding instead of Start Stepping Also some programs will not work when the keys are pressed i e When pressing the Hr Training Program Key the Total Body program or Warm Up program will start If you experience any of these symptoms engage the Maintenance mode to correct the Model setting Engaging Maintenance Mode gt E A Press and hold the and keys together A beep will sound and the MAINTENANCE M
10. dware version Ver3 CSAFE Turns on off CSAFE functionality Off Auto Status Wall Power Turns the wall power setting on off Off IRDA Turns on off infrared port functionality Off OPER Hours Total operating hours 0 Quick Start Number of times the Quick Start program was run since last reset 0 Manual Number of times the Manual program was run since last reset 0 Fat Burner Number of times the Fat Burner program was run since the last reset 0 C since the last reset 0 since last reset 0 Fit Test Number of times the Fitness Test program was run since last reset 0 GLT Sculpt Number of times the Glute Sculptor program was run since last reset 0 Thigh TNR Number of times the Thigh Toner program was run since last reset 0 Famous Step Number of times the Famous Step program was run since last reset 0 Comm Lost Number of times a Comm Lost condition has occurred See Display Codes Key Down Number of times a Key Down condition has occurred See Display Codes LED Test Access to integral LED test function Keypad Test Access to integral keypad test function Heart Rate Test Access to integral heart rate system test function Measurements Access to integral measurements function 5 Pro Stepper Service Manual 620 7619 Rev A Dala Pro Stepper Service Manual Display Codes Star Trac Pro Steppers perform a self test at the beginning of every workout If a problem is detected a message display
11. e Star Trac will cover lab costs for required esairs 0 nor wear ite ll parts or a period of one 1 year from date of purcnase Star Trac wi cover labor costs for required repairs o wear item parts for a period of sx f6j months from date of purchase The manufacturer does not warrant tha heart ratc system performance on this product as ine car rate system performance vanes based or a users physiology tnass level age method of use and other factors Furthermore the hear rate system is not for medical use In ordel to implement the provisions of this limited warranty the original purchaser must contact Star Trac Product Suppor at 8001503 1221 Be prepared to provide the procucl senal number and a detailed description of the problem Proof of purchase or warranty registration will be needed 10 verify warranty effectivity and obra n waranty service and or parts Do nol retum defective panis for repair or replacement without prior authorization 110m Star Trac Star Trac reserves the right to review defective part s AB costs of shipping defective part s to and from Star Trac tor inspection shall be borne solely by he original purchaser Any repair or modification 01 defective parts by anyone other than a Star T ac Technical Representative or Authorized Service Provider will void Itis warranty If Star lac determines in its solo discretion that it is impractical to ship defective part s 10 Star Tmc Star Trac may designate in its sole discretion a
12. e Manual 620 7619 Rev A 1 Pro Stepper Service Manual Quarterly Maintenance Perform all the steps in weekly and monthly maintenance plus the following services each month or as needed Remove the return springs form the chains Raise and lower the pedal arms and inspect for smoothness Binding or excessive looseness might indicate a worn bushing Rotate the clutch sprocket and inspect for smoothness As you rotate the clutch towards the pedals it will turn the drive belt but as you turn the clutch towards the drive belt it will spin freely and will not turn the drive belt Inspect the chain pulleys by spinning them a If they spin freely they are ok b If they bind check for areas that bind and adjust or replace as needed Inspect the chains and springs for wear a Frozen links will require a chain replacement Lubricate the chain with white lithium grease Rotate the clutch sprockets 180 degrees from the original position and reassemble the springs and chain back onto the sprockets 3 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual The Maintenance Mode allows you to query and modify the basic settings of the Star Trac Pro Stepper Engaging Maintenance Mode Press and hold the and keys together A beep will sound and the MAINTENANCE MODE will display momentarily in the information window Release all keys SERIAL NO XXXXX will display in the information window Modifying
13. er Service Manual 620 7619 Rev A Pro Stepper Service Manual I e Check all hardware under the pedals for looseness e Check clips and springs to make sure they are aligned properly so they do not come off 16 Pro Stepper Service Manual 620 7619 Rev A STAR TRAC Pro Stepper Service Manual Parts Replacement Shroud s Parts Needed Shroud Left 711 3165 01 Shroud Right 711 3165 02 sw Tools Needed Phillips Head Screwdriver Procedure Remove the Shroud by unscrewing the 6 screws on each side of the shroud and lift the shroud off the frame Be careful not to pull on any of the cables as you remove the shroud iSy 17 Pro Stepper Service Manual 620 7619 Rev A Tar TRAC Part Installation Procedure Shrouds The RPM sensor and alternator adjustments are accessible from the right side The gap on the RPM sensor should be approx 1 credit card 18 Pro Stepper Service Manual 620 7619 Rev A e by Pro Stepper Service Manual To adjust the tension of the main drive belt perform the following check Ifthe drive belt Is slipping on the adjustable bracket assembly or the main pulley in between the clutch sprockets the belt will have to be tightened Using a 9 16 inch open end wrench loosen the large nuts holding the adjustable bracket on the frame of the stepper Using a 7 16 open end wrench or socket wrench tum the bolt in the fro
14. ll other warranties express or impliec including without limitation tne implied warranties of merchantability and fitness for a particular purpose Repar or repiacement as provided above shall be the soe and exclusive remedy available the purchaser Correction of defects the manner anc tor Ite period of lime cescrived above shall constitute complete fuifl ent of all liabilities and responsibilities of Star Tlac to the purchaser with respect 10 contract negligence st cl ability or otherwise Star Trac shali not be able or in any way responsibie for any incidental or consequen ial damages based upon breach 0 nv express or ir pied warranty on this product or otherwise Some states 00 no allow the exclusion or kmitation of implied warranties or incidental or consecuential damages so the above exciusions and limitat ns may noi aoply to you Th warranty give ou specific legal r ghts and you may also have other nghis which may vary from state o state PIN 620 7135 REVISION E DOC WA COMM ust 35 Pro Stepper Service Manual 620 7619 Rev A 800 503 1221 http support startrac com
15. nt of the frame e To tighten the belt tum the bolt clockwise this will pull the adjustable bracket forward This will tighten the belt To loosen the belt tum the bolt counter clockwise This will push the adjustable bracket closer to the pedals This will loosen the belt 19 Pro Stepper Service Manual 620 7619 Rev A oni t kas HE 3 v L Dow 4 ea Wiring The LCB is protected from sweat and moisture by a clear plastic cover remove this cover while accessing the LCB All the connectors are keyed and will only fit properly in one direction Make sure the connector is fully seated and locked Run wires away from moving parts and tie wrap as needed e Notthe RPM led this will be lit when the rpm sensor is detecting the rotation of the alt flywheel 20 Pro Stepper Service Manual 620 7619 Rev A Alternator Wiring The alternator is wired as shown in the above photo Make sure contacts are clean and secure ASSY NUTS PROVIDED B POSITIVE IPUI RED GND GREE LARGE FIELD BLUE Alternator Wiring Diagram Pro Stepper 21 Pro Stepper Service Manual 620 7619 Rev A Part Assemblies Hardware Kit 711 3182 Kit Hardware 5100 Stepper REW MOXTO NEUK JUIN I TEMNO PART NUMBER 110 0506 2 110 3172 290 0040 DESCRIPTION SCREW 1 4 28x3 8 BHC HK SS BO SCREW ISO10542 M6x16 HEX L KEY 5 32 22 Pro Stepper Service Manual 620 7619 Rev A
16. s before or after the workout depending on the nature of the problem Key Down One or more keys on the display panel are stuck in the on position for at least 10 seconds This can occur if a user presses keys before the system is turned on Comm Lost Communication between the Load Control Board LCB and the display are lost This can occur if the display cable is not connected securely at install 6 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual LED Test The LED Test can be used to verify that all LED lights are functioning on the display assembly To engage the LED Test Enter the Maintenance Mode see Settings Maintenance Mode Press until LED Test is displayed in the information window ba Press to enter the LED Test All lights on the display should be on Check for any bumed out lights 7 e To exit the LED Test press If any of the LED s do not illuminate they may not be functioning and the display electronics should be replaced SETTE n PE it i inn 7 Pro Stepper Service Manual 620 7619 Rev A TAR TRAC Keypad Test The Keypad Test can be used to verify that all keys are functioning on the display assembly To engage the Keypad Test Enter the Maintenance Mode see Settings Maintenance Mode Press until Keypad Test is displayed in the information window Press to enter the Keypad Test Press each key on the display E
17. such as with the pedal springs one spring may make a noise and not the other Swap the springs to determine if the spring is at fault or the pulley etc e Check for worn or damaged parts such as a worn spot on a plastic pulley Look for metal shavings which might indicate a worn bearing or a set screw that is not tight The following pages discuss some areas that have moving parts and could be the source of noise Proper cleaning and lubrication as suggested in maintenance can prevent noises 13 Pro Stepper Service Manual 620 7619 Rev A The noise that you might hear as a result of the pillow block bearings being loose is a slight click or ticking sound Use two 9 16 wrenches or socket and wrench to verify that all 4 bolts and nuts on the upper and lower pillow block assemblies are tight Loosen the nuts and then ride it a little to let it settle then tighten the nuts to determine if the noise is from the alignment of the shaft to the bearing Loosen the set screws and rotate the shaft so the set screw is in the detent in the shaft Tighten the set screw in the detent first then the other set screw and repeat the procedure on the other side 14 Pro Stepper Service Manual 620 7619 Rev A Pro Stepper Service Manual i Noise from the springs may make a pinging or a rubbing sound Check the spring to make sure it is not twisted and the pulley is turning as the spring rolls over it 15 Pro Stepp
18. the Maintenance Mode The following keys are used to modify Maintenance Settings Upper and Lower Data Infonnation Window SCROLL keys Display the next previous settings Increase and Decrease Level Keys Adjust the value of the displayed setting up and down respectively in increments of 1 unit OK Key Updates saves the value of the display setting in the Flash memory and exits GA Maintenance Mode OK Maintenance Mode Settings The items that you may display and change Default values set in Pro Stepper serial number 0 Serial Number O Date Manufactures date for the Pro Stepper 01 05 Display Vers 1 Display software version N A Display Vers 2 Display software version N A LCa Vers LCB software version N A Units English units of pounds miles feet inches English Metric units of kilograms kilometers centimeters Maximum time in minutes allowed for program excluding warm up and cool down 20 Default to user typical weight in Ib UNITS English or kg UNITS Metric 350 lbs 159 KG Time 4 Pro Stepper Service Manual 620 7619 Rev A so Pro Stepper Service Manual Language Language is English Dutch French German Spanish Swedish Italian or Katakana English Model PB UB Pro Bike Upright PB RB Pro Bike Recumbent Pro CT Pro CrossTrainer Elite CT Elite CrossTrainer Stepper Pro Stepper LCB Type LCB har
19. you are actually changing the workout level of the user Press the increase UP A level key the pedals will fall faster and there is less resistance so you have to work harder to keep up with it Press the down level DOWN Y it makes the pedals move slower so it is easier to keep up with it Do not let the pedals touch the floor Step fast enough to keep the pedals in their middle range with step heights from 2 to 16 inches If the pedals sink to the floor step faster or decrease your work level by pressing the level down key V 10 Pro Stepper Service Manual 620 7619 Rev A Ulla Pro Stepper Service Manual Page Symptom Possible Problem Squeaking noise Check all bearings e Examine clutch Clicking Noise Possible spacer missing assembly Popping noise Frozen link on chain Examine chain links 27 Pedals Slip Possible clutch failure Ha 2m clutch and belt Inspect bushings on Loose Pedals Bushing wear pedal arms and pedals No Power Low battery ENCON nanan ana connections N P N N N En e e N N No resistance Possible low battery or Chase bansarvelaes Pedals fall at leveli RPM sensor out of y vo tag and rpm senor alignment to 5 alignment Too much resistance Check model in i Possible model error or Pedals won t move at LCB failure Maintenance mode level 10 to 15 iii Swap LCB Tir GA Bi desi Check RPM sensor LED RPM sensor on LCB Load control give spee
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