Service Manual
Contents
1. nut place the black voltmeter probe on the alternator black wire nut labeled E 4 6 C No Alternator Output Flowchart Take a voltage reading at the alternator and LeB see Note 5 and Diagram 2 Verify voltage is between 9 10 volts Voltage correct Diagram 2 YES Replace the wire harness Take a voltage reading at the alternator see Note 6 and Diagram 3 Verify voltage is between Stop 8 9 volts YES WHITE Voltage correct 9 NOT USED NO YELLOW Pro Bike Service Manual STAR mae ein No Alternator Output Flowchart s IRAC NOTE 7 Place the red voltmeter probe into the yellow wire at the Lea J4 connector place the black voltmeter probe on the alternator black wire nut labeled E Take a voltage reading at the alternator and LCB see Note 7 and Diagram 4 Verify WHITE voltage is between 8 9 volts NOT USED Voltage YELLOW correct Diagram 4 YES Replace the cable Replace the LeB harness Stop Stop Pro Bike Service Manual 4 7 STAR UNISEN INC ME RAC NOTE 1 Press and hold the Enter 0 and 2 keys at the same time While holding the Enter and 0 keys release the 2 key The unit will beep once and the message Service Settings will display Release the Enter and 0 keys press the 8 key The message Measurements will display NOTE 2 The LCa panel is se2. straight into the display electronics by passing the combiner heart rate board If polar is working replace the combiner heart rate board replace the polar board heat rate grip connection to the grips and heart rate board Pro Bike Service Manual No Contact Heart Rate Remove the two screws continue which supports the heart rate grips and check connection Using a Multi meter check continuity between the grips and the heart rate cables Ceasing hard to pedal 1 Transfer case bearings are Loosen or remove the Poly damaged V belts Manually by hand rotate the transfer case pulley feel for any loosening or mechanical grinding bearings as the pulley is rotated If the pulley is hard to turn or completely loose replace the transfer case No resistance 1 Faulty Alternator Check all connections from the LCB and alternator Enter System Measurement Mode see section 3 page 3 9 and check Alternator Voltage Output voltage range should be between 11 5 13 5 Voltage outside the this range indicates a faulty Alternator 2 Faulty LCB Enter System Measurement 2 Mode see section 3 page 3 9 and check Load Voltage Output voltage range should be between 1 0 10 0 Voltage outside the this range indicates a faulty LCB Pro Bike Service Manual 4 3 STAR UNISEN INC SE RAC NOTE 1 The LCa panel is secured with three Phillips head screws two located un
3. Active DHRC ON Values shall be On and OFF This shall determine whether the Heart Rate Control programs shall be accessible from the HEART KEY Watts OFF Values shall be ON and OFF This shall determine whether or not a Watts value shall be displayed with other program statistics at the Info display during a workout Mets OFF Values shall be ON and OFF This shall determine whether or not a Mets value shall be displayed with other program statistics at the text display during a workout Lang ENGL Values of ENGL GER SPAN DUTC FREN ITAL PORT and SWED shall be available for language settings Prompts in the Info Window shall be translated to the selected language Pro Bike Service Manual STR IRAC Service Settings The PRO BIKE records and stores usage data which may be used as an aid in maintaining the unit and diagnosing malfunctions The Service Settings Mode lets you view this usage data as well as software version numbers and the serial number and date of manufacture for the unit To enter the Service Settings Mode 1 Press and hold the Enter 0 and 2 keys at the same time 2 While continuing to hold the Enter and 0 keys release the 2 key The unit will beep once and the message Service Settings will show in the upper information display 3 Release the Enter and 0 keys Once the unit is in the Service Settings Mode use the k
4. YELLOW Diagram 2 Voltage correct YES NO Take a voltage reading at the alternator and LCB see Note 7 and Diagram 3 Verify voltage is between 8 9 volts Diagram 3 Replace the alternator Replace the cable harness Yyes gt Replace the alternator Voltage correct 2 4 11 Pro Bike Service Manual STAR UNISEN INC MA SE IRAC NOTE 1 Press and hold the Enter 0 and 2 keys at the same time While holding the Enter and 0 keys release the 2 key The unit will beep once and the message Service Settings will display Release the Enter and Q keys press the 8 key The message Measurements will display ay Engage System Measurement Mode see Note 1 Use Scroll key to select Battery Voltage Begin striding display shows battery voltage while in use Verify voltage is between 6 7 volts Voltage correct YES Pro Bike Service Manual Low Battery Flowchart Voltage above 7V Voltage below 6 2V YES Replace the LeB YES Battery charge is low or battery is faulty Refer to the procedures on page 3 7 to service the battery 4 12 Heart Rate IRAC Symptom Intermittent or no heart rate readings STEP 1 Confirm the user is using the grips correctly Hands must be completely making contact with the heart rate plates STEP 2 An exce
5. front shroud Lift the front shroud off the unit NOTE 3 From the System Measure ments mode press the Enter key to return to the Service Settings mode From the Service Settings mode press the Enter key to return to the Manual mode NOTE 4 Place the red voltmeter probe on the alternator red wire connector labeled B place the black volt meter probe on the alternator black wire nut labeled E STAR UNISEN INC M of RAC Remove the front shroud see Note 2 Engage System Measurement Mode see Note 1 Use Scroll key to select Alternator Voltage Re engage the Manual Mode see Note 3 Press the Scroll key until speed is displayed Pedal the unit at a seed of 1 5 MPH Begin striding display shows alternator output Take an output voltage reading at the alternator see Note 4 and Diagram 1 Verify voltage is between NO 9 10 volts voltage while in use Verify voltage is between 10 5 13 5 volts Voltage correct Voltage correct nNno Replace the alternator 4 co WHITE NOT USED YELLOW Diagram 1 Pro Bike Service Manual 4 5 STAR Y UNISEN INC MEENE ol el NOTES Place the red voltmeter probe into the red wire at the a J4 connector place the black voltmeter probe on the alternator black wire nut labeled E NOTE 6 Place the red voltmeter probe on the alternator yellow wire
6. pull back the sticker to locate the directional indicator circular groove located on the center top of the chip 2 Using your index finger and thumb carefully position the new chip with the directional indicator lined up with the arrow located on the printed circuit board display electronic Carefully using your thumb apply gentle pressure so that the chip is inserted into the chip socket on the printed circuit board 3 Reposition the back panel Using the flat screwdriver tighten down the single screw Pro Bike Service Manual 6 7 STAR Y UNISEN INC o TRA 6 8 Heart Rate Grip Replacement Tools e 1 16 inch Allen Wrench e Phillips Head Screwdriver String or Scotch Tape Procedure Remove the display board 1 Using a 1 16 inch Allen Wrench carefully remove the 7 screws from the rear of the display panel mount It s important to use both hands so that the display board doesn t fall and damage any connections See diagram below 2 Carefully disconnect the heart rate cables power cable and the Display signal cable from the back of the display and gently lay the display panel down 7 PLACES EMOVE ae ieee 2 N Pro Bike Service Manual STAR UN SEN NC Haart Rate Grip Replacement TRAC Procedure Remove the heart rate grips 1 Using a Phillips head screwdriver remove the 2 screws which support the heart rate plates to the handlebar Do this for both the Left and Right hear
7. this value shall clear it to O Value of 0 65535 Number of model mismatch errors recorded for the system Pressing CLEAR or 0 while viewing this value shall clear it to O Low Batt Model Err Fld Short Values of 0 65535 Number of field short failures recorded for the system Pressing CLEAR or 0 while viewing this value shall clear it to O 3 7 Pro Bike Service Manual STAR o no RAC System Measurements Mode The System Measurements Mode lets you measure critical voltages in the battery alternator circuits under both idle and operating conditions To enter the System Measurements Mode e While in the Service Settings Mode press the 8 key e Press the Scroll key to view the system measurements available e Press the Enter key to exit the System Measurements Mode and return to the Service Settings Mode MEASUREMENT DESCRIPTION Battery Voltage Measures and displays battery output voltage while the unit is idle Output voltage for a normal battery should range between 6 2 7 5 volts Output voltage below 6 2 volts indicates a low battery charge or a damaged battery Output voltage above 7 7 volts indicates a fault in the Load Control Board Alternator Voltage Measures and displays alternator output voltage while the unit is in use To check the alternator output voltage Pedal the unit at a speed above 1 5 miles per hour Alternator output voltage should range between 11
8. yellow wire nut place the black voltmeter probe on the alternator black wire nut labeled E NOTET Place the red voltmeter probe into the yellow wire at Lea connector J4 place the black voltmeter probe on the alternator black wire nut labeled E Replace the front NOT USED shroud see Note 5 Take a voltage reading at the alternator see Note 6 and Diagram 2 Verify voltage is between 9 10 volts YELLOW Diagram 2 Voltage correct Take a voltage reading at the alternator and LCB l see Note 7 and Diagram Diagram 3 3 Verify voltage is petween gisgvolts Replace the alternator Replace the cable o nae gt C stop a yes Replace the alternator gt Stop Voltage correct 4 9 Pro Bike Service Manual STAR UNISEN IN C No Load Flowchart SIRAC 1A WHITE NOTE 5 Remove eight Phillips head screws from the front shroud Lift the front shroud off the unit NOTE 6 Place the red voltmeter probe on the alternator yellow wire nut labeled EXC place the black voltmeter probe on the alternator black wire nut labeled E NOTE 7 Place the red voltmeter probe into the yellow wire at LCa connector J4 place the black voltmeter probe on the alternator black wire nut labeled E Replace the front NOT USED shroud see Note 5 Take a voltage reading at the alternator see Note 6 and Diagram 2 Verify voltage is between 8 9 volts
9. 5 13 5 volts Voltages outside this range indicate a fault in the Load Control Board Wall Power Measures and displays the voltage delivered to the unit from an optional external wall between 11 0 1 8 0 voltage The power pack should be replaced if the voltage is outside this range Load Voltage Measures and displays the voltage generated across the workout loading resistor while the unit is in use To measure the load voltage Pedal the unit at a speed above 1 5 miles per hour Load voltage should range between 1 0 10 0 volts Voltages outside this range indicate a fault in the Load Control Board LED Test LED test display are accessible by pressing 9 at the start of SERVICE SETTINGS The LED test display shall be all LEDs lit in the Profile Window and 8 characters filling both the Info Window and the Feedback Window Pro Bike Service Manual l STIR ne Section 4 RAC Troubleshooting The PRO BIKE incorporates built in self test and diagnostic features which assist in diagnosing electrical system problems Section 3 Diagnostics contains the procedures for using these self test and diagnostic features This section contains troubleshooting information for mechanical problems which may occur as a result of normal usage of the PRO BIKE Troubleshooting information is presented in chart form The Troubleshooting Chart identifies symptoms of problems which may occur lists the most pr
10. AC Tools and Materials S The following tools and materials are required to perform adjustment and parts replacement procedures for the PRO BIKE TOOUMATERIAL USED FOR Flat head screwdriver Crank Bearings Phillips head screwdriver Crank Bearings Heart rate grips Alternator Batter 1 16 Allen Transfer case Display board Heart rate grips 9 16 Socket Transfer Case 9 16 in open end Transfer Case wrench Needle nose pliers Crank Bearings Mallet Crank Bearings Transfer case String Scotch Tape Heart rate cables Pro Bike Service manual 1 ol Section 2 TRAC Preventive Maintenance Schedules Performing regular scheduled preventive maintenance is essential in keeping your PRO BIKE in top operating condition Without preventive maintenance normal wear and tear may cause cumulative effects such as misalignment and early replacement of parts This section provides a list of factory recommended preventive maintenance requirements along with detailed procedures for performing each task Contents Preventative Maintenance Chart 2 1 Pro Bike Service Manual STAR oven M Preventive Maintenance Chart The Preventive Maintenance Chart lists the scheduled maintenance tasks for the Pro Bike The chart lists the time interval when each procedure should be performed and provides the general steps necessary to perform the task In some cases the chart references detailed maintenance proce
11. Alternator Replacement 5 9 Battery Replacement 6 3 Display Replacement 6 4 PROM Replacement 6 6 Heart rate grips Replacement 6 8 Pro Bike Service Manual 5 1 STAR UN SEN NC A oI RAC Tools e 1 8 Hex keys e 11 4 Open end wrench 14mm Open end wrench e Adjustable crescent wrench Crank Bearings Replacement e Punch e Flat and Phillips head screwdriver e Mallet e Needle nose pliers Time Required 20 Minutes Procedure Remove both pedals 1 Using a 14 mm open end wrench hold the opposite side of crank arm and loosen pedal Note The pedals loosen by turning to the right See page 5 7 in this section Pedal Replacement for more details 2 Repeat the same step for the opposite side Remove shroud 1 Using a 1 8 hex key remove the shroud screws 8 total 2 Using a Phillips screwdriver remove the side shroud screws 4 total 3 Tum the crank arm toward the front of the bike Left side first Gently slide the shroud towards the front of the bike until the shroud has been removed Do the same to the right side of the bike 5 2 Pro Bike Service Manual STAR UN SEN NC Crank Bearings Replacement FRAC 4 Bend the tabs up on locking retaining washer See diagram for picture of part 8 Use a pair of needle nose pliers or a flat head screwdriver to bend both tabs up 5 Slide the crank belt off the crank pulley 1 6 Using a 1 open end or an adjustable crescent w
12. STAR M Section 1 oPRAC Introduction Welcome to the world of STAR TRAC In your hands is the STAR TRAC PRO Service Manual This manual is designed to be easy to use providing detailed instructions on how to service and maintain the PRO BIKE 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 Contents How to Use the Manual 1 2 Precautions 1 3 Product Support Assistance 1 4 Tools and Materials 1 5 Product Overview 1 6 Part Order 800 3437 Pro Bike Service manual STAR UNISEN INC TRAC How to Use the Manual THIS IS NOT AN OWNER S MANUAL This Service Manual is intencied for use by qualified repair technicians as a guide to diagnose and correct service problems The Service Manual is divided into six sections 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 Section 1 Introduction Provides a general overview of the Elliptical Edge outlines safety precautions to be observed when performing maintenance or repair and lists tools and materials required Section 2 Preventive Maintenance Schedules Outlines periodic preventive maintenance checks and services provides de
13. bike Re install both pedals Pro Bike Service Manual STM Rne vA ransfer Case Replacement Tools e 1 16 Allen Wrench 9 16 Socket e 9 16 Open End Wrench e Rubber MalletJHarnmer e Retaining Clip Tool or small flat head screwdriver and needlenose pliers Time Required 20 minutes Procedure Remove transfer case 1 Remove screws from the bike shroud using the 1 16 allen wrench Set the shroud and screws aside 2 Remove the alternator belt by gently pushing it off of the 9 12 pulley See Diagram A 3 Loosen the top nut on transfer case See Diagram B 4 Remove the drive belt by slipping it off of the crank pulley and transfer case pulley See Diagram C 5 Remove the 91 2 pulley by removing the c ring retaining clip Use the retaining clip tool or the small flat head screw driver and needlenose pliers Alternator Belt Pro Bike Service Manual 5 5 STAR UNISEN INC 111 L s TRA Transfer Case Replacement Bottom Nut Diagram B 6 Loosen the bottom nut on the transfer case and remove both the top and bottom bolts washers and nuts See Diagram B 7 Remove the transfer case 5 6 Pro Bike Service Manual STAR oo N _ Transfer Case Replacement TRAC Drive Belt Diagram C 8 Place the new transfer case into place The crank pulley shroud be facing towards the right side 9 Replace the transfer case bolts The long bolt goes on the bottom and the small
14. bolt on the top Slide the drive belt back on pulleys 10 Tighten the bottom bolt on the transfer case first with the 9 16 open end wrench 11 Tighten the top bolt again until finger tight to allow for proper tensioning 12 Using a rubber mallet or hammer tap the top end of the transfer case to tighten the drive belt Proper tension should be 85 Ibs 5 lbs 13 When proper tension is achieved tighten top bolt completely with the 91 6 open end wrench 14 Check the alignment of the belt to pulleys Adjust the transfer case pulley by loosening the set screws on the transfer case pulley When proper alignment is obtained re tighten the set screws Pro Bike Service Manual 5 7 STAR UNISEN INC ____ 5 8 RAC Transfer Case Replacement 15 Replace the 91 2 pulley on the transfer case Put the flush side of pulley against the transfer case The recessed side out for the c ring retainer dip 16 Replace the retaining clip on the shaft to hold pUlley in place Make sure the pulley moves when you tum the crank 17 Walk the alternator belt back on the pulleys 18 Replace shroud and screws using the 1 26 allen key Pro Bike Service Manual STAR UNISEN INC Alternator Replacement RAC Tools e Phillips head screw driver 12mm socket 10mm socket 14mm socket e Y socket e socket Time Required 1Hr Procedure Remove Pedals 1 Place right foot on the right pedal and apply en
15. cket remove the black ground wire from Terminal EXC Remove the Alternator 1 Using the 14mm socket loosen the nut on the tension bracket Do not remove completely 2 With the 7 8 socket loosen and remove the large nut on the right side of the alternator Be careful to note the presence of a washer and lock washer associated with this nut 3 Remove the bolt securing the alternator to the tension bracket Note the presence of a washer at the bolt head and a spacer on the Upright Bike only between the bracket and the alternator 4 Loosen and remove the 1 2 nut from the main alternator mount 5 Remove the 14 bolt from the main alternator mount Be careful to cradle the alternator with one hand as the last bolt is being removed to prevent it from falling and damaging the frame Pro Bike Service Manual Alternator Replacement 1 2 3 ST TR gy UN SEN INC a ARAC Re installation Procedure Re position Alternator on to support member Retrieve the 3 8 bolt position washer and insert from the right side of unit On the Upright bike only be sure to include the thick spacer between the alternator and the support member Position the alternator and tension bracket together and insert the large 14 bolt from the left side of the unit to the right Again note the presence of the spacer on the Upright Bike only Attach RPM Sensor Using the other 3 8 bolt and nut secure the RPM Sen
16. cured with three Phillips head screws two located under the flap from the rubber grommet and the other located in front of the panel NOTE 3 From the System Measure ments mode press the Enter key to return to the Service Settings mode From the Service Settings mode press the Enter key to return to the Manual mode NOTE 4 Place the red voltmeter probe on LCa test point TP8 FIELDDRV place the black voltmeter probe on LCa test point TP11 AGND C Engage System Measurement Mode see Note 1 Use Scroll key to select Alternator Voltage Begin striding display shows alternator output voltage while in use Verify voltage is between 10 5 13 5 volts NO Voltage correct YES Stop Pro Bike Service Manual No Alternator Field Flowchart Remove the LCB panel from the front shroud see Note 2 Re engage the Manual Mode see Note 3 Press the Scroll key until speed is displayed Pedal the unit at a seed of 1 5 MPH etl Take a voltage reading at the LCB see Note 4 and Diagram 1 Verify voltage is between 5 5 6 5 volts Voltage correct Replace the LCB Oiagram 1 4 8 STM UNISEN IN mes No Alternator Field Flowchart s IRAC WHITE NOTE 5 Remove eight Phillips head screws from the front shroud Lift the front shroud off the unit NOTE 6 Place the red voltmeter probe on the alternator
17. der the flap from the rubber grommet and the other located in front of the panel NOTE 2 LED 02 provides a steady series of flashes at 20 per second indi cating communication between the LCa and the display board The LED remains flashing for 20 seconds after initial stride NOTE 3 You may temporarily use a 6 pin line telephone exten sion cable in place of the communication cable to verify if the communication cable is defective 4 4 Remove LCB panel from front shroud see Note i Locate LED 02 see Diagram 1 Begin striding Verify LED 02 flashes steady see Note 2 YES NO Remove PROM slot cover from back of display see Diagram 2 Verify communication cable is connected to connector J4 Cable connected Replace the communication cable see Note 3 Code continues to display Reconnect the communication cable No Communication Flowchart Diagram 1 Replace LCB DISPLAY SIGNAL CONNECTOR Diagram 2 Pro Bike Service Manual No Alternator Output Flowchart NOTE 1 Press and hold the Enter 0 and 2 keys at the same time While holding the Enter and Q keys release the 2 key The unit will beep once and the message Service Settings will display Release the Enter and 0 keys press the 8 key The message Measurements will display NOTE 2 Remove eight Phillips head screws from the
18. dures provided later in the section D Daily W Weekly M Monthly depending on the amount of use Quarterly procedures may need to be performed more frequently INTERVAL PROCEDURE Clean dust and dirt from the unit using a soft clean cloth dampened with a non abrasive liquid cleaner Give particular attention to the display panel handlebars seat pedals and heart rate grips if used Vacuum the floor under a around the unit MAKE SURE that the unit is at its maximum elevation when vacuuming or move the unit to another location Check the display panel pedals seat and shroud to ensure they are securely attached to the unit Retighten the screws as needed Tighten the handlebars by turning the four attaching screws gt Tighten the pedals to their respective crank arms Pro Bike Service Manual 22 Section 3 TRAC Diagnostics The PRO BIKE contains several customizing and diagnostics features The customizing feature allows you to tailor the unit operation to suit your particular needs Diagnostics features let you view accumulated data related to machine usage and check critical operating parameters as an aid in maintenance and troubleshooting These features include e Diagnostic LEDs Provide and indication of the operating status of the Load Control Board LCB and the alternator Display Maintenance Mode Displays start up and shut down service messages as a result of self test or when scheduled pe
19. eypad to view service settings service messages or system Setting Description Disp Ver x y Values of x y x shall be 1 24 and y shall be 0 9 Current Display software version number shall be built into the software and shall not be modified from the keypad LCB Ver Xy Values of X y x shall be 1 24 and y shall be 0 9 Current LCB firmware version number is built into the LCB software and shall not be modified from the keypad Run Hrs Values of 0 65535 Current number of whole hours of program time Value entered from the keypad shall be up to a 4 digit number Run Dist Values of 0 65535 Current number of whole miles of program distance Value entered from the keypad shall be up to a 4 digit number Bat Hrs Values of 0 65535 Current number of whole hours on the current battery Value entered from the keypad shall be up to a 4 digit number oo Values of 0 65535 Current number of whole hours on wall power Value entered from the keypad shall be up to a 4 digit number fe al Values of 0 22 10 number of key pressed previous to a NEEDS SERVICE or KEY DOWN condition O Values of 0 22 10 number of key pressed previous Key1 o Values of 0 22 10 number of key pressed previous Key2 O0 Values of 0 22 10 number of key pressed previous Key3 O0 Values of 0 22 10 number of key pressed previous Key4 XXXXXX Values of P Vbike AND EE4600 When the model selection is changed from default the Disp Ver wi
20. ighten first nut on crank only enough to align the bearing no more then finger tight then back the nut off 1 8 tum Make sure the is no play from side to side Remember to tighten tum to the left Insert the locking retairfing washer 8 There is a flat tab on the inside hole that tab will slide into the slot on the crank threads Apply a small drop Loctite 243 to threads on the crank arm Screw in the locking crank nut 7 and tighten Using a 1 open end or adjustable crescent wrench tighten nut Ensure the conical bearing nut does not tighten or loosen during this process After tightening the crank locking nut spin crank and ensure that the crank spins freely The crank should spin a couple of times with finger pressure If it does not spin freely adjust locking nut in a counter clock wise direction Grab the end of the crank and move the crank towards and away from the bike to check for play If there is any play tighten conical bearing nut but be sure not to over tighten Use a punch or a flat head screwdriver and mallet bend down retaining washer tabs one on first nut and one on second nut Slip the crank belt back on to the crank pulley Re install shroud 1 Gently slide the shroud towards back of the bike until shroud is installed 2 Using a 1 8 Hex key screw in the shroud screws 8 total 3 Using a Phillips screwdriver screw in the side shroud screws 4 total 4 Do the same to the right side of
21. inch Allen Wrench DISPLAY POWER CONNECTOR DISPLAY SIGNAL CONNECTOR NOT USED CENTER KEYPAD CONNECTOR LEFT KEYPAD CONNECTOR CARDIO CONNECTOR ENSURE CONN IS SHUNTED DISPLAY BOARD E CONNECTORS CONNECTOR CONTACT PLATES CONNECTOR CONNECTOR Pro Bike Service Manual 6 5 6 6 STAR UN SEN NC ME 1 TRAC PROM Replacement Tools Small flat screwdriver PLCC Extractor This spring assisted chip extractor tool is especially designed for safe removal of PLCC IC s from 18 to 124 pins This tool can be purchase at any electronic store or through Star Trac Product Support Procedure Remove the PROM 1 Locate the small back panel located on the back of the display mount supported by a single screw Using the flat screwdriver loosen not remove the single screw Gently slide the back plate to view the PROM socket Using the extractor carefully remove the PROM from the back of the display It s critical that when using the extractor that you gently press to release the chip from its socket Diagram 1 Shows the display without the backing plate only as an example of the location of the chip Pro Bike Service Manual ST TR UN SEN NC od oh well C PROM Replacement Diagram 2 Shows the location and how to remove the chip Procedure Re install the PROM 1 The new PROM will have a sticker showing the software version Carefully
22. ll automatically update Pro Bike Service Manual 3 6 STAR ol Service Messages The PRO BIKE self test function monitors critical electrical circuits while a workout is in progress Ifa malfunction or failure in a monitored circuit occurs during a workout the Needs Service message displays as described in Display Maintenance Mode and a specific service message is set Service message can be accessed and viewed from the Service Settings Mode To view Service Messages While in the Service Settings Mode press the 5 key The first recorded service message will display in the upper information display Press the Scroll key to view additional service messages if any have been set e Press the Enter key to exit Service Messages and return to the Service Settings Mode The following service messages may be set by the self test function Default Value Description No Comm Values of 0 65535 Number of communication failures recorded for the system Pressing CLEAR or 0 while No Alt viewing this value shall clear it to O Values of 0 65535 Number of alternator failures recorded for the system Pressing CLEAR or 0 while viewing this value shall clear it to O Values of 0 65535 Number of no load failures recorded for the system Pressing CLEAR or 0 while viewing this value shall clear it to O Values of 0 65535 Number of low battery failures recorded for the system Pressing CLEAR or 0 while viewing
23. obable cause s for the problem and provides suggested remedies to return the unit to operating condition Contents Troubleshooting Chart No Communication Flowchart 4 4 No Alternator Output Flowchart No Alternator Field Flowchart 4 8 No eoad Fome ha i a alee a aa a 4 10 Low Battery Flowchart 4 12 Heart Rate Troubleshooting N 4 13 Pro Bike Service Manual 4 1 Troubleshooting Chart SYMPTOM PROBABLE CAUSE SUGGESTED REMEDY No power to display No Polar reading No Contact Heart Rate reading 4 2 Low or dead battery Disconnected or shorted Communication or Power cable Faulty LCB Faulty display Disconnected or faulty Polar cable 1 Disconnected or faulty Heart Rate grips or board Connect the polar board No polar readings continue Remove the display check Enter System Measurement Mode see Section 3 page 3 9 and check battery output Using a volt meter manually check battery output voltage Readings lower than 6 2 volts indicates a low battery Remove top shroud cover Check LED s 02 and 03 verify they flash while pedaling see Section 3 page 3 2 for details Check all connections to the LCB See No Power Flowchart in this section page 4 13 Remove the display and check Communication and Power cables connection Swap or replace display Remove the display check polar connector to the combiner heart rate board
24. on is provided in Section 4 Shutdown Service Message The PRO BIKE displays a Needs Service message when a periodic preventive maintenance procedure is due This message displays for 2 3 seconds at the end of a workout session Call Star Trac Customer Support for assistance Preventive maintenance procedures are outlined in Section 2 3 3 Pro Bike Service Manual NR sy UN SEN NC TRAC Display Setting Mode The Display Settings Mode lets you view and modify several unit settings which affect the way the machine operates during a workout Use the keypad to enter the Display Settings Mode view the current settings and make any desired changes To enter the Display Settings Mode 1 Press and hold the Enter 0 and 1 keys at the same time 2 While continuing to hold the ENTER 0 keys release the 1 key The unit will beep once and the message Display Settings will show in the upper display screen 3 Release the Enter and 0 keys Once the unit is in the Display Settings Mode use the keypad to select and enter changes to unit settings KEY FUNCTION Scroll Key Press the Scroll key to scroll through the display settings and select the setting you wish to view or change for each setting the current value is displayed in the upper information window Pressing and holding the Scroll key will scroll continuously through the available settings When a new value for the setting has been selec
25. rench remove the crank locking nut 7 and slide the locking retaining washer completely off Remember to loosen tum to the right 7 Using a 1 open end or an adjustable crescent wrench remove conical bearing nut 6 completely 8 Loosen the outer bearing Nut 10 with a Channel lock wrench 9 Remove the left side bearing from the bearing housing 10 Remove the inner bearing spacer sleeve from the crank housing 11 11 Remove the outer bearing spacer sleeve from the crank housing 11 12 Remove the crank from the bearing housing The bearing may come out with crank arm if not use a flat head screw driver to pry the bearing out Install new spacers and bearings 13 Grease both sides of the bearing housing Use black lithium grease and apply to both bearing cups 14 Slide the bearing on the crank 15 Slide the crank arm starting from the right side through the bearing housing 16 Insert the first bearing 3 through the crank arm and crank housing 17 Insert both inner and outer bearing spacer sleeves 11 through crank arm in the crank housing 18 Insert second bearing 3 through the crank arm in the crank housing 19 Apply a small drop of Loctite RED with a channel lock wrench to 15 20lbs Pro Bike Service Manual 5 3 ST T3 UN SEN NC 5 4 RAC Crank Bearings Replacement 20 21 22 23 24 25 26 27 28 Screw in the conical bearing nut 6 first T
26. riodic maintenance is required Display Settings Mode Lets you modify certain operating and display settings for the unit Service Settings Mode Displays accumulated statistical data related to machine usage and troubleshooting Service Messages Display during machine use if certain electrical failures or out of tolerance conditions are detected System Measurements Mode Lets you monitor critical electrical parameters under both idle and in usage to help diagnose Contents Diagnostic LEOs A 3 2 Display Maintenance Mode 3 3 Display Settings Mode 3 4 Service Settings Mode 3 6 Service Messages 3 7 System Measurements Mode 3 8 3 1 Pro Bike Service Manual Diagnostic LEOs The Load Control Board LCB is equipped with three diagnostic LEOs These LEOs provide indications of the operating status of the LCB and the alternator The LCB diagnostic LEOs function as follows LED FUNCTION This Led provides a steady series of flashes at 20 per second indicating communication 02 between the LCB and the display panel is functional If this LED is off or flashes erratically replacement of the LCB the display panel or the communication cable may be required 03 This LED provides a steady series of flashes at one per second indicating the LCB microprocessor is functional and the loop circuit is operating If this LED is off or flashes erratically replacement of the LCB may be required 013 Thi
27. s LED is normally off If alternator output voltage exceeds 19 volts the LED lights steady on This condition will also cause the Needs Service message to display see Display Maintenance Mode for details NOTE The diagnostic LEOs provide a general indication of certain equipment malfunctions Refer to Systems Measurement Mode and in Section 4 Troubleshooting to aid in locating the most likely cause ofthe problem Pro Bike Service Manual 3 2 STAR 01 2 NC _ Display Maintenance Mode FRAC The PRO BIKE displays start up and shutdown service messages if an error is detected during use or when periodic maintenance is due Start up Service Messages The unit performs a self test at the beginning of every workout The self test is initiated as soon as operation of the unit begins and continues throughout the duration of the workout If a failure in an e bc Horiic clrcUlt or component S detected one of the following messages WII dispkv Key Down One or more keys on the keypad s are stuck in the depressed on position maintenance service is required Call Star Trac Customer Support for assistance Needs Service Self test has detected an electronic component failure maintenance service is required Call Star Trac Customer Support for assistance Specific service messages describing the equipment malfunction or failure can be accessed and viewed using the Service Settings feature Additional troubleshooting informati
28. sor to the casing of the alternator Tighten the nut and bolt finger tight and position the sensor lobe to 1 32 distance away from the large sensor discJflywheel 1 32 is about equal to the thickness of one business card Tighten RPM sensor bolt Attach Alternator Belt 1 Place the alternator belt around the alternator flywheel pulley assembly Loop the other end around the 9 5 crank pulley While pressing the belt grooves and crank grooves together slowly rotate the crank allowing the alternator belt to seat on to the crank Make sure all grooves are aligned Adjustment is easily made by pressing to the side of the belt and slowly rotating crank Adjust belt tension using the socket Tension is rated at 1001bs The tension can be accurately approximated by tightening the forward facing tension bolt until there is no more than inch of up and down play in the belt Tighten the large bolt and nut securing the alternator to the tension bracket with the 7 8 and 3 4 sockets Pro Bike Service Manual 6 1 6 2 STAR o INC _ ry Alternator Replacement Re wire the Alternator WHITE BLACK NOT USED YELLOW Replace Motor Shroud and Pedals 1 Be cautious of the extended pedal cranks when replacing the shroud 2 Using the 1 S Allen Wrench and the Phillips Head screwdriver fasten all shroud screws 3 Using the 14mm open end wrench or Crescent Wrench secure pedal shoulder bol
29. ssively tight grip on the heart rate grips can cause erratic readings The probability of the erratic readings can be therefor be lessened by reduce upper torso movement a proper grasp on the grips Clean hands clean grips Excessive foreign matter dirt or hand lotions on the hands can biochemical generate electrical interference which will cause erratic readings STEP 3 No heart rate is registered check connections and continuity between the grips Remove the display and verify that the heart rate cables are connected Remove the heart rate cover plates and check connection see diagram 1 4 13 Pro Service Manual STAR nen INC oo TRAC Heart Rate Using a Multi meter check the continuity between the heart rate grips see diagram below Disconnect the heart rate cables Using the Multi meter check continuity between the heart rate grips and cables Place the red meter on the red cable and using the black meter probe test each heart rate grip plate for continuity One ofthe plates should register Perform the same test with black heart rate cable Pro Service Manual 4 14 Section 5 IRAC Parts Replacements Should the PRO BIKE experience a problem requiring replacement of a specific part the following procedures will help and instruct in the replacement of major parts Contents Crank Bearing Replacement 5 2 Transfer Case Replacement 5 5
30. t rate grips See diagram below 2 Carefully disconnect the heart rate cables from the back of the heart rate plates 3 Remove the plastic end caps from the tips of the handlebar See diagram below 2 5 S CABLES EXIT RIGHT HAND LEFT HAND 4 Attach the new cables with the old by using string or Scotch Tape and gently pull the old cable out from the back of the display post Pro Bike Service Manual 6 9 STAR UNISEN INC mm B IRAC Heart Rate Grip Replacement Procedure Re install the heart rate grips 1 Carefully pull the connector plugs through the front handlebar holes 2 Re connect the heart rate cables to the heart rate plates Using the Phillips head screwdriver re install the 2 screws which attach the heart rate plates to the handlebar Do this for both the Left and Right grips 3 Using both hands to support the display board carefully re connect the heart rate cables power cable and display signal cable See diagram below 4 Carefully supporting the display board re install the 7 Allen screws to the back of the display using the 1 16 inch Allen Wrench DISPLAY POWER CONNECTOR CENTER KEYPAD CONNECTOR LEFT KEYPAD CONNECTOR CARDIO CONNECTOR ENSURE CONN IS SHUNTED DISPLA Y BOARD RIGHT KEYPAD CONNECTORS CONNECTOR HEART RATE DISPLAY CONNECTOR CONTACT PLATES CONNECTOR 7 0 Pro Bike Service Manual
31. tailed procedures for specific maintenance tasks Section 3 Diagnostics Describes how to access and use built in diagnostic and customizing features and capabilities Section 4 Troubleshooting Provides information designed to help diagnose and correct equipment problems Troubleshooting information is arranged in a Symptom Probable Cause and Suggested Remedy format Section 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 BIKE Pro Bike Service manual STAR UN SEN INC IRAC Precautions i The following general precautions apply whenever performing any maintenance or parts replacement procedure on the PRO BIKE 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 starting any work 3 When disconnecting cable connectors ALWAYS pull on the connector itself NEVER the wires Pro Bike Service manual 1 3 STAR UNISEN NC A TRAC Product Support PRODUCT SUPPORT DEPARTMENT STAR TRAC Product Support Department sets the industry standard in Customer Service and Technical Assistance world wide Pro
32. ted press the Scroll key to save the new value and advance to the next setting Up Down Use the Up Down Arrow keys to scroll through the available values for the setting Arrow Keys and to select a new value NOTE To return display settings to their original values after changes have been made and saved you must MANUALL Y re enter the factory default settings Enter Key Press the Enter key to exit the Display Settings Mode and return to the standard operating mode Pro Bike Service Manual 3 4 Display Settings Mode STARR UNISEN INC IRAC The following display settings may be changed using the keypad as previously described Setting Default Value Description Minutes 60 Values shall be from 1 99 This shall be the maximum number of minutes for a program NONE shall be used for no limit If counter reaches limit of 99 minutes it will roll over to O Units ENGL Values shall be ENGL and METR This shall determine whether units shall be displayed and received in English units Pounds Miles or Metric Kg Km Weight 155 Values shall be 0 350 when UNITS is set to ENGL and 0 160 when UNITS is set to METRIC This number is provided as a default only user will be prompted to enter their weight which is used for calculating total calories burned POL polar Values shall be ON and OFF This shall determine whether Heart Rate Sensing shall be
33. tire body weight 2 simultaneously rotate opposite pedal mounting bolt in counter clockwise direction Remove shroud 1 Using the 1 8 hex wrench and the Phillips head screwdriver Remove the 9 screws holding the shroud in place 2 Be cautious of the pedal cranks as the shroud is removed Remove Alternator Belt 1 Move to the left side of the bike and note the Transfer Case Assembly 2 Slowly rotate the large clutch pulley counter clockwise while simultaneously working the belt grooves to the outside of the pulley See Diagram A Pro Bike Service Manual 5 9 STAR UNISEN INC ____ 6 0 FRAC Alternator Replacement Remove the RPM Sensor 1 First note the gapping between the rpm sensor and the rpm disc or f ywheel The gap should be no greater than 1 S2 _ 2 With the socket remove the nut located directly behind the rom sensor mounting bracket 3 Then remove the 1 bolt on the face of the rom sensor bracket 4 Letthe rpm sensor remain attached to the wiring harness and set aside the 2 nut and bolt 5 Refer to Figure A prior to removing wires 6 Remove wires in clockwise sequence 7 With the12mm socket remove the large red positive wire from Terminal B 8 With the 10mm socket remove the black ground wire from the post directly underneath Terminal B on the altemator casing 9 With the 10mm socket remove the narrow green field wire from Terminal S 10 Using the 10mm so
34. ts on to pedal cranks Pro Bike Service Manual STAR sus INC _ Battery Replacement AMRMC Tis Phillips head screwdriver Time Required 5 minutes Procedure Disconnect the battery 1 Disconnect the red cable and the black cable lt lt oe Remove screws 1 Using the Phillips head screw driver remove the two screws supporting the battery to the frame See diagram Install Battery 1 Using the Phillips head screwdriver re install the two screws through the battery to the frame Pro Bike Service Manual 6 3 STAR an s PRAC Display Replacement Tools e 1 16 inch Allen Wrench Procedure Remove the display board 1 Using a 1 16 inch Allen Wrench carefully remove the 7 screws from the rear of the display panel mount It s important to use both hands so that the display board doesn t fall and damage any connections See diagram below 2 Carefully disconnect the heart rate cables power cable and the Display signal cable from the back ofthe display and gently lay the panel down REMOVE SCREWS 7 PLACES 6 4 Pro Bike Service Manual STAR UN SEN NC mm s TRAC Display Replacement ne install Procedure Using both han ds to support the display board carefully re connect the heart rate cables power cable and display signal cable See diagram below for connection layout 2 Carefully supporting the display board re install the 7 Allen screws using the 1 16
35. viding 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 DepartmentCALL TOLL FREE 1 800 535 4634 or 800 503 1221 US and CANADA or 714 669 1660 When placing a 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 a 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 714 669 0739 When Placing the fax please supply the following information 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 NOaPwh gt Product Support Documentation Access Web page hittp www startrac com supportl Docufacts CALL TOLL FREE 1 800 429 3228 ext 640 US and Canada or 714 253 3878 for a list of Product Support Procedures and Bulletins 1 4 Pro Bike Service manual TR
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