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Renesas 6NM Laptop User Manual

1. Drive Motor Replacement CAUTION Always turn the power switch to the off position Unplug the treadmill power cord from the power outlet Tools Running Belt Drive Motor Philips head screwdriver Bungee cord approx 24 inches Needle nose pliers 5 16 in socket and torque socket wrench to measure 110 in Ib 1 8 in Allen torque wrench to measure 75 in Ib Plastic hammer Punch Straight edge 24 inch Belt Tension Gauge to 90 Ibs optional Procedure Lift motor shroud The drive motor is located below the plastic shroud at the front of the treadmill To remove the shroud at access the motor proceed as follows 1 Remove the Philips head screw at the center of the front edge of the shroud 2 Lift up the front of the shroud lifting from both sides to separate the Velcro strips 3 Lift the shroud up the vertical rails as far as it can go then suspend it using a bungee cord looped over the gooseneck rail and hooked up under the upper edge of the shroud The drive motor is now accessible for replacement Disconnecting Motor Wiring 1 Follow the green ground wire from the motor to the grounding point in the frame marked with the ground symbol then remove the screw that hold the wire terminal to the frame 2 Cut the two wire ties that hold together the remaining wiring from the motor 3 Using needle nose pliers pull apart the black plug in connector of the red and black wires Do not pull on the
2. 1 5 Section 2 TRAC Preventive Maintenance Schedules Performing regular preventive maintenance on all Star Trac treadmills is strongly recommended Without preventive maintenance normal wear and tear may cause cumulative effects such as misalignment and early replacement of parts This may result in downtime For this reason we highly recommend following the manufacturer s maintenance schedules Contents 2 1 Preventative Maintenace Chart 2 2 Waxing Procedure SIR UNISEN INC AM mmm Weekly Monthly Quarterly Preventive Maintenance Chart ee al aii Using a liquid non abrasive cleaner wipe down the following display board handrails shroud heart rate grips Note Do not spray directly onto the display board or heart grips Elevate the treadmill and vacuum under the unit Note Unplug the unit when vacuuming Lift the motor shroud and vacuum around the motor and electronics Clean and lub ricate the elev tion screws Note This must be done with the unit unplugged and turned off Inspect for wear and tear on ex terior parts regularly especially under the running belt Inspect the line cord plug and cord for possible damage or loose connection Using a silicone spray lubricate the elevation screws while the unit is elevated Note This must be done with the unit unplugged and turned off Verify running belt alignment and tension Insp
3. 2 12 140 3138 Gasketgrey base handrail 2 16 020 5037 Rail side left w stop sw hole black 1 N 17 020 5038 Railside left w stop sw hole bgrey 1 N 18 020 4582 Handrail side right black 1 N 19 020 4588 Handrilside right grey 1 N 20 020 4581 Rail front black 2 N 020 4587 Rail front gey 2 N 22 020 4589 Hanorail top cont Hr black 1 N 23 020 4590 Handrail top contHr grey 1 N 24 020 4580 Handrail top black no HR 1 N 020 4586 Handrail top grey 1 N Product Support Phn 800 503 1221 Revision Date 09 18 00 Do Not Duplicate or Distribute Lala TR 4500 amp 3900 Series 3900 Handrail Assy TR 4500 amp 3900 Series Page 6 TAR TRA STAR TRAC 3900 Handrail Assy NT me omen Y ee 1 800 0126 Cable Display 39 4000 18 35 900 1 1 N 2 110 0685 Scew 5 618X6 hex 2 N 3 1200480 X Washer 5 16 cut 1 1 2 N Washer 5 16 x 1 5 od flat 2 N 5 110 0506 Screw 14 28x3 8 Bhss 8 N 6 7100521 HandRallinset Cd 2 N 7 1403127 Gasketbasehandralblack 2 N 8 0204555 Handrail fro 1 N 9 020 4535 Handrail left black Ct N 10 020 4540 Handrail right black Ct N 11 7090550 Mylar Sleeve 1 1 IN Product Support Phn 800 503
4. Engage MAINTENANCE mode Verify RPM feedback in Test Mode See note 1 Display reads XXX 30 at 096 XXX will read 240 Press the and bring the middle number 3 up to 50 display read RPM feedback see note 3 Does the running belt move 9 Check the following 1 RPM connection to J3 connector 2 Check alignement See note 5 Diagram 2 amp 3 Bring the speed back to NO 0 then engage automatic speed calibration See note 4 Left motor shroud and verify PWM LED for 110v units or MOTOR CONTROL LED for 220v units response See note 2 8 Diagram 1 Does unit auto calibrate YES PWM LED responds YES NO 4 36 Code NO RPM Flowchart If no appearant damage is visable Manually Note 5 RPM k z Sensor gap for possible intermittent between the Halll connection Effect pickup adn teh flywheel should be no more than 1 8 inch If not adjust the RPM sensor to correct gap If the PWM LED does not flash or intermittently respond replace the display cable toggle the display cable Diagram 2 4 37 Does display read RPM feedback Replace RMP Sensor Engage automatic speed calibration See note 4 Code NO RPM Flowchart Check the following connections drive motor to choke filter to MOB Re engage Test Mode Bring speed command 3 back up to 50 Does the r
5. Verify elevation screws are being lubricated and no foriegn obsructions are binding the elevation system Code EL STL Flowchart Note 4 Diagram 2 Place your red meter probe into the Using a multi meter ma wire vf pin 4 verify voltage at the located at connector J5 Then following pins se 5 place your black from the Elevation meter probe to AC1 Motor connector J5 on the M C B See note 4 Voltage should Diagram 2 amp 3 read 110v or 220v depending on model When pressing the elevation DOWN key the voltage Does voltage change should drop down at pins 4 amp 5 to Ov or 1v This would indicate a good response Replace the from the M C B M C B Then clear all error codes Do the same for pin see note 5 5 red wire as Replace the shown in Diagram 4 Then Elevation Motor Then press the elevation clear all error codes UP key Voltage see note 3 should drop down to Ov or 1v Diagram 2 4 47 Section 5 mAC Parts Replacement Should the STAR TRAC 4500 Treadmill experience a problem requiring replacement of a specific part the following procedures will help and instruct in the replacement of major parts Contents 5 1 5 Drive Motor Replacement 5 13 15 Auto transformer Replacement 5 6 9 Elevation Motor Replacement 5 16 19 Heart Rate Grip Replacement 5 10 12 Side Bed Cover Replacement 5 0 SIR UNISEN INC NE A
6. scroll up through the menu to the different error references by using the UP elevation key Clear all error codes by pressing the HEART key Note 5 Thi would indicate that the elevation is within range and should be operating correctly if not contact Unisen NO Is incline less than 57 or 80 Is incline greater than 240 treadmill above 15 2 elevation respond up amp decrease Proceed to EL STL flowchart YES Elevate treadmill down to 240 Elevation esponds 2 Elevate treadmill until display reads 240 Treadmill should physically be at 0 Re ingage regular mode Verify if elevation is operating correctly If elevation is working see note 4 If display code continues contact Unisen Treadmill at 0 physically Re ingage regular mode Verify if elevation is operating correctly If elevation is working see note 4 If display code continues contact Unisen 4 44 Disconnect the elevation motor belt and manually bring down the elevation until display read 240 Re connect the elevation belt Re ingage regular mode Verify if elevation is operating correctly If elevation is working see note 4 If display code continues contact Unisen Bring the treadmill down to physical 096 240 using the elevation down key Elevation responds V Re ingage regular mode Verify if elevation is oper
7. Loosen or remove the tail roller by backing of the Allen screws Use a Allen wrench 2 Remove the largest buildup of wax deposits from the tail roller Use a plastic scraper credit card or piece of wood Never scrap with a sharp metal object 4 22 SAC Drive Belt Troubleshootin The drive belt tension may require tightening if a slipping problem occurs on the drive pulley Symptom Running belt slips when running or walking 1 Loosen the four motor mount kep nuts and washer using a 5 16 wrench 2 Adjust the drive belt tension by turning the motor mount adjustment socket head cap screw See diagram below Tension should be no more than 90 Ibs e f too tight turn the belt tension screw counter clockwise e If too loose turn the belt tension screw clockwise 3 Simultaneously tighten the belt tension lock nut while holding the belt tension screw with a 5 16 wrench 4 Simultaneously tighten the right rear motor mount nut then tighten the remaining bolts 5 Verify if the belt is tensioned properly 4 23 RA Running Belt Troubleshootinc Note For optimal To prevent belt problems from occurring verify the running belt is properly performance during thejadjusted and working smoothly by performing the following steps lifetime of the treadmill 1 Feel the underside center of the running belt for glaze Glaze is described as a smooth glass texture the correct feeling should be a
8. When placing the call please have the following information available STAR TRAC model STAR TRAC serial number Problem statement symptom Return phone number and contact name AUN Oo e 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 SNOCGR0ON Je Product Support Documentation Access e Web page http www startrac com support e Docufacts CALL TOLL FREE 1 800 429 3228 ext 640 US and Canada or 714 253 3878 for a list Product Support Procedures and Bulletins 1 3 STAR UNISEN INC Tools and Eguipment TRAC Philips Head Screwdriver 2 Shroud Motor Control Board Assembly Side Bed Cover and End Caps Auto Transformer Small Slotted Screwdriver 3 32 Motor Control Potentiometers MAX SPD 8 IRCOMP Bungee Cord 28 Suspend Motor Shroud on Display Rail 5 32 Hex Allen key Handrail assembly 5 64 Hex Allen key Display Board set screws 1 8 Hex Allen key Display Assembly 1 4 Hex Allen key Running Belt Head Roller Tail Roller 5 16 Wrench or Nut Driver Drive Motor Bolts 9 64 Allen Wrench Elevation Motor 17 mm Socket Wrench Multi meter Voltage Checks Continuity OHM Checks 1 4 STAR UNISEN INC ME IRA Tre
9. leveling procedure see the following page 2 Verify that the Leveling feet are adjusted correctly 3 Verify the following assemblies e Handrails e Slick deck e Display board e Motor mount e Flywheel NOTE Wien whacking 4 Remove the drive belt and isolate the motor motor brushes the e Ifthe drive motor vibrates check motor mount bolts treadmill must be e Verify that the motor brushes aren t cracked turned off and unplugged 4 31 CAUTION When checking motor brushes always turn the treadmill off and unplug sec ee N A The treadmill may cause a slight shock from the display panel or handrails due to a faulty ground wire or a worn running belt and deck 1 Static Shock TRAC Symptom Slight shock from handrails or when using the display panel Check the line cord and plug prongs for signs of damage Verify no prongs are broken loose or missing Check the green ground wires attached to the frame for the following Motor Line cord Check running belt condition Check for glazing Replace the running belt if glazed Wax slick deck Check drive motor conditions Verify motor brush wear 4 32 CAUTION Do not stand on the running belt while performing these steps NOTE Treadmill should be turned off and un plugged from the wall when looking under the motor shroud NOTE Contact STAR TRAC Product Support Department at 1 800 501 1221 or through our
10. rough texture such as found on the undersides of the belt running belt adjust ments may become necessary All adjust ments are performed by adjusting the tail roller Allen screws with a 1 4 Allen wrench If glazed replace the running belt Contact your local retailer or act STAR TRAC Product Support Department at 800 501 1221 or through our web site at http www startrac com 2 Activate the treadmill Stand at the back of the treadmill and visually inspect the running belt The running belt should move smoothly without drifting to far to the left or right This will cause fraying or damage to the running belt For proper tension and tracking refer to Running Belt Tension and Running Belt Tracking in this section If you observe the following symptoms running belt needs to be replaced 1 On off switch tripping to the off position after treadmill is used for short period of time 2 Running belt continues to slip after tightening Provided the drive belt has been checked for proper tension 3 Edges of the running belt are frayed 4 Running belt seam is coming apart 5 Running belt beginning to fold in the middle 4 24 SITAR UNISEN INC EI Running Belt Trackin IRAC Note The running belt If the running belt is not centered on the tailroller and is either to far left or may mis track due to right adjust tracking using the following steps the style of the walker or runner 1 Turn tread
11. torque tightly at this time 5 Place a 5 16 inch flat washer onto each mountain screw then loosely turn a 5 16 inch lock nut onto each screw 6 Place the drive belt over the motor pulley aligned with pulley surfaces 7T Using a hand on each end of the motor press motor towards the front of the treadmill to tighten the belt 8 Slightly tighten the four mounting nuts just tight enough to hold the motor in place 9 Check motor alignment relative to the running belt pulley Hold the edge of a steel straightedge against the outer face of the running belt pulley The straightedge should be flush against the outer face of the motor pulley See Diagram B 10 If the straightedge is not flush against the motor pulley loosen motor mount nuts adjust motor position so that it becomes flush and then slightly retighten mounting nuts 5 3 SIR UNISEN INC Drive Motor Replacement TRAC ORIVE MOTOR PULLEY DRIVE BELT ALIGNMENT Check and Adjust Belt Tension 1 Place a tension gauge onto the center of the belt and check tension The gauge should indicate 90 inch pounds 2 If you have not tension gauge press down on top of the belt midway between pulleys very hard with your thumb The belt should deflect between 3 8 inch and inch 3 Screw the motor adjustment screw against the motor mount moving the motor towards the front of the treadmill pulleys to equalize tension through the belt 4 When the gauge indicates 90
12. web site at http www startrac com Please have your serial number and display code available Display Codes Chart FRAC STAR TRAC recommends that you refer your questions about your STAR TRAC 4000 TREADMILL operation and suspected malfunctions to STAR TRAC s PRODUCT SUPPORT DEPARTMENT However you may wish to investigate display codes that appear on the display You may do so by reviewing the below chart or follow the step by step flowcharts for the corresponding display code Display Codes Symptoms KEY DN e This code generally occurs when a key other than 5 or 8 is held pressed while turning the treadmill ON using the on off switch e It may also happen if a key becomes stuck NO STO e This code generally occurs when the Stop Switch is not connected tightly to the electronic board of the Display e It may also happen if the circuitry associated with the switch develops a fault ids RPM SP CNG These codes generally occur when the RPM speed sensor is disconnected faulty or misaligned They may also happen if the RPM Sensor cable is damaged Motor Control Board MCB is misadjusted miscalibrated or faulty Pinched or faulty Display Cable Drive Motor arcing or faulty EL STL EL RNG EL LOST and EL NOZ These display codes generally occur when the elevation incline potentiometer is faulty or out of limits Elevation motor disconnected or receiving low power May also happen if the MCB is
13. 1221 Revision Date 09 18 00 Do Not Duplicate or Distribute GZS TR 4500 amp 3900 Series 4500 Display Assy TR 4500 amp 3900 Series Page 7 STAR TRAC 4500 Display Assy D mer Pesonen o JR eee 2 050 1722 Keypad Overlay 4500 4200 left 1 N 3 050 1723 Keypad Overlay 4500 4200 center 1 N 4 050 1724 Keypad Overlay 4500 4200 right 1 N 020 4576 Lens small upper 1 x6 5 1 NO 6 020 4577 Lens large lower 3 x8 1 N 7 140 2497 Contact Heartrate Board 1 N 8 7153131 Contac Polar Hr Combiner Board 1 N 9 711 1030 PolarReceiver o 1 11 N 10 715 3280 Display Electronic Pcb 4500 sm lower 1 N 11 800 3360 Display Housing w kpol lenses no elec 1 N 12 120 3012 Standofi Mf6 32X10 L 5 NO 13 110 3086 Screw 8 32 X 1 4 Bes 5 NO 14 110 0250 Screw 632X1 2 Rhms 3 No Screw 4 40 x 1 4 Phil Pan 5 N 16 020 4579 Display Housing lower cover 1 N ab EE l Product Support Phn 800 503 1221 Revision Date 09 18 00 Do Not Duplicate or Distribute Lana TR 4500 amp 3900 Series 3900 Display Assy Page 8 TR 4500 amp 3900 Series TAR TRA STAR TRAC 3900 Display Assy RT Ramer reserpine 2 050 1705 Keypad Overlay 3900 3500 1 N 02044906 ens 3x8 tN 4 020 4492 Display H
14. HEARTRATE CABLES HEARTRATE CABLE REPLACEMENT PULL LO HEARTRATE CABLES OOWNWARD DIRECTION 10 ALLOW NYLON CORO TO BE PULLED THROLGH THE DISPLAY RAIL 5 17 NER Heart Grip Replacement Remove the Handgrips 1 3 Pull and twist the handgrips free of the rail tubing If they will not slide off the tubing use a knife or scissors to cut the rubber along its length then slide the handgrips off the tubing Continue to pull each of the handgrip cables though the gooseneck and the display rail until they emerge with the nylon cord attached Remove the nylon cord from each cable and discard the handgrips Replace the Handgrips Remove the new handgrips from their package Mark cable connector of the handgrip that is to be on the left hand side Tie each nylon cord securely to the end of a handgrip cable just below the connector For each handgrip cable pull the related nylon cord out of the gooseneck drawing the cable up though the gooseneck Before each handgrip is drawn to the rail tubing lubricate the inside of the rubber until the rubber sleeve fits snugly against the tubing joint Pull the remainder of the cable out of the gooseneck during this step Bring the cable ends together and apply a cable tie approximately 12 inches from the ends Wrap Velcro strips furnished around both cables approximately 2 1 2 to 3 inches from the cable ends Connect the cable connectors t
15. TRAC NOTE Engage Motor RPM SENSOR Indicates input signal from the RPM Sensor to the MCB Test Mode and If this LED is not flashing during operation verify the following manually push on 1 RPM sensor disconnected from connector J3 at the MCB the running belt to 2 RPM sesnor gap misaligned verify RPM feedback 3 RPM sensor faulty After the above have been verified and the RPM LED is still OFF the MCB should be replaced MOTOR CONTROL indicates that there is a valid control command from the display to the MCB If this LED is not lit verify the following 1 Verify if the display cable is connected 2 Verify if the display cable is damaged or pinched After the above have been verified and the MOTOR CONTROL LED is still OFF the MCB should be replaced UP LED indicates that the incline is being commanded up If this LED is not lit and the elevation motor will not respond verify the following 1 Display cable for possible pinch or tear see page 4 17 in this section for Display Cable symptoms 2 Replace MCB DOWN LED indicates that the incline is being commanded down If this LED is not lit and the elevation motor will not respond verify the following 1 Display cable for possible pinch or tear see page 4 17 in this section for Display Cable symptoms 2 Replace MCB 4 4 STA UNISEN INC AM ARAC Calibration Troubleshooting The following steps help troubleshoot in case Auto Calibrati
16. be adjusted to conform to the floor surface After the treadmill has been leveled tracking of the belt must be tested and adjustments made as necessary This two step procedure is particularly important for treadmill installed in a residence where floors are commonly uneven When a treadmill is installed on carpet a repeat adjustment may be required after the carpet and padding have been compressed by the treadmill feet 1 Place the treadmill in the exact location where it is to be used 2 Check the leveling feet at each corner of the treadmill to ensure that they make contact with the floor surface It may be helpful to have one person bear their weight at one corner of the running belt then move to another corner etc while another person notes whether one or more corners lift from the floor as weight is applied Using a 9 16 inch open end wrench loosen the lock number see diagram Adjust leveler height by turning the leveler base The wrench may be used on the lower nut for this purpose Tighten the lock nut LOCK NUT ADJUSTABLE LEVELER 4 30 ST eo ARAC vibration P A treadmill vibrates during use if the floor or leveling feet are uneven or when V assembly bolts are loose Symptom Unit vibrates while running 1 Verify the treadmill is on an even uncarpeted floor e fno move the treadmill to an even floor NOTE Ef dune e If floor is carpeted place the treadmill on a rubber mat
17. belt tracking procedure The running belt has been tightened too much and may require loosening if Note Do not over 1 The edges of the running belt curls down or up causing the middle of the tighten the running belt belt to bubble up Over tightening will cause premature 2 Running belt creaks as it goes over the rollers failure Note If the running 3 Treadmill trips the circuit breaker on off switch after tensioning belt creaks in spite of being loosened apply dry lubricant such as TFE Teflon or powered wax to the deck 4 26 SIR UNISEN INC AM AG amp Running Deck The following procedure will help determine and properly adjust the deck bumpers Symptom Running deck squeaks when running 1 When properly located the side bumpers two on each side bear against the delrin rods in the frame rails The rear bumpers bear against the steel posts at the end of the frame rails If the bumpers are not located so they bear against the rods as described the running deck may shift to one side or the other during use This allows the rear edge of the deck to rub against the steel post This causes a high pitched squeak as the user runs on the treadmill To determine if a deck has the bumpers properly located look under the end cap finger guard to see if the bumpers on the end of the deck bear against the steel posts A problem definitely exists if the bumpers are to one sode of the steel posts and the e
18. following procedure verifies elevation motor potentiometer response AN Symptoms Do not standon Elevation motor hesitates during operation the running belt No elevation count reading in Test Mode while performing these steps 1 The elevation motor potentiometer may have failed or register incorrect values causing the motor to hesitate while operating The chart below see diagram A NOTE Several of is a guide for the correct elevation readings on the TR 4500 the following e Using a Volt Meter verify the following values from the elevation motor at steps require certain elevation grades see the chart for elevation grades dealing with live The voltage readings may vary by 05 volts The ohms may vary by voltage Have the 01 k ohms See diagram B for meter reference treadmill turned off and unplugg Diagram A ed when check ing wire connec tions NOTE The pot Motor Test wire on the Elev elev motor display Grade Incline DC Voltage across Ohm reading between DC Voltage on number in Blue and Orange the Blue and Orange Pin 4 of the Mode motor connector unplugged electronics entiometer values can be read in Kolar Teo Made 240 0 57 15 for 110v units or 80 15 for 220v units NOTE The values in diag ram A were taken from a properly functioning elevation system You may expect slight variation from machine to machine If the values are 0 check display cabl
19. high 1 Verify the running belt drive belt are not loose or slipping speed during e Accelerate the running belt to 3 0 5 0 kph Stand on the side of the Step 1 amp 3 treadmill while grasping the handrails firmly place one foot on the running belt with a very sharp impact Running belt should not stop CAUTION instead slip for a split second forcing your foot back Drive belt should When checking never stop rotating over the headroller during this procedure motor brushes e f running belt or drive belt appears loose see page 4 26 in this section have the treadmill turned off and unplugged 2 Verify motor brushes are making contact and are seated correctly e Remove the motor brush cover check brushes are seated correctly by removing the brush clip and verify contact See diagram A for removal instructions e Cleaning the motor armature with a commutator stone is highly recom mended to remove any possible carbon dust build up causing the the brushes to skip over resulting in a brief motor hesitation Note Brushes should show a smooth pattern of wear cracks or unusual wear will cause motor to jerk replace if 3 Adjust the IRCOMP potentiometer located on the MCB see diagram B brusnos IT nedan e Bring the treadmill to its minimum speed e Stand on the running belt if the belt feels jerky hesitates adjust the IRCOMP potentiometer until running belts feels smooth Symptom Treadmill hesitates during init
20. in verifing the correct elevation values Diagram 2 4 43 Code EL RNG Flowchart Definition ELEVATION RANGE BEYOND 0 or 15 RANGE Possible Cause Out of range elevation count or elevation system malfunctioned Note 1 Press and hold the 0 2 8 START keys down at the same time then release the 1 key The display will read MAINTENANCE Press and release the 8 key Or manually hold the 8 key and simultaneously turn the treadmill on by the on amp off switch Both methods will engage Test Mode Engage TEST MODE Verify elevation response in Test Mode See note 1 Note 2 In TEST MODE the number under ELAPSED TIME on the display represents the elevation range When physically at 096 the range will register 240 When elevating the range will fluctuate from 240 80 Elevation range 80 represents 1596 for 220v units 57 represents 15 for 110v units Do not elevate beyond the range Note 3 Exit out of TEST MODE Re ingage MAINTENANCE Mode scroll through the menu using your elevation keys until display reads LST POT The following variables store the condition when the last display code occurred Is incline within range See note 2 YES Go to capture information See note 3 If LST POT registers 253 255 verify display cable connection If connection is good replace the display cable Note 4 Engage MAINTENANCE Mode
21. less than 3 minutes belt will be in motion during this test Auto calibration should be done every time MN MX SPD amp UNITS parameters have been changed in either SETTINGS or CONFIGURE Mode Auto calibration must be engaged when ever speed controlling components have been upgraded or replaced such as MCB Display Board Drive Motor amp RPM Sensor 1 Press and hold the 0 1 amp START keys together or the 0 2 While holding the 0 amp START keys down release the 1 or 2 key The display will beep and display MANAGER or MAINTENANCE momentarily then UNITS will be displayed 2 Press and release the 8 key Display will read XXX 3 0 if treadmill is at 0 display will read 240 3 0 3 Press HEART key display will read CAL treadmill will go into an automatic speed calibration for less than 3 minutes Press STOP key to exit Motor Test NOTE If Auto calibration fails to give the correct response refer to Section 4 SIR Y UNISEN INC AM TRAC Display Test Mode Display Test Mode allows you to test the light emitting diodes LEDs 15 segment displays and the watchdog timer of the Display Control Panel by way of its own controls and displays It also allows EPROM version to be displayed To enter Display Test Mode Caution Do not stand on the running belt while performing these test 1 Press and hold the 0 1 amp START keys toge
22. miscalibrated or faulty Display Cable pinched or faulty Elevation Belt damaged or binding 4 33 Code KEY DN Flowchart Definition KEY STUCK Possible Cause Damaged or shorted key keypad Note 1 This code may occur when a user tried entering Test Mode or Display Test Mode using the wrong key Look for any indentations on any of the keys The plus or fast key are used most often and may cause this error Note 2 Press and hold the 0 2 8 START keys down at the same time then release the 2 key The display will read MAINTENANCE Press and release the 5 key Or manually hold the 5 key and simultaneously turn the treadmill on by the on amp off switch Note 3 If you are unable to enter the ENGINEERING or Display Test the panel may have a key that is permanently stuck Replace the display panel If any of the LED segments do not light up there may be a failure in the electronics and you will need to replace the electronic board only Note 4 Verify that the PWM LED is flashing while the treadmill is on The PWM LED indicates a valid control command is being sent from the Display Board to the PWM Board If the LED is not flashing check connection and look for pinch or tear marks Reset the treadmill Turn unit off wait 2 seconds then retry See note 1 Code continues to display Engage ENGINEERING mode Verify keypad response in Display
23. off and unplugged before starting any work unless otherwise noted or when necessary for voltage testing 2 Read each section through for NOTES before starting any work 3 To pull apart electrical connectors pull on the connector itself not the wires 4 When replacing fuses be sure the new fuses is the correct amperage rating Do Not exceed the fuse amp rating If necessary use a fuse of lower rating until the proper fuse may be attained 5 When checking continuity at the wire connector insert the test probe carefully to prevent the terminals from bending 1 2 STAR UNISEN INC ME IRAC Product Support Asistance PRODUCT SUPPORT DEPARTMENT STAR TRAC Product Support Department sets the industry standard in Customer Service and Technical Assistance World Wide Providing superior product support and customer service is at the very heart of STAR TRAC s business philosophy This commitment to service has been a major contributor to STAR TRAC s success and growth in the worldwide fitness equipment industry Technical Assistance e 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 e When placing the call please have the following information available 1 STAR TRAC model 2 STAR TRAC serial number 3 Problem statement symptom After Hours Voicemail Direct CALL TOLL FREE 1 800 486 4736
24. or when deflection is as specified in preceding step 1 tighten the motor mount nut nearest the adjustment screw 5 4 STAR UNISEN INC ME ARAC Drive Motor Replacement 5 Recheck pulley alignment and belt tension 6 When alignment and tension are correct tighten all four motor mount nuts using a Socket torque wrench set at 75 inch pounds 7 Lock the motor adjustment screw by tightening the locking nut against the frame 8 Loosen the set screw at the motor pulley then recheck alignment 9 Slide the pulley on the shaft until alignment is restored 10 Check to see that the pulley locking key still extends about 1 16 inch past the inner face of the pulley Tighten the set screw over the keyway first then tighten the other set screw Use a 1 8 inch Allen torque wrench set for 50 inch pounds 11 Recheck both tension and alignment Check alignment while rotating the belt and pulleys Use a thickness gauge to measure any gap If the gap between the outer face of the pulley at its edge and the straightedge exceeds 0 007 inches repeat alignment procedures until that gap is reduced to less than 0 007 inches Reconnect Motor Wiring 1 Connect the gray sensor cable to the connector marked J3 on the left end of the circuit board 2 Press together connectors for the red wires and then for the black wires 3 Using a Philips head screwdriver secure the lug on the green wire to the ground point on the frame using the screw
25. panel and disconnect the emergency stop switch from the back of the display board If all or few keys do not respond replace Display Board If connection is good replace the stop switch assembly Short the two pins on the display board together using either a jumper or paper clip Turn the treadmill back on 4 35 Code NO RPM Flowchart Definition RPM LOSS Possible Cause Damaged or misaligned RPM sensor Note 1 Press and hold the 0 1 8 START keys down at the same time then release the 1 key The display will read MAINTENANCE Then press and release the 8 key Or manually hold the 8 key and simultaneously turn the treadmill on by the on amp off switch Both methods will engage Test mode Note 2 Verify that the PWM LED is flashing while the treadmill is on The PWM LED indicates a valid control command is being sent from the Display Board to the M C B If the LED is not flashing check connection and look for pinch or tear marks on the display cable Note 3 Verify that RPM feedback is being displayed under speed as the running belt moves Note 4 To engage automatic speed calibration press the HEART key Display will read CALI Treadmill will then go into a self auto speed calibration This will automatically calibrate MIN PWM 1 2 max and MAX PWM for min and max speed This will take less than 3 minutes Treadmill will be in motion during this test
26. removed previously 4 Using small wire ties neatly tie together the four wires Replace Shroud 1 Release the shroud from the bungee cord that has held it to the handrail gooseneck and carefully slide the shroud downwards so that it rests on the treadmill frame 2 Match the screw hole in the lower front edge of the shroud with the mating hole in the frame then insert and star the Philips head screw previously removed 3 Press down on the side and front of the shroud to engage the Velcro strips on the frame Tighten the screw to complete shroud replacement 5 5 Elevation Motor Replacement TRAC CAUTION Always turn the power switch to the off position Unplug the treadmill power cord from the power outlet Tools Replacement elevation motor Philips head screwdriver Pliers Tap nuts inch 2 Allen wrench 9 64 in Socket wrench with 17 mm socket Shop hammer Large screwdriver or steel chisel Procedure Lift motor shroud The drive motor is located below the plastic shroud at the front of the treadmill To remove the shroud at access the motor proceed as follows 1 Remove the Philips head screw at the center of the front edge of the shroud 2 Lift up the front of the shroud lifting from both sides to separate the Velcro strips 3 Lift the shroud up the vertical rails as far as it can go then suspend it using a bungee cord looped over the gooseneck rail and hooked up under the upper edge
27. units response See note 2 Diagram 1 Does drive motor surge Adjust the IRCOMP See note 3 Diagram 2 Does drive motor surge 4 39 Diagram 1 display read RPM feedback see note 4 YES NO Code SP CNG Flowchart Check motor brushes for unusual wear See note 5 LED responds V Diagram 3 Note 5 Turn the treadmill off and unplug Remove one brush at a time Check for unusual wear replace if needed Manually toggle the Replace the M C B display cable for Brushes possible intermittent good connection Replace motor brushes Then clear all error codes Note 8 If the PWM LED does not flash or intermittently respond when cable is toggled replace the display YES cable Treadmill runs smooth 9 Diagram 2 O PVIILALVISLILITA TILI LASTI Vo NAM E cmm cmm cum um umm S ni AAAS ERSTE ES ES EDI 110 Volt 220 Volt 4 40 Code SP CNG Flowchart Note 6 To engage automatic speed calibration press the HEART in Test Mode The Engage automatic a aa Ji speed calibration then go into a self See note 6 auto speed calibration This will automatically calibrate MIN PWM 1 2 MAX and MAX PWM for min and max speed This will take less than 3 minutes Treadmill will be in motion during this test Check the following 1 RPM connection to J3 connector 2 Check alignement See not
28. wires 4 Follow the gray sensor cable to the connector marked J on the left end of the circuit board and pull the cable connector upwards to disconnect it from the board 5 1 STA UNISEN INC Drive Motor Replacement TRAC Remove Motor 1 Loosen the 5 16 inch nut that locks the motor alignment screw then unscrew the Screw several turns 2 Loosen the four 5 16 inch motor mount nuts so that the motor slides freely on the frame See Diagram A below STAR UNISEN INC ME ARAC Drive Motor Replacement 3 Using a 1 8 inch Allen wrench loosen the two set screws in the motor pulley 4 Slide the motor towards the rear of the treadmill to give slack to the motor drive belt 5 Slip the drive belt off the motor pulley then remove the pulley and the locking key 6 Remove the four motor mount nuts then lift the motor out of the treadmill and set I aside Mark it as the removed motor to avoid confusion with the replacement motor This completes motor removal procedures Install Replacement Motor 1 Set motor mount onto the four captive screws in the frame 2 Fit the motor pulley over the motor shaft so that thither of the set screws is aligned with the shaft s keyway 3 Using a plastic hammer and a punch tap the locking key into the keyway so that it s end protrudes about 1 16 inch past the inner face of the pulley 4 Tighten the set screws that is over the keyway to hold the pulley in place but do not
29. 23 Nuthex 12 13X5 16 2 N 17 020 4454 Finger Guard Plate 18 35 45 4000 left 1 N 18 020 4627 Finger Guard Plate 18 35 45 4000 right 1 N 19 110 3008 Screw6X5 8 4 NO 21 110 0475 Screw 1032x127 Sajn 22 110 1790 Tinnerman Clip HOnut TN 23 110 1000 U Bol 88 16 1 1 1 1 2 N Washer 3 8 flat 4 oN 1104830 Nuthex 3 8 16 nyoc 1 1 1 4 N 26 140 0492 Velcro Tape Loops lt t2 sirips gt 2 N 27 050 1721 abe Tr4500Series 2 N 28 050 1716 Label Tr3900Series 2 N 29 140 3180 JBotleCawax TN 30 710 1031 Frame welded painted black 1 N 31 710 1035 Frame welded painted grey 1 CN Product Support Phn 800 503 1221 Revision Date 09 18 00 Do Not Duplicate or Distribute GZS TR 4500 amp 3900 Series Elevation Assy TR 4500 amp 3900 Series STAR TRAC bee Elevation Assy m imoer Dein tt eve 1 260 0285 Motor Elevation 110vac 1 N 2 708 0151 EevationCan 2 N 3 7150110 Elevation Screw drilled 2 N 4 130 0250 jPuley Elevation elevmotor 1 N 5 1101415 AxePushCapsi2 2 N 6 7080045 Axle a IN 7 020 6266 Sleeve Elevation Axe 1 N 8 020 6268 Spacer Elevation screwwhee 2 N 9 1301280 Wheel 3 x1 x1 2 bore 2 N 130 0050 ElevationBet 1 N 11
30. 800 0225 Elevation Idler Pulley Assy 1 N 12 110 0477 Screw 1 4 20 X 3 4 Shes 12 N 120 0420 Washer i4 lock 12 N Product Support Phn 800 503 1221 Revision Date 09 18 00 Page 2 Do Not Duplicate or Distribute Motor amp Electrical Assy TR 4500 amp 3900 Series TR 4500 amp 3900 Series Page 3 TAR TRAC STARTRAC Motor 8 Electrical Assy Mm aimer Dosorpnon oy eee 800 3259 Filter Network 110v 1 N 4 800 3258 Filter Network 220v TN 5 260 0220 Motonit0v 2 5hp3500pm mag Y 6 260 0903 Motor220v 25hp3500pm mag Y 7 1403141 Fan 4 5 X 5 8 bore 9 blades 1 n amp 800 3260 Flom Sensor Cherry brackev screws 1 NO o ee a re eee 10 800 3229 Power Cord 220v nema6 15p 1 CN c Onoff beaker 110v 2 pole 1 oN 12 4700180 _ Switch Oro breaker 220v 4 pole 1 NO Bau mi MNE vrvmi S an 020 0681 Flywheel8 o 1 N 15 020 0493 FlywheelRpmDisk 31Slts 1 N Screw 8 32 x 3 8 Rhms 2 Nn 17 110 8006 Screw 10 24x3 4 Phtcs 10 No 110 1870 NuL5 6 38 5 5 N 19 120 0480 jWashen5 6 cut 4 N Bolt 5 16 18 X 1 carriage aly 110 2510 Bol 5 16 18 x 1 75 1 N 22 140 0020 jPad Motor 1 16 2 N Product Support Phn 800 503 1221 Revision Date 09 18 00 Do Not Duplicate or Distribu
31. ION 1 Engage TEST MODE Press and hold the 0 1 amp START keys together Do not stand on or the 0 2 While holding the 0 amp START keys down release the 1 the running belt or 2 key The display will beep and display SETTINGS or CONFIGURE while perform momentarily then UNITS will be displayed ing these steps 2 Press and release the 8 key Display will read XXX 3 0 XXX is a variable NOTE Alter number depending on the elevation position the treadmill is at 3 indicates Speed native mode to Command 0 indicates RPM If the treadmill is at 096 the display will read 240 3 0 enter Motor Test Mode turn 3 Press the key speed to the desired MN SPD 1 2 MX and MX SPD Write the power down the corresponding Speed Command number displayed for each desired switch ON setting while pressing the 8 key sim 4 Press the STOP key Engage Configuration Settings Mode as described in ultaneously on STEP 1 the display 5 Using the UP ELEVATION key go to MN PWM parameter and enter the new NOTE The MN MN SPD Speed Command number by using the or keys then press the SPD should not START enter key to save the new setting Do this for the 1 2 MX and MX SPD exceed 5 MPH or 1KPH The 6 Press the STOP key to exit 1 2 MX SPD should be exactly half of the desired MX SPD The MX MX SPD must not exceed 10 MPH or 20 KPH 220 units NOTE Speed Comm
32. Metric 20 0 10 0 Maximum speed in MPH or KM HR EL OPT ON OFF ON Turns the elevation system ON or OFF TIME 9 Maximum time in minutes allowed for program including warm up cool down DIST Total treadmill miles Units English or kilometers Units Metric WEIGHT 399 155 Defaults to user typical weight in Ibs kg depending on what setting UNITS English or Metric Treadmill serial number LANG English Language in English Dutch German Portuguese Spanish Swedish or Italian ENTRY Units Tenths Units This variable changes the starting speed in Units or Tenths 3 4 SIR UNISEN INC EMI TRAC Maintenance Mode imam kolk oli kal kA eni HRT CON ON OFF OFF OFF Heart Control disable ON Heart Control enabled HRT CNT DN CNT DN CNT DN CNT DN Manual POLAR POLAR countdown heart rate CONTACT CONTACT POLAR CONTACT or BOTH BOTH BOTH Polar amp Contact 10 REV 22 0 74 0 30 7 For 35 8 For Inches of running belt 110v units 220v units travel for 10 flywheel revolutions measured in inches 1 8 pulley 30 7 110v 2 1 pulley 35 8 220v CNT REV 31 7 125 Number of counts per Magnetic Optical RPM Sensor RPM Sensor Sensor revolution Minimum PWM to obtain minimum speed automatically done 1 2 PWM 1 2 Maximum PWM to obtain 1 2 maximum speed automatically done MX PWM 255 230 Maximum PWM to obtain maximum speed automatically done DATE 1 00 12 99 1 96 Treadmill manufacturing date NO STO 255
33. Number of times the Stop Switch was down or disconnected on power up since last reset 3 5 SIR UNISEN INC AM RAC Maintenance Mode Parameters Lowest Highest Default Value Value Value i lg LL LLL 41 Ll d 1 fad M udi Na AN ELE E LLL PP LI L II ood BLA odi MEINE UJM Mi sued IL di U i HR UE n I Lb oL Bi O NI ME IM 3 6 Number of times the Stop Switch was down or disconnected on power up since last reset Number of times the display did not detect a RMP signal Number of times a sudden change in speed was detected Number of times an elevation stall was detected Number of counts per RPM Sensor revolution Number of times no elevation was detected Represents the incline number for 096 Represents the incline number for 15 Indicates what display code appeared last 18 NO STO 19 KEYDN 20 lt NO RPM 21 SP CNG 22 EL STL 23 EL RNG 24 ELLOST Displays the target elevation prior to the display code Displays the incline number prior to the display code SIR UNISEN INC AM RAC Maintenance Mode Parameters Lowest Highest Default Value Value Value LSTRES 2 Displays 1 Unit was resetting to 096 0 Unit finished resetting to 096 prior to the display code LSTSSP 255 Displays the speed prior to the display code LSTPWM 255 Displays the PWM number prior to the display code LSTMSP 255 Display the actual measured speed prior to the display
34. PLACE Display board if display cable checks OK 4 9 a NOTE Activation of the thermal protection break er does not cause damage to the elevation actuator or other treadmill compon ents Elevation Motor TRAC The following procedure explains the elevation system Thermal Protection and limitations Symptom Elevation system shuts off when used consistently 1 The Star Trac Model 4500 elevation system actuator is protected from overheating by a thermal protection circuit In the event that the thermal protection breaker is activated the treadmill s elevation system is temporarily disabled and an EL STL display codes is displayed e A simple resetting of the treadmill restores full operation once the elevation actuator has been allowed to cool for a few minutes 2 The pre defined workout programs 1 through 8 as well as other typical workout regimens include elevation changes that easily fall within the operating limits of the Model 4500 s elevation system actuator The following information serves as a guide for users that may wish to set a custom program that requires frequent and or large changes in incline e Incline changes greater than 5 percent should not be programmed for intervals less than 1 minute e Full range incline changes from 0 percent to 15 percent or vice versa should not be programmed for intervals less than 3 minutes 4 10 STA UNISEN INC EE TRAC Elevation Motor The
35. Section 1 O smAC Introduction Welcome to the world of STAR TRAC In your hands is the STAR TRAC TR 4500 Service Manual This manual is designed to be easy to use providing detailed instructions on how to service and maintain the TR 4500 We highly recommend that you read all the applicable sections of the service manual prior to serving the treadmill The information on the following pages will enable you to begin easily quickly and safely Contents 1 1 How to use the Service Manual 1 4 Tools and Test Equipment 1 2 Precautions 1 5 Treadmill Overview 1 3 Product Support Assistance 1 0 TRAC How To Use This Manual This Service Manual has been written to assist and instruct the repair technician on key components for quick and efficient diagnosis of service problems To assist in finding the applicable sections in the Service Manual Each Section has a table of contents to help locate specific symptoms and topics Titles and major headings are located at the top of every page This manual is to be used strictly as a Maintenance manual for service and repair not as an owner s manual An illustrated Parts List is located at the back of this manual for identifying parts with part numbers Troubleshooting tables and Error Code Flowcharts are included for certain sections to help diagnose the system problem and find the root cause 1 1 STA UNISEN INC AN Precautions TRAC 1 Always make sure that the treadmill is turned
36. Test See note 2 display engage Display mode Replace display faceplate See note 3 4 34 Note4 Carefully peal off the affected keypad Wipe the display surface with degreaser Windex works well Re apply the keypad starting from one edge and using your fingers or a rag press the keypad in one direction to remove the air bubbles Press each key Verify that the display beeps and changes LED segments with every key on the display All keys respond Replace display panel Code NO STO Flowchart Definition NO STOP KEY Possible Cause Disconnected or shorted stop switch Note 1 Try pushing the emergency stop switch on and off If switch appears to Verify stop switch Code stick replace stop switch activation continmiBs do assembly See note 1 display 2 Note 2 Some units Press and hold the 0 2 and START keys down at the same time then release the 2 key The display will read Does stop switch activate Engage MAINTENANCE or MANAG Check stop switch ENGINEERING ER Press and release the connection in the mode Verify keypad 5 key handrail response in Display Other units Press and hold Test See note 2 the 0 1 and START keys down at the same time and release the 1 key The dis play will read ENGINEER ING Press and release the 5 key Turn the treadmill off Remove the display
37. a 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 the 0 8 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 Ite INCLINE KEY Displays the next or previous parameter it SPEED KEYS Allows the variable to be changed within the parameter io ENTER KEY Saves the value if changed in the EPROM software START Note ENTER KEY must be pressed for each value changed V s M sue STOP KEY Exists Manager Mode and restarts the treadmill with a warm start 0 9 KEYS Enters new parameter values If UNITS parameter is displayed key 5 1 starts DISPLAY TEST and key 8 starts MOTOR TEST HEART KEY When pressed will automatically display manufactures default value Note ENTER KEY must be pressed to save the default values if changed SIR INC MA Maintenance Mode TRAC 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 MPH or KM HR MX SPD 5 0 20 0 English 10 0
38. admill Overview MCB ASSEMBLY UP DN COMMAND ELEVATION a MOTOR I SYSTEM POSITION C ELEVATION REF POSITION ELEV DIR ENABLE POWER PANEL POWER 1 SPEED COMMAND PANEL SPEED FEED BACK MOTOR CONTROLLER DRIVER HALL EFFECT SENSOR I 1 I PWM POWER SSR e a zan na MOTOR 1 MOTOR TERMINAL VOLTAGE FEEDBACK BELT I 1 HALL EFFECT L l CONDITIONER l I i HALL EFFECT ANALOG OUTPUT i I 110VAC 220VAC DC POWER SUPPLY The MCB provides power to the display assembly Establishes a reference voltage and potentiameter position from the elevation motor RUNNING BELT MOTOR DRIVE CONTROL Takes Alternating Current and converts it to Pulse Width Modulation PWM to power the Drive Motor Motor voltage feedback and control speed commands determine the level of PWM power delivered to the motor Motor Control circuits include fault sensing and safety functions TACHOMETER SIGNAL CONDITIONING The signal from the RPM sensor is fed to signal conditioning circuits on the MCB where the signal is converted to a digital output that is utilized by the Display Assembly to indicate belt speed ELEVATION MOTOR CONTROL The elevation circuit on the MCB receives elevation direction and enable information from the Display Assembly using these signals to provide control to the Elevation Motor Elevation position information in turn is fed to the Display Assembly to indicate percent of incline
39. and 255 is the max imum the tread mill will reach 4 7 No Display Power 9 The following steps help troubleshoot in case the display board fails to power up during or before regular operation SIR UNISEN INC A 110v UNIT Diagram A Diagram B em Z ld 1 Lift and suspend the motor shroud SAUTION The following steps 2 Verify if LED AC is lit AC LED indicates that AC power is being applied to are performed with the MCB does not indicate voltage level If this LED is lit go to step 3 the treadmill ON If LED is not lit verify the following see diagram A e The treadmill is plugged into the wall The ON OFF Switch is turned to the ON position Verify wire connection AC1 AC2 on the MCB Verify the ON OFF Switch Breaker wires are connected Verify 110v 10 AC voltage at AC1 AC2 if the voltage is 0 or less than 90v check wall voltage verify unit is on a dedicated line e f wall voltage is correct verify linecord continuity see diagram B REPLACE MCB if all the above check OK 3 Verify if LED 18 is lit LED 18 indicates the presence of an acceptable level of voltage for MCB operation REPLACE MCB if 18 is not lit 4 Verify if LED 11 is lit LED 11 indicates 11v are being applied to power the display board If the LED is lit go to step 5 REPLACE MCB if 11 is not lit 5 Verify display cable connection e Verify display cable for possible pinch or tear mark REPLACE Display boa
40. ating correctly If elevation is working see note 4 If display code continues contact Unisen 4 45 Code EL RNG Flowchart Proceed to EL STL flowchart Code EL STL Flowchart Definition ELEVATION STALL BEYOND 0 or 15 RANGE Possible Cause Out of range elevation count or elevation system malfunctioned On OO n8 WE NA AS on os mown 153 Ow TI Note 1 Press and hold the 0 2 8 START keys down at the same Engage time then release the 1 TEST MODE key The display will read MAINTENANCE Verify elevation Press and release the response in Test 8 key Mode Or manually hold the 8 key and simultaneously turn the treadmill on by the on amp off switch Both methods will engage Test Mode See note 1 Diagram 41 treadmill elevate EITEITIGOE SION Verify elevation UP amp Hi Tal MODE DOWN LED s toggle when elevation keys are Note 2 Engage MAINTENANCE moce scroll up through the menu to the bei d different error references eing presseo l by using the UP elevation See diagram 1 Replace Display key Clear all error codes by pressing the HEART key Cable Do elevation LED s toggle Clear display Note 3 Visually check code both fuses Replace fuses if burned or cracked If a multi meter is available verify continuity YES Check fuses 1 amp 2 on the M C B Replace fuses See note 2
41. both directions native mode to reads EL LOST across display in regular operation mode enter Motor 3 In Test Mode no elevation response reads EL STL across display in regular Test Mode turn operation mode the power 4 In Test Mode elevation count registers slow to actual elevation response switch ON 5 Treadmill elevation without command in regular operation mode while pressing 6 Elevation motor hesitates in between elevation percents MCB LEDs UP amp the 8 key sim Down toggle back and forth ultaneously on 7 Elevation intermittently responds registers different elevation display codes in the display regular operation mode Intermittent or no speed reading 1 In Test Mode belt movement but no RPM reading MCB LED RPM remains of on 220v units registers NO RPM code across display in regular operation mode 2 In Test Mode or regular operation mode RPM reading intermittently flashes 3 In Test Mode or regular operation mode RPM speed fluctuates 4 In Test Mode MCB LED PWM 110v units or MOTOR CONTROL 220v units remains off and no RPM reading is registered 4 20 Drive Motor TRAC The following symptoms indicates a faulty drive motor Symptom d Tripping the ON OFF switch breaker CAUTION 1 Disconnect the drive motor belt Do not stand on 2 Run the drive motor for ten minutes at a high speed 6 MPH 10 KPH If the the running belt ON OFF switch trips verify if the MCB LED I LIMIT light
42. code LST TM 65355 Displays the elapsed time in seconds prior to the display code LSTDCK 65355 Number of miles when the deck was last waxed After a 2000 mile or 3000 KM difference REWAX BELT will scroll in the display until LST DCK miles are updated LSTBLT 65355 Number of miles when the last belt was replaced 3 7 TRAC Motor Test Mode Motor Test Mode allows the treadmill to calibrate both elevation and running belt speed Verifies RPM Sensor feedback Drive Motor and MCB response and verifies Elevation Motor range count Also burns in the motor by way of the controls and displays of the treadmill Caution Do not stand on the running belt while performing these test Engage Test Mode 1 Press and hold the 0 1 amp START keys together or the 0 2 While holding the 0 amp START keys down release the 1 or 2 key only The display will beep and display MANAGER or MAINTENANCE momentarily then UNITS will be displayed 2 Press and release the 8 key Display will read 240 3 0 if treadmill is at 0 Alternative mode to enter Motor Test Mode 1 Turn the power switch on while pressing the 8 key simultaneously on the display 240 3 O0 A Elevation Motor Range B PWM Duty Cycle C RPM Sensor Feedback Once the treadmill is in TEST Mode you may use the following keys INCLINE KEY Adjust voltage to incline motor incl
43. d and the AC LED is still OFF the MCB should be replaced NOTE The display 18v LED Indicates the presence of an acceptable level of voltage to console may still operate the MCB If this LED is off or dim the AC voltage level is power up with the AC not acceptable to properly power the MCB Verify the following LED off 1 Verify with a VOLT METER that 110VAC is present on on pins AC1 8 AC2 After the above step has been verified and the 18V LED is still OFF and the display does not power up replace the MCB 11v LED indicates there is 11 volts supplied to the display board If this LED is not lit verify the following 1 The display cable is damaged or pinched disconnect the display cable and verify if the LED lights up If LED lights up replace the cable After the above has been verified and the 11 LED is still OFF the MCB should be replaced 4 1 STA UNISEN INC NIH 110v MCB LED Layout TRAC NOTE Engage Motor MOTOR LED indicates the presence of acceptable voltage to the motor Test Mode and If this LED is not lit one of the following conditions exists manually push on 1 Verify AC voltage is being applied the running belt to 2 Verify that MTR1 MTR2 wires are connected to the MCB verify RPM feedback This should be done with the treadmill unplugged and turned off After the above have been verified and the MOTOR LED is still OFF the MCB should be replaced PWM LED Indicates
44. dge of the deck is bearing against the posts Remove the screws securing each of the four delrin rods and pull them out Look through the hole in the frame to see if the running deck bumper is adjacent to the hold such that it would bear against the delrin rod if it was reinstalled in the hole If all bumpers are properly located replace the delrin rods and examine the treadmill further for the other causes of squeaks If one or more bumpers is misalign follow the procedure given below 4 27 AG Running Deck STA UNISEN INC EMI Symptom Running deck squeaks when running continued Correcting the problem 1 Position the deck with the rear bumpers properly aligned with the steel posts With a pencil make a mark on the deck adjacent to each of the four delrin rods as seen from the top of the side rails Reach under the running deck shift the deck as far as possible to tone side On the side that now has the edge of the deck exposed from under the frame pull the rear edge of the deck upward until it is just above the frame rail Use a screwdriver or putty knife to hold the deck above the frame Using another screwdriver raise and hold the front of the deck Remove the bumper s that are not aligned with the pencil marks by carefully prying them away from the deck with a screwdriver knife or putty knife Position the bumpers removed in the previous step so they are adjacent to the pencil mar
45. djust the tension on the tail roller screws until the running belt is loose Spin each roller by itself to determine where the noise is coming from The Stethoscope Method 1 Using a long screwdriver as a stethoscope put the handle of the screwdriver to your ear Place the opposite end of to the area where you are listening This will help locate where a specific noise is coming from Symptoms Rumbling Wax buildup on the rollers Head tail roller bearings Adjustable feet leveling Floor condition thick carpet or wood floors Elevation screws dry Elevation motor stripped Squeaking Deck rubbing against the frame Adjustable feet leveling Head roller and drive motor pulleys not aligned Drive belt tensioning Running belt tensioning Drive motor brushes Knocking e Drive motor bearings e Head tail roller bearings e Running belt hitting the back or front of the frame e Missing or worn deck cushions Grinding e Drive motor bearings e Head tail roller bearings Motor brushes worn 4 29 a NOTE If a leveling foot does not make contact with the floor or if it lifts upwards as weight is applied to one corner of the deck this will cause the running belt to mis track STAR UNISEN INC ME Levelin IRAC To ensure proper tracking of the running belt treadmill leveling should be verified Symptoms e Running belt travels to one side e Treadmill vibrates Leveling feet must
46. e 7 Diagram 4 4 5 Does unit auto calibrate YES STOP Note 7 The RPM sensor gap between sensor and flywheel is no more than 1 8 inch wide If not adjust the sensor Diagram 4 Does display read RPM feedback Replace RPM sensor or Hall effect depending on style Then clear all Engage automatic error codes speed calibration Then see note 8 clear all error codes see note 8 Code SP CNG Flowchart ensor Gap Note 8 Engage Maintenance zu Mode Scroll up through the menu to the different error references by using the UP elevation key Clear all error codes by pressing the HEART key Diagram 45 Does display read RPM feedback Engage automatic speed calibration Replace the RPM sensor or Hall Effect depending on style Then clear all error codes see note 8 Exit Test Mode by pressing the stop key Re engage Engineering Mode and clear all error codes See note 8 4 42 Code EL LOST Flowchart Definition ELEVATION LOST BEYOND 0 or 15 RANGE Possible Cause Out of range elevation count or elevation system malfunctioned Note 1 Press oy hold the 0 2 8 START keys down at the same Engage time then release the 1 TEST MODE key The display will Verify elevation read MAINTENANCE response in Test Press and release the Mode 8 key Or manually hold the
47. e for possible short see page 4 17 Display Cable Symptoms If values are err aticly different replace the Elevation Motor CAUTION Do not stand on the running belt while perform ing these steps NOTE These ran ges were chosen to optimize the output voltage to the elevation motor within an acceptable operating range while still using the present manufacturing tolerances of the transformer manufacturer Elevation Troubleshooting IRAC 220v treadmill Incline Range Adjustment for Free wheeling symptom Symptom Treadmill free wheels at high elevation causing the running belt to slowly accelerates beyond the selected speed 1 This symptom may be easily fixed by changing certain values in the Configure Mode Engage Manager Maintenance Mode by holding down the 0 1 and Start keys at the same time and then release the 1 key only 2 Press the elevation T key until the display window reads EL MAX 57 Change the 57 to 80 by pressing the key 3 Press the START key and the display window will show UPDATING This will save the 80 in the parameter 4 Press the STOP key to exit the Manager or Maintenance Mode Procedure completed Symptom Elevation Motor overheats and blows the MCB fuse 1 The elevation motor on the 4500 series treadmill uses 115 VAC On 230 volt treadmills there is an autotransformer which will lower the voltage to operate the elevatio
48. e left hand side of the motor plate 1 Pull the connectors of the red and blue wires from the transformer lugs See Diagram A for wire color layout 2 Pull the connector of the transformer s black wire from the connector AC1 at the left rear corner of the Motor Control Board 3 Using a slot screwdriver disconnect the transformer s white wire from the WHT terminal on the barrier strip 4 Disconnect the transformer s brown wire from terminal AC1on the barrier strip 5 Using a Philips head screwdriver remove the four screws that hold the autotransformer to the motor plate Reach under the treadmill to hold and retrieve the related washers and nuts 5 13 STAR UNISEN INC ME Autotransformer Replacement TRAC SE 18 D MEU ME aux IB Ca VRE 26 DES Replace the Autotransformer 1 Position the replacement autotransformer over the four holes in the motor plate so that the connector lugs are towards the left hand side of the treadmill Drop the four screws removed in the preceding step 5 into the mounting holes of the autotransformer Reaching under the treadmill install related washers and nuts and tighten the mounting screws Reconnect the autotransformer s brown wire to terminal AC1 on the barrier strip Reconnect the autotransformer s white wire tot he terminal marked WHT on the barrier strip 5 14 TRAC Autotransformer Replacment Reconnect the autotransformer s blac
49. ect the area under the treadmill for obstructions Inspect the display and handrail screws for loosening Inspect the display panel keys for wear Wax the running belt and deck using Unisen powder wax 2 1 Note Apply wax powder while belt and deck are still warm from 5 to 15 minutes of use for optimum benefit The foll owing steps are done with the treadmill off Note Blow away extra wax first from around the siderails and deck before wip ing Note The RE WAX prompt may be cleared either in Settings or Configure Mode mAC The treadmill is designed with an automatic prompt which will display RE WAX across the display screen every 2 000 miles or 3 000 kilometers The procedure below explains step by step how to apply wax and clear the RE WAX prompt Quarterly Waxing Time Required 5 minutes Tools Required 1 Wax Powder Bag Unisen Teaspoon 1 Clean Towel Paint Stick or Yard Stick Diluted All purpose Cleaner 409 Bristle Brush PROCEDURE STEP 1 Cleaning the deck and belt e Using the stick or ruler slide a towel under the middle of the running belt from one side of the frame to the other e Hold the edges of the towel pull from head roller down to the tailroller then pull the belt down to wipe the remaining of the belt TIP Careful when removing the towel it will be dirty Fold the dirty towel and shake into trash STEP 2 Re waxing the deck and belt e Li
50. ed 3 Verify the following parameters are set correctly in the Configuration Mode Configuration Mode details in Section 3 e MN SPD 0 5 MPH or 1 0 KM PH e MX SPD 10 0 MPH 110v or 20 0 KM PH 220v e CNT RV 31 Magnetic Cherry RPM Sensors e 10REV 29 1 for 1 7 dia motor pulley 110v e 10REV 35 8 for 2 1 dia motor pulley 220v NOTE To reach 20 0 KM PH on 220v units drive motor pulley must be 2 1 If not sure what your 10 REV settings should be manually measure the drive motor pulley diameter 4 Verify RPM Sensor alignment e Hall Effect Cherry RPM Sensor is being used verify the gap is approximately 3 business cards or 1 credit card If adjustment is necessary loosen the flywheel to re position NOTE See Diagram 41 REPLACE RPM Sensor if RPM reading is sensitive or feedback appears erratic 5 Adjust the MAX SPEED potentiometer NOTE See Diagram 2 220v units only GO TO Section 3 7 Manual Calibration if problem continues 4 6 Diagram 1 E 3g RPM Sensor Gap Diagram 2 TOTI OIZIOZ I AA LA oi CONS icum mam irum uum Hd SX Exc 5 KRIKTJ KIII SIR Y UNISEN INC A RAC Manual Calibration The following procedure allows the treadmill to manually calibrate Minimum and Maximum speeds only in the case Auto Calibration is not functioning correctly Symptom Will not calibrate to MN or MX speed in the Auto Calibration Mode V CAUT
51. estarts the treadmill with a warm start 0 9 KEYS Enters new parameter values If UNITS parameter is displayed key 5 starts DISPLAY TEST and key 8 starts MOTOR TEST HEART KEY When pressed will automatically display manufactures default value Note ENTER KEY must be pressed to save the default values if changed STAR UNISEN INC ME Manager Mode 8 C 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 MPH or KM HR MX SPD 5 0 20 0 English 10 0 Metric 20 0 10 0 Maximum speed in MPH or KM HR EL OPT ON OFF ON Turns the elevation system ON or OFF TIME 9 Maximum time in minutes allowed for program including warm up cool down DIST 65 635 Total treadmill miles Units 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 3 2 STA UNISEN INC EBEN TRAC Maintenance Mode Maintenance Mode includes all of the items of Manager Mode plus additional dat
52. ft the left side facing the display of the belt about 12 inches down from the motor shroud see above figure Hold the belt up such that the width of the belt is elevated from the deck e Gently place one level teaspoon of wax powder on the deck about two inches from the edge and blow the wax steadily under the belt so that the wax powder is spread evenly across the deck see above figure Gently place a second level teaspoon of wax 18 inches down the belt e Repeat the above step to the right side of the belt and deck STEP 3 Walking the wax in e Start the treadmill at 1 mph and walk on all sections of the belt and deck for 1 minute to ensure the wax has been evenly distributed and worked in properly STEP 4 Clean up e Remove any excess wax with diluted cleaner 409 and towel or bristle brush STEP 5 Clear RE WAX prompt e Engage Settings or Configure Modes Press and hold the 0 1 or 2 8 START keys down release the 1 or 2 key only Display will beep and display SETTINGS or CONFIGURE momentarily depending if the 1 or 2 key was released then UNITS will be displayed e Press the Incline Down Key elevation until LSTDCK is displayed Press and release the HEART Key this will automatically transfer the accumulated miles kilometers into the LSTDCK press the ENTER Key to save 2 2 STA UNISEN INC EMI Section 3 TRAC Diagnostics The STAR TRAC 4500 Treadmill series contains diagnostic and custom
53. he front end of the side bed cover near the outside edge and pry the edge upwards until the outer flange is clear of the frame See Diagram B Diagram A MAC Side Bed Cover Replacement etarting at the raised corner of the flange lift upwards and outwards to free its outer edge from the frame along its length Lifting the outer edge of the cover push the cover towards the center of the treadmill to clear the cover s inner flange from the frame and remove from the treadmill Installing Replacement Side Bed Cover To replace the cover proceed as follows 1 To be sure that you have the correct cover right or left position it so that the wider flange is at the outside edge of the frame The hole in the cover should be located nearer the front end of the treadmill Position the new cover so that the hole is nearest the front of the treadmill If it is a left hand cover be sure to position the front end first fitting the inner flange to clear the running belt pulley Move the cover parallel to the frame and hook the inner flange over the frame 5 11 Side Bed Cover Replacement TRAC 4 Atthe front end pull the outer flange over the frame then use your hand or a soft mallet to pop the outer flange over the frame along its full length The rear end of the cover should butt against the end cap See Diagram C Diagram C SIDEBED COVER DELRIN ROD TR4500 CROSS SECTION 5 If the rear e
54. ial speed start up 1 Manually calibrate the minimum PWM as described in page 4 7 in this section 4 15 CAUTION Do not stand on the running belt while performing these steps Heart Rate Troubleshooting TRAC Before any troubleshooting is performed verify that the heart rate grips are being used and maintained properly Symptom Intermittent or erratic heart rate reading 1 User failing to grip all four rings completely with both left and right hands 2 An excessively tight grip on the rings can cause erratic readings The probability of erratic readings can be therefore lessened by reduced upper torso movement a proper grasp on the grips clean hands clean grips 3 Excessive foreign matter dirt on the hands can generate electrical interference which will cause erratic readings 4 Clean and wipe heart rate grips after each use for optimum results 4 16 STA UNISEN INC EBEN FRAC Heart Rate Troubleshooting Symptom Diagram 1 No Heart Rate reading 1 Engage HEART RATE TEST Turn the power switch on while pressing key 5 simultaneously on the display All the display LEDs will light up when engaged e Press the HEART key once EPROM ver sion will be displayed HEART key twice displays Heart Seeking HR e Grip heart rate handles The negative symbol will begin to flash indicating heart rate system is being registered Do not squeeze excessively to avo
55. id excessive muscle contraction faulse readings If no reading is displayed go to STEP 2 2 Verify Contact Heart Rate settings Engage MANAGER MODE Hold the 0 1 and START keys together and re lease the 1 key only Display will read MANAGER MODE momentarily then UNITS will be displayed e Scroll through the parameters using the elevation UP key until display reads CONTCT contact heart rate BOTH both contact and polar can be used if software available e Press the or key to change START key to save 3 Verify Heart Rate receiver connection e Remove the display board verify wire a connections HEART RATE NOTE See diagram 41 Display removal NOTE See diagram 2 Wire connection Connection is wrong or loose reconnect and repeat step 1 POLAR ECARD 4 Verify Heart Rate grip cables Diagram 3 NOTE See diagram 3 If connections are wrong or loose reconnect and repeat step 1 4 17 FRAC Heart Rate Troubleshooting 5 Connect Heart Rate Board straight to the display input e By pass the Combiner Board insert the heart rate wires straight to the display See Diagram 3 amp 3a After connection has been repeat step 1 REPLACE Combiner Board if Heart Rate registers If no Heart Rate is registered go to step 6 NOTE Step 5 can only be performed if the software includes both Polar and Contact 6 Check continuity resistance between Heart Rate grip rings and input
56. ines the treadmill in increments of 1 Te WEN When using the Incline Keys verify the elevation system is responding correctly by the x following e As the treadmill elevates up and down verify the corresponding LEDs light up on the MCB 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 the following e As the treadmill begins to increase speed verify that the display registers RPM feedback see above C column in increments of 0 1 mph km START KEY Starts burn in mode continuous operation of running belt and incline using program 8 at maximum speed Press STOP KEY to stop burn in i NO se se STOP KEY Exists MOTOR TEST Mode and restarts the treadmill HEART KEY Starts automatic calibration of minimum 1 2 maximum 8 maximum speed Calibration TRAC Caution Do not stand on the running belt while performing these test Automatic Speed Calibration In this mode minimum and maximum speed is automatically calibrated Calibration lasts
57. ixed by 1 Engage Maintenance Mode by holding down the 0 2 and Start keys at the verifying certain same time and then release the 1 key only Display will read MAINTENANCE values in the momentarily then display UNITS Configure Mode Note For each 2 Using the elevation T key to go through the parameters verify the value changed following parameters have the correct values the ENTER key must be pressed 110V 220V Units English 220v Units Metric to be saved e UNITS ENGLISH METRIC e MN SPD 0 5 1 0 Note All 110v units are design e MX SPD 10 0 20 0 ed to reach a i e ENTRY UNITS TENTHS UNITS TENTHS maximum spee MOONE e 10 REV 30 7 35 8 220v units setin je CNT REV 31 31 metric will reach a maximum 20 0 KM PH 3 If any values have been changed or set back to default settings re engage Me er ee Auto Calibration and re calibrate age is very critical when dealing with maximum speed Voltages 1 wall voltage 10 under 100v for 110v units will 2 Dedicated Circuit Breaker distin 3 Adjust MAX SPEED potentiometer 220v units See Diagram below ages under 200v for 220v units will cause the same problem IF the problem continues verify the following Note Each unit must be on its own dedicated circuit very main 4 14 wall breaker Speed Troubleshooting TRAC VA Symptom Treadmill jerks or hesitates during operation CAUTION Running belt will be moving at
58. izing modes In these modes you are able to check accumulated data about the past usage of the treadmill test its motor and display controls and investigate display code messages For these reasons your treadmill is equipped with a e Manager Mode customize e Display Test Mode diagnostics e Maintenance Mode diagnostics e Heart Rate Test Mode diagnostics e Motor Test Mode diagnostics Contents 3 1 Engaging Manager Mode 3 8 Engaging Motor Test Mode 3 2 Engaging Maintenance Mode 3 9 Calibration 3 3 Description of parameters 3 10 Engaging Display Test Mode Heart rate test SIR Y UNISEN INC A TRAC Manager Mode After having used you Star Trac 4500 treadmill for several workouts you may wish to specially customize your treadmill by changing some of its settings To engage Manager Mode 1 Press and hold the 0 1 amp START keys together While holding the 0 8 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 Ite INCLINE KEY Displays the next or previous parameter it SPEED KEYS Allows the variable to be changed within the parameter Ke ENTER KEY Saves the value if changed in the EPROM software START Note ENTER KEY must be pressed for each value changed s M sue F STOP KEY Exists Manager Mode and r
59. k s and drive them into the edge of the deck using a hammer Once the bumpers on the side have been installed in the proper locations remove the screwdrivers used to hold the deck above the frame Repeat process on opposite side of the treadmill After the bumpers have been properly installed on both sides of the running deck position the deck properly and verify that all bumpers have adjacent o the holes Reinstall the delrin rods Test the treadmill thoroughly The squeak should be gone 4 28 STAR UNISEN INC ME A Isolating Noise NOTE Verify that the treadmill is level before isolating any specific component NOTE Ensure all assembly screws are tight 1 Handrails 2 Display board 3 Motor shroud NOTE When doing the stethoscope method be careful of body placement Ensure all loose items hair clothing jewelry etc are secure and away from moving parts Sounds travel throughout the treadmill making it difficult to isolate the cause of a sound The following procedure will help determine where a noise may be coming from Isolate the noise 1 If the noise seems to be coming from two different parts drive motor or roller etc isolate the noise by disconnecting the drive belt Then run the drive motor by itself If the noise goes away manually push the running belt to see if the noise returns If it does then it is coming from the rollers 2 Isolate the rollers A
60. k wire to terminal AC1 at the left rear corner of the Motor Control Board Connect the blue wire to the lug on the autotransformer 1 Connect the red wire to the same lug from which it was removed in the previous step If there is a question about the available line voltage or if EL STL messages have been appearing on the display check and follow the recommendations in Selecting the Voltage Tap Replace the Shroud 1 Release the should from the bungee cord that has held it to the handrail gooseneck and carefully slide the shroud downward so that it rests on the treadmill frame 2 Match the screw hole in the lower front edge of the shroud with the mating hole in the frame then insert and start the Philips head screw previously removed 3 Press down on the sides and front of the shroud to engage the Velcro strips on the frame 4 Tighten the screw to complete shroud replacement procedures Test Treadmill Operation After you have completed replacement of the autotransformer perform a complete system test Selecting the Voltage Tap if there have been EL STL messages The treadmill may be operated over a wide range of line voltages Either of two voltage taps on the autotransformer may be selected optimize the voltage at the elevation motor If the treadmill has been generating EL STL messages on the display the elevation motor has either been overheating and shutting down or it has been failing to respond to the elevation comma
61. mill on Increase speed to 3 0 mph 5 0 kph Note The running belt 2 Adjust tracking by adjusting the tailroller Allen screws located at the back will track to the side sides of the tail roller with a 1 4 Allen wrench in 1 4 turn increments less tensioned See below diagram 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 tail roller bolt by turning counter clockwise If your running belt is tracking to the right then adjust the running belt to track to the left Tighten the right tail roller Allen screw by turning clock wise or loosen the left tail roller bolt by turning counter clockwise 3 After running belt appears to be tracking properly increase speed to 10 mph 16 kph and verify belt stays centered 4 Verify correct running belt tension as outlined in the Running Belt Tension procedure in this section Note To ensure proper tracking the treadmill leveling feet must be adjusted to conform to the floor surface For proper procedure see Feet Leveling in this section RA Running Belt Tension Note Prior to making The running belt tension may need to be adjusted over time to keep the any adjustments to the the belt from slipping with each jogging step or at high speeds Use the running belt tension following procedure for testing belt tension verify the drive motor belt is
62. ms 4 13 Heart Rate Symptoms 4 16 Polar Symptoms 4 17 Display Cable Symptoms 4 18 Drive Motor Symptoms 4 19 Head Tail Roller Symptoms 4 20 Drive Belt Symptoms 4 21 Running Belt Symptoms 4 0 4 24 Running Deck Symptoms 4 26 Isolating Noise 4 27 Leveling 4 28 Static Symptoms 4 29 Vibration 4 30 Display Codes Chart 4 31 KEY DN Flowchart 4 32 NO STO Flowchart 4 33 No RPM Flowchart 4 37 SP CNG Flowchart 4 41 EL STL Flowchart 4 45 EL RNG Flowchart 4 49 EL LOST Flowchart 4 53 EL NOZ Flowchart SIR UNISEN INC AM RAC 440v MCB LED Layout The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems amp C 100 eng 0000 Lom Les o 00000 c c c c Oo C gt gt 000 amp HIN SPEEO IR COP CAUTION AC LED Indicates that AC power has been applied to the MCB It does Several of the follow not give indication of voltage level if this LED is not lit and the tread ing troubleshooting mill does not power up verify the following require dealing with 1 The treadmill is plugged into a wall outlet live voltage Have the 2 The ON OFF switch is turned to the ON position treadmill turned off 3 Verify with a VOLT METER that 110VAC is present at the and unplugged when outlet Units with step down transformers need 220VAC checking wire 4 Verify 110v 10 AC voltage at AC1 amp AC2 wires connections After the above have been verifie
63. n system 2 Line voltage may vary from location to location Some locations have line voltages as low as 195 VAC or as high as 250 VAC The autotransformer has been manufactured with two taps to accommodate these variations in voltage The two taps are e 190to 210 VAC line voltage e 210 to 250 VAC line voltage RED 18 G YIRE 24 INDES BLAK 18 GA WIRE 26 INDES WITE 18 GA WIRE 24 INCHES 4 12 TRAC Speed Troubleshooting Note This sym ptom may be easily fixed by verifying certain values in the Configure Mode Note For each value changed the ENTER key must be pressed to be saved Symptom Treadmill appears feels faster slower than other STAR TRAC treadmills 1 Engage Maintenance Mode by holding down the 0 2 and Start keys at the same time and then release the 1 key only Display will read MAINTENANCE momentarily then display UNITS 2 Using the elevation T key to go through the parameteres verify the following parameterts have the correct values 110V 220V Units English 220v Units Metric e UNITS ENGLISH METRIC e MN SPD 0 5 1 0 e MX SPD 10 0 20 0 e ENTRY UNITS TENTHS UNITS TENTHS e 10 REV 30 7 35 8 e CNT REV 31 31 3 If any values have been changed or set back to default settings re engage Auto Calibration and re calibrate 4 13 Speed Troubleshooting TRAC VA Symptom Treadmill will not reach maximum speed Note This sym ptom may be easily f
64. nd of the cover does not meet the end cap set a short section of wooden board against the front end of the cover then tap the board with a plastic hammer to slide the cover flush against the end cap 6 Lift the vertical section of the handrail to clear the new side bed cover then set it carefully into the hole in the side bed cover Be careful not to scratch the side bed cover 7 Screw the 5 8 inch hex head screw through the bottom of the frame and into the bottom of the vertical section of the handrail and tighten This completes side bed cover replacement procedures 5 12 RAC Autotransformer Replacement The autotransformer may be tapped to accommodate line voltages from 195VAC to 250VAC Following are procedures for replacing a failed autotransformer Tools e Replacement autotransformer e Philips head screwdriver e Slot screwdriver Procedure Lift motor shroud The drive motor is located below the plastic shroud at the front of the treadmill To remove the shroud at access the motor proceed as follows 1 Remove the Philips head screw at the center of the front edge of the shroud 2 Lift up the front of the shroud lifting from both sides to separate the Velcro strips 3 Lift the shroud up the vertical rails as far as it can go then suspend it using a bungee cord looped over the gooseneck rail and hooked up under the upper edge of the shroud Remove the Autotransformer The autotransformer is located on th
65. nds Measure the line voltage when the facility s power line is under a typical load e If line voltage is less than 220 VAC connect the red wire to the lower lug on the autotransformer e lfthe voltage is greater than 210 VAC connect the wire to the upper lug 5 15 RAC Heart Grip Replacement VA Tools e Handgrip Kit CAUTION He 1 16 inch Allen wrench Always turn the e Light nylon cord e power switch to Isopropyl alcohol the off position Unplug the treadmill power cord from the power outlet 1 Using a 1 16 inch Allen wrench remove the five screws from the rear of the display panel mount and carefully lay the panel down on the display rail Procedure Remove the Display Panel 2 Unplug the two handgrip cables from their connectors See Diagram A Diagram A PCLAR BOARD CONTACT HEART RATE BGARD Heart Grip Replacement TRAC 3 Lift the handgrip cables to separate the Velcro strips on the cable from the Velcro on the rear of the panel then remove the two Velcro strips that hold the two cables together 4 Cut and remove the cable ties from the handgrip cables 5 Tie a 4 foot length of strong nylon cord to each cable just below the connector See Diagram B Secure the free end of each cord so that it will not be pulled into the gooseneck The cord will be the means of pulling the new cables back through the gooseneck to the display panel Diagram B NYLON CORO TIE NYLON CORO 10 OLO
66. o the mating connectors on the rear of the display panel Press Velcro strips on the cables down onto the Velcro strip on the rear of the display panel 5 18 Heart Grip Replacement TRAC Replace Display Panel 1 Position the display panel over the display panel mount matching screw holes in the back of the panel with holes in the mount 2 Using a 1 16 inch Allen wrench replace and tighten each of the five screws removed in a previous step Test Treadmill Operation After you have completed replacement of the handgrips perform a complete system test 5 19 CILCERLI TR 4500 8 3900 Series Deck 8 Frame Assy TR 4500 amp 3900 Series Page 1 STAR TRAC T Deck amp Frame Assy m imoer Dein tt ee 020 4497 Shroud Motor black 45 39 4000Sm 41 N 020 4500 Shroud motor grey 45 39 4000Sm 1 n 020 4452 End Cap 45 39 4000 left black 1 n 020 4480 nd Cap 45 39 4000 left gre 7 10 6 020 4481 End Cap 45 39 4000 right grey 7 050 1680 jSlkdeck dbksided tt 8 010 3061 Deck Rubber Cushion 60 strip 2 9 140 3108 Bumper Rubber hollow stem deck 6 10 715 3196 Delrin Deck Stop Rod wscrew 6 11 020 4544 Side Bed Cover left black 1 CN 12 020 4584 Side Bed Cover left grey 1 N 13 020 4543 Side Bed Cover right black 1 ON 14 020 4583 Side Bed Cover right grey 1 N Adjustable Foot 3 Base 2 Nn 16 110 18
67. of the shroud Tip the Treadmill on its side Lift either side of the treadmill and tip the treadmill on its side This makes accessible both the elevation motor and the belt drive train below the motor plate Remove the Elevation Motor 1 Using pliers remove the end cap tap nuts from both ends of the wheel axle at the front end of the treadmill 2 Remove the wheels and the bushings from both ends of the axle then remove the axle from the treadmill 3 Atthe bottom of the motor plate loosen the idler pulley mounting nut using a 17 mm socket wrench See Diagram A 5 6 STAR UNISEN INC EBEN RAC Elevation Motor Replacement Diagram A zi ELEVATION AE WEELS AND CS REMIX MOIR 4 1 CR ELEVATION REPLACEMENT P ELEVATION MOIR PULLEY 7 MU ALLEY 4 Slide the idler pulley in its slot to loosen the elevation drive belt then remove the belt from the idler pulley 5 Using an Allen wrench loosen the screws around the drive pulley then remove the pulley from the elevation motor shaft 6 At the Motor Control Board disconnect the elevation motor cable from connector J5 7 At the upper surface of the motor plate remove the four screws that hold the elevation motor to the motor plate Use a 9 64 inch Allen wrench 8 Remove the elevation motor from the treadmill 5 7 FRAC Elevation Motor Replacement Replacement the Elevation Motor 1 Position the elevation motor in its moun
68. olar wireless heart rate chest strap reception capability To enter Heart Rate Test Mode 1 Press and hold the 0 1 amp START keys together or the 0 2 While holding the 0 amp START keys down release the 1 or 2 key 2 The display will beep and display MANAGER or MAINTENANCE momentarily then UNITS will be displayed 3 Press and release the 5 key Observe all the LEDs light up 4 Press ne KO key 3X s display will read SEEKING HR across the display 5 Grasp the stainless steel contact rings or place the Polar wireless heart rate chest strap around your chest treadmill must be equiped with both contact and Polar 6 In the far right display screen a blinking LED segement will flash then the average heart rate will be displayed NOTE If the above Heart Rate Test fails to give the correct reading or response refer to Section 4 3 11 Section 4 mmm STA UNISEN INC EMI Troubleshooting Should the STAR TRAC 4500 Treadmill experience a problem or a display code appear the following procedures will help determine the precise reason for the problem Included are flow charts breaking down each individual display code with problem statements and solutions Contents 4 1 110v MCB Layout 4 3 220v MCB Layout 4 5 Calibration Symptoms 4 7 Manual Calibration 4 8 No Display Power 110v 4 9 No Display Power 220v 4 10 Elevation Motor Symptoms 4 12 Elevation Sympto
69. on procedures fail to give the correct reading or response Symptom Auto Calibration fluctuates 1 Verify line voltage for sufficient voltage supply e f wall voltage is less than 10 than what is required this will cause speed fluctuation 2 Verify unit is on a dedicated circuit breaker e Treadmills sharing the same circuit line will cause intermittent problems and variation in speed 3 Verify the following parameters are set correctly in the Configuration Mode Configuration Mode details in Section 3 e CNT RV 31 Magnetic Cherry RPM Sensors e 10REV 29 1 for 1 7 dia motor pulley 110v e 10REV 35 8 for 2 1 dia motor pulley 220v NOTE If not sure what your 10 REV settings should be manually measure your drive motor pulley diameter Above measurements are done in inches 4 Verify RPM Sensor alignment e Hall Effect Cherry RPM Sensor is being used verify the gap is no more than 1 8 inch NOTE See Diagram 1 5 Adjust IR COMP potentiometer NOTE See Diagram 72 adjustment REPLACE MCB if symptom continues 4 5 Calibration Troubleshootin IRAC Symptom Will not Calibrate to MAX speed 1 Verify line voltage for sufficient voltage supply e f wall voltage is less than 10 than what is required this will cause speed fluctuation 2 Verify unit is on a dedicated circuit breaker e Treadmills sharing the same circuit line will cause intermittent problems and variation in spe
70. ousing 1 N 5 120 3004 Standofi 6 32X38 5 N 6 1100130 Screw 632X1 4 IN 7 1203000 X Washens Cd 4 NM 8 Ooo S oOo 705 1630 Display Assy Complete Tr3500 Product Support Phn 800 503 1221 Revision Date 09 18 00 Page 8 Do Not Duplicate or Distribute
71. positioned Chest strap electrodes must be NOTE Secure properly positioned and wet See below diagrams the chest strap transmitter as high under the pectoral muscle CIEST BELT TRANSHITTER breast as is HE STEP 1 s m comfortable and allow normal FIG 1 ELASTIC STRAP breathing STEP 2 NOTE Wet the electrodes the two grooved rectangular areas thorou ghly with water NOTE Verify STEP 3 STEP 4 heart rate resp onse without operating the 3 Connect Polar Board straight to the display input running belt e By pass the Combiner Board insert the heart rate wires straight to the Straddling the display See Diagram 1 1a treadmill press the HEART key REPLACE Polar Board if Heart Rate registers If no Heart Rate is registered go to If heart rate is not picked up engage Heart Rate Test refer section 2 8 CONTACT HEART RATE BOARD Display Cable TRAC The following symptoms indicates a faulty or pinched display cable Symptom d No display power related CAUTION 1 No display power treadmill elevation bottoms out during start up Do not stand on 2 No display power MCB LED 11 remains lit on 110v units MCB LED Display the running belt remains lit on 220v units while perform ing these steps Intermittent or no elevation 1 In Test Mode only up direction works MCB LED UP remains lit NOTE Alter 2 In Test Mode no elevation count elevation motor pot will elevate
72. properly 1 Accelerate the running belt to 3 0 mph 5 0 kph tensioned 2 Stand on the side of the treadmill Grasping the handrails firmly place one foot on the running belt with a very sharp impact The running belt should not come to a complete stop The running belt should slip for a split second then forcing your foot back If the running belt does not stop with impact the running belt may be to tight and cause the belt and other components to premature fail Loosening the tail roller Allen screws a 1 4 of a turn counter clockwise and re checking will be necessary If the running belt stops and noticeable slippage occurs check the location of the slippage It can be slipping due to the drive belt slipping over the drive motor pulley and head roller or from the running belt slipping over the rollers f the slippage is caused from the drive belt slipping over the drive motor pulley loosen the motor mount bolts located at the mount of the drive motor and tighten the adjustment bolt For detail more details refer to Drive Belt Tension procedure in this section If the slippage is caused by the running belt slipping over the rollers tighten the running belt 3 Tighten the left and right tail roller Allen screws clockwise in equal 1 4 increments Repeat Step Two until running belt is tensioned properly Note If you do not tighten Allen screws in equal increments you Will mis track the running belt Verify correct
73. ptoms 2 Replace MCB 4 2 STA Y UNISEN INC MM mm amp 220v MCB LED Layout The Following LEDs will help diagnose if the MCB has failed or causing intermittent problems CAUTION Several of the follow ing troubleshooting steps require dealing with live voltage Have the treadmill turned off and unplu gged when checking wire connections NOTE The display console may still power up with the AC PWR LED off AC PWR Indicates that AC power has been applied to the MCB It does not give indication of voltage level if this LED is not lit and the treadmill does not power up verify the following 1 The treadmill is plugged into a wall outlet 2 The ON OFF switch is turned to the on position 3 Verify with a VOLT METER that 110VAC is present at the outlet Units with step down transformers need 220VAC 4 Verify 220v 1096 AC voltage at AC1 amp AC2 wires After the above have been verified and the AC LED is still OFF the MCB should be replaced if the treadmill is not operating DISPLAY PWR indicates there is 11 volts supplied to the display board If this LED is not lit verify the following 1 The display cable is damaged or pinched disconnect the display cable and verify if the DISPLAY PWR LED lights up If the LED lights up replace the cable After the above has been verified and the DISPLAY PWR LED is still OFF the MCB should be replaced 4 3 STIR er nc 220v MCB LED Layout
74. rd if display cable checks OK 4 8 SIR Y UNISEN INC A amp No Display Power The following steps help troubleshoot in case the display board fails to power up during or before regular operation Diagram A SAUTION The following steps are performed with with treadmill ON 220v UNIT Diagram B 1 Lift and suspend the motor shroud 2 Verify if LED AC is lit AC LED indicates that AC power is being applied to the MCB does not indicate voltage level If this LED is lit go to step 3 If LED is not lit verify the following see diagram A e The treadmill is plugged into the wall The ON OFF Switch is turned to the ON position Verify wire connection AC1 AC2 on the MCB Verify the ON OFF Switch Breaker wires are connected Verify 220v 10 AC voltage at AC1 AC2 if the voltage is 0 or less than 200v check wall voltage verify unit is on a dedicated line e f wall voltage is correct verify linecord continuity see diagram B REPLACE MCB if all the above check OK 3 Verify if LED DISPLAY POWER is lit This LED indicates 11v are being applied to power the display board If the LED is lit go to step 4 REPLACE MCB if DISPLAY POWER LED is not lit 4 Verify if LED MOTOR CONTROL is lit This LED indicates there is a valid control command from the display to the MCB Verify the following if LED is off e Verify display cable connection e Verify display cable for possible pinch or tear mark RE
75. s See note 1 key and simultaneously turn the treadmill on by the on amp off switch Both methods will engage Test Mode Is incline within range See note 2 9 Diagram 1 Note 2 When treadmill is at physical 0 the elevation range will read 240 across the display screen If incline reading is less than 20 verify elevation motor Incline DC Voltage across Ohm reading between DC Voltage on Pressing the elevation UP potentiometer numberin BlueandOrange the Blue and Orange Pin4ofthe k Motor Test wire on the Elev elev motor display key the elevation range readings Mode motor connector unplugged electronics number will decrease 57 See note 4 15 for 110v units 80 15 for 220v units Clear display code Note 3 Engage See note 3 MAINTENANCE mode scroll up through the menu to the different error references If elevation motor readings register 0 check display cable for possible pinch or tear by using the UP elevation Manually toggle the key Clear all error codes cable if readings are by dii the HEART now registered replace ey the display cable Note 4 The elevation motor potentiometer may have failed or register the If no readings are incorrect elevation value registered by toggling causing the motor to the display cable hesitate while operating replace the elevation Using a Volt Meter see diagram 41 use the chart motor in diagram 2 to instruct you
76. s up 110v units this while perform would indicate Drive Motor pulling higher amps than desired ing these steps NOTE Ifthe Drive Motor making noise ON OFF swith 1 Disconnect the drive motor belt trips only with a 2 Isolate the noise Bellow is a list of discriptions related to motor noise load running Knocking Noise described for bearing failure or motor magnet belt may be Grinding Noise describing bearings motor brush wear worned Squeaking Motor brushes installed incorrectly flywheel loose motor bearings Howling Usually described when motor increases to higher speeds 4 21 Note Do not remove all the was as it is required to lubricate both the running belt and deck STAR sen nc mm Head Tail Roller TRAC You may need to replace the head or tail roller if the following symptoms are Observed Symptom Thumping knocking noise as the running belt goes over the roller Verify the following e Delron end caps are loosening e Bearings are grinding or knocking e Lagging coating is loose e Thumping sounds may also indicate a possible wax build up The running deck surface is coated with a special wax During breaking period first 20 30 hours of operation some wax may form on the tail roller causing a loud thumping noise In worse cases this may cause mis tracking If the thumping noise continues remove the wax buildup With the following procedure 1
77. t Be sure to hold the motor s electrical cable closely against the motor to prevent its being pinched between the motor and the treadmill frame Replace and tighten the four screws that hold the elevation motor to the motor plate Use a 9 64 inch Allen wrench Connect the motor cable connector to the connector J5 on the Motor Control Board At the bottom of the motor plate replace the drive pulley on the motor shaft Check vertical alignment of the drive pulley idler pulley and right hand elevation screw bearing To do this rest a straightedge on the pulley and the bearing faces then position the drive pulley on the shaft until alignment is achieved See Diagram B ELEVATION PULLEY ALIGNMENT ALIGN BOTH PULLEYS WITH SIPAIGHT POLE 5 8 STAR UNISEN INC ME Elevation Motor Replacement IRAC 6 Tighten Allen screws in the drive pulley taking care to preserve the alignment achieved in the preceding step 7 Place the drive belt over the idler pulley 8 Slide the idler pulley tightly against the belt then finger tighten the mounting screw on the idler pulley shaft 9 Manipulate the drive belt so tat tit is flush with the inside surface of all pulley flnages and the right hand drive screw bearing 10 Tighten the idler pulley mounting nut 74 to 75 turn 11 Using a large screwdriver or steel chisel and a hammer tap the middle of the idler pulley shaft sharply to drive the pulley against the belt 12 If yo
78. te GZS TR 4500 amp 3900 Series Running Belt Assy TO TAILROLLER BELT OVERLAP EE Page 4 TR 4500 amp 3900 Series Page 4 TAR TRAC GIT kunning Belt Assy E ee me NENA Running Belt 20 x128 5 1 Y 708 0061 4 130 0121 Drive Belt 28010 1 1 1 N 130 1629 Drive Belt 285 10 1 N 6 130 7009 Pulley drive motor 10 180 1 8 dia 1 n Pulley drive motor 10J210 2 1 dia 1 n 8 110 1442 Key motor pulley 3 16 X15 1 N 9 1103056 Screw 5 1618 X 2 Shes black 2 N 10 110 0651 Screw 5 16 18 X 1 3 4 Shes Thd 2 N 11 120 0490 Washer 5 16 x1 2 od fiat 4 N Washer 5 16 lock 283 NL Product Support Phn 800 503 1221 Revision Date 09 18 00 Do Not Duplicate or Distribute GAGE TR 4500 amp 3900 Series 4500 Handrail Assy TR 4500 amp 3900 Series Page 5 STAR TRAC T 4500 Handrail Assy MD me omen te ee 1 715 3301 Cable Display lower m f Tr4500_ 1 N 2 715 8302 Cable Display upper m m T4500 1 N 2 7 2 2 2 10 11 2 12 2 6 020 4600 Cap side rail one color ony 2 7 110 0685 Screw 546 18XG hex 2 8 120 0480 Washer s 16 cut_ 2 9 120 0491 Wasner 5 16x1 5 od flat 2 10 110 0506 Screw 1 4 28 x 3 8 Bhss e 11 140 3127 Gasket base handrail black
79. that there is a valid control command from the display to the MCB this LED flashes only when the treadmill is operating If this LED is not lit verify the following 1 Verify if the display cable is connected 2 Verify if the display cable is damaged or pinched see page 4 17 in this section for Display Cable symptoms After the above have been verified and the PWM LED is still OFF the MCB should be replaced NOTE If the current I LIMIT LED Indicates that an excessiveload is being placed on the limit is reached the motor Amp readings of 26 or higher will cause the LED to MCB will shut the light If this LED is lit one of the following conditions exists treadmill down and 1 Running belt is worn the I LIMIT LED will 2 Belt and deck require lubrication remain on until it 3 Drive motor drawing over the 26 amp peak resets After the above has been verified and the I LIMIT LED is still ON the MCB should be replaced UP LED indicates that the incline is being commanded up If this LED is not lit and the elevation motor will not respond verify the following 1 Display cable for possible pinch or tear see page 4 17 in this section for Display Cable symptoms 2 Replace MCB DOWN LED Indicates that the incline is being commanded up If this LED is not lit and the elevation motor will not respond verify the following 1 Display cable for possible pinch or tear see page 4 17 in this section for Display Cable sym
80. ther or the 0 2 While holding the 0 amp START keys down release the 1 or 2 key 2 The display will beep and display MANAGER or MAINTENANCE momentarily then UNITS will be displayed 3 Press and release the 5 key Observe all the LEDs light up 4 Pressing any key once will display the EPROM version Alternative mode to enter Motor Test Mode 1 Turn the power switch on while pressing the 5 key simultaneously on the display Observe all the LEDs light up Once the treadmill is in Display Test Mode you may use the following keys h INCLINE KEYS Lights grade LED s one at a time also segments of 15 segment n screen one at a time E TS PROGRAM PROGRAM SELECT KEY Lights the six LEDs bordering the 15 segment display SELECT HEART KEY Displays HEART HEART on the 15 segment display D START KEY Displays START START on the 15 segment display o s 0 9 KEYS Lights corresponding LEDs in the Number Program Select Keys except for key 9 alongside the Pre Designed Program profiles 3 STUP Q se J STOP KEY Displays WD TEST on the 15 segment display Activates the watchdog timer resetting the processor and returning the program back to Start Mode 3 10 SIR Y UNISEN INC MM Heart Rate Test TRAC Heart Rate Test Mode tests the heart rate calculation and display capability of the treadmill if it is equipped with contact rings or P
81. u have a belt gauge measure belt tension Adjust tension until the gauge indicates 50 to 60 pounds then tighten the idler pulley mount nut If you have not suitable belt gauge pinch the sides of the belt together using strong thumb and finger pressure in the middle of the belt length The sides of the belt should not quite touch Re adjust belt tension if necessary loosening the idler pulley mounting nut then repeating the preceding steps 11 and 12 until correct belt tension is achieved 13 Re install the wheel axle align with bushings wheels and new tap nuts Set the Treadmill Upright Test Treadmill Operation After you have completed replacement of the elevation motor perform a complete system test 5 9 Side Bed Cover Replacement TRAC CAUTION Always turn the power switch to the off position Unplug the treadmill power cord from the power outlet Tools Side bed cover Philips head screwdriver Slot head screwdriver 1 8 in Allen wrench 5 8 in socket and socket wrench with ratchet Plastic head hammer Wooden block Procedure Removing the Side Bed Cover 1 Remove the 5 8 in hex head screw at the bottom of the frame and inline with the bottom end of the vertical section of the handrail See Diagram A Lift the bottom of the vertical section of the handrail to clear the side bed cover and pull it to the side of the frame only far enough to clear the side bed cover Slip a screwdriver under t
82. unning belt move 9 Re engage Auto Calibration See note 4 NO By pass the choke filter from the MCB and drive motor Does the running belt move NO Replace the chokeffilter Replace the MCB system 4 38 Code SP CNG Flowchart Definition SUDDEN SPEED CHANGE Possible Cause RPM pick up misaligned gt gt eJ s s STO ous Gero in oe Engage Note 1 Press and hold MAINTENANCE the 0 1 amp START mode Verify RPM feedback keys down at the same in Test Mode See note time then release the 1 1 key The display will read MAINTENANC then press and release the 8 key Or manually hold the Display reads 8 key and XXX 30 simultaneously turn the at 096 XXX will read 240 treadmill on by the on amp Press the and bring off switch Bath methods vill the middle number 3 up to engage 50 Test Mode Note 2 Verify that the PWM LED is flashing while the treadmill is on The PWM LED indicates a valid control command is being sent from the Display Board to the M C B If the LED is not flashing check connection and look for pinch or tear marks Note 3 Adjust the potentiometer clockwise or counterclockwise Note 4 Verify that RPM feedback is being displayed under speed as the running belt moves Does the running belt move 9 Left motor shroud and verify PWM LED for 110v units or MOTOR CONTROL LED for 220v
83. wires e Disconnect both heart rate grip inputs red amp black wires from back of display e Using a Multi meter check continuity between the heart rate rings and its corr esponding output wires e Red wire outside rings e Black wires inside rings NOTE See Diagram 4 REPLACE Heart Rate grip s if reading is greater than 1 00 T Check continuity resistance of each hand rate grip e Using a Multi meter check continuity between the two rings on the same grip e Black meter probe to inside ring and red meter probe to outside ring NOTE See diagram 45 REPLACE Heart Rate grip s if reading is lower than 3 MO 8 Check continuity resistance between the two hand rate grips e Measure the resistance between the two outside rings NOTE See diagram 46 REPLACE Heart Rate grip s if reading is less than 18 09 Diagram 4 Diagram 5 COMBINER BOARD g EF Mic in ua eT c E 1e I HEART RATE BOARD III i ic D Gmt POLAR BOARD j RED PROC Q2310 TT Diagram 6 4 18 RAC Polar Heart Troubleshooting If the display is having difficulty picking up polar heart rate readings verify proper usage VA Symptom CAUTION Intermittent or erratic polar heart reading Do not stand on the running belt while perform ing these step 1 The maximum distance for polar heart rate to receive a signal is 3 feet 2 Verify chest strap is correctly

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