Star Trac Elliptical Edge User manual
Section 1
Introduction
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Welcome to the world of STAR TRAC. In your hands is the STAR TRAC Elliptical Edge Service Manual. This
manual is designed to be easy to use, providing detailed instructions
on
how to service and maintain the Elliptical
Edge.
We highly recommend that you read the entire manual prior to performing any maintenance or repair procedure. The
information on the following pages will enable you to begin easily, quickly and safely.
Contents
How to Use the Manual 1.2
Precautions 1.3
Product Support Assistance 1.4
Tools and Materials 1.5
Elliptical Edge Overview 1.7
Elliptical Edge Service Manual
1.1
How to Use the Manual
THIS
IS
NOT AN OWNER'S MANUAL. This Service Manual is intended for use
by
qualified repair technicians as a
guide to diagnose and correct service problems.
The Service Manual is divided into six sections. Each section is provided with it's own Table
of
Contents to assist
in
locating specific topics and procedures. Titles and major headings are located at the top
of
every page.
The Service Manual contains the following sections:
Section
1:
Introduction
-Provides ageneral overview
of
the Elliptical Edge, outlines safety precautions to be ob-
served when performing maintenance or repair, and lists tools and materials required.
Section
2:
Preventive
Maintenance
Schedules
-Outlines periodic preventive maintenance checks and services;
provides detailed procedures for specific maintenance tasks.
Section
3:
Diagnostics
-Describes how to access and use built-in diagnostic and customizing features and capa-
bilities.
Section
4:
Troubleshooting
-Provides information designed to help diagnose and correct equipment problems.
Troubleshooting information is arranged
in
aSymptom -Probable Cause -Suggested Remedy format.
Section
5:
Parts
Replacement
-Provides step-by-step illustrated procedures to remove and install authorized in-
field replacement parts.
Section
6: Parts
Breakdown
-Contains
an
illustrated listing of all parts and assemblies contained
in
the Elliptical
Edge.
1.2
Elliptical
Edge Service Manual
-Precautions
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The following general precautions apply whenever performing any maintenance or parts replacement procedure
on
the Elliptical Edge:
1. Read each procedure COMPLETELY before starting any work. Give particular attention to
all
NOTES,
CAUTIONS and/or WARNINGS.
2. If the optional external wall powered power pack
is
used with the unit, MAKE SURE the power pack
is
un-
plugged from the wall before starting any work.
3.
When disconnecting cable connectors, ALWAYS pull
on
the connector itself, NEVER the wires.
Elliptical Edge Service Manual 1.3
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PRODUCT
SUPPORT
DEPARTMENT
Product Support Assistance
STAR TRAC
Product
Support
Department sets the industry standard
in
Customer Service and Technical Assis-
tance 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 amajor contributor to STAR TRAC's success and
growth
in
the worldwide fitness equipment industry.
Technical
Assistance
•When purchasing apart or requesting technical assistanvce, please contact our Product Support Department:
CALL TOLL-FREE: 1-800-535-4634 or 800-503-1221
US
and CANADA or 714-669-1660.
•When placing acall, please have the following information available:
1. STAR TRAC model.
2.
STAR TRAC serial number.
3.
Problem statement/symptom.
After
Hours
Voicemail
Direct
•CALL TOLL-FREE: 1-800-486-4736
•When placing acall, please have the following information available:
1. STAR TRAC model.
2. STAR TRAC serial number.
3.
Problem statement/symptom.
4. Return phone number and contact name.
Fax Requests
•Domestic and international: FAX 714-669-0739
•When Placing the fax, please supply the following information:
1. STAR TRAC model.
2.
STAR TRAC serial number.
3.
Problem statement/symptom.
4. Return phone fax number and contact name.
5.
Purchase order or reference number.
6.
Part description and quantity.
7. Ship to/bill
to.
Product
Support
Documentation
Access
Web page http://www.startrac.com/supportl
Docufacts
CALL
TOLL
FREE: 1-800-429-3228 ext. 640
US
and Canada or 714-253-3878 for alist
of
Product Sup-
port Procedures and Bulletins.
1.4
Elliptical
Edge Service Manual
Tools and Materials
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The following tools and materials are required to perform adjustment and parts replacement proceudres for the Ellip-
tical Edge:
TOOUMATERIAL USED FOR
Flat head screwdriver Shuttle Adjustment
Phillips head screwdriver Communication Cable Replacement
Display Power Cable Replacement
Cable Harness Replacement
Local Control Board Replacement
Battery Replacement
Shuttle Replacement
Skate Rail Replacement
Stride Belt Replacement
Transmission Bearings Replacement
Crank Bearings replacement
5/64-in. Allen Wrench Crank Bearings Replacement
3/32-in. Allen Wrench Display Panel Replacement
Communication Cable Replacement
Display Power Cable Replacement
Transmission Bearings Replacement
7/64-in. Allen Wrench Crank Bearings Replacement
1/8-in. Allen Wrench Skate Rail Replacement
Stride Belt Replacement
5/32-in. Allen Wrench Shuttle Replacement
Skate Rail Replacement
3/16-in. Allen Wrench Stride Belt Replacement
Crank Bearings Replacement
1/2-in open-end wrench Cable Harness Replacement
9/16-in. open-end wrench Transmisstion Bearings Replacement
Crank Bearings Replacement
3/16-in. socket wrench Shuttle Replacement
Skate Rail Replacement
7/16-in. socket wrench* Skate Rail Replacement
Stride Belt Replacement
1/2-in. socket wrench* Skate Rail Replacement
Stride Belt Replacement
Elliptical Edge Service Manual 1.5
Tools and Materials
TOOUMATERIAL USED FOR
9/16-in. socket wrench Transmission Bearings Replacement
Crank Bearings Replacement
Needle-nose clippers Cable Harness Replacement
Needle-nose pliers Skate Rail Replacement
External Retainer Ring Crank Bearings Replacement
Pliers (13/32-1-in. with
0.051 tip diameter)
Rubber Mallet Transmission Bearings Replacement
Crank Bearings Replacement
Belt tensioner gauge Transmission Bearings Replacement
Crank Bearings Replacement
Tape Communication Cable Replacement
Display Power Cable Replacement
Tie Straps Cable Harness Replacement
1.6 Elliptical Edge Service Manual
Elliptical Edge Overview
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THIS INFORMATION TO
BE
PROVIDED UPON RECEIPT OF THEORY OF OPERATION SOURCE DATA AND
BLOCK DIAGRAM.
Elliptical Edge Service Manual 1.7
Sec,ticn 2
..
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Preventive Maintenance
Schedules
Performing regular scheduled preventive maintenance is essential
in
keeping your Elliptical Edge
in
top operating
condition. Without preventive maintenance, normal wear and tear may cause cumulative effects, such as misalign-
ment and early replacement
of
parts.
This section provides alist
of
factory-recommended preventive maintenance requirements, along with detailed pro-
cedures for performing each task.
Contents
Preventive Maintenance Chart 2.2
Shuttle Alignment 2.3
Stride Belt Adjustment 2.4
Crank Belt Adjustment
2.E
Elliptical Edge Service Manual
2.1
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Preventive Maintenance Chart
The Preventive Maintenance Chart lists the scheduled maintenance tasks for the Elliptical Edge. The chart lists the
time interval when each procedure should be performed, and provides the general steps necessary to perform the
task. In some cases, the chart references detailed maintenance procedures provided later
in
the section.
D=Daily; W=
Weekly;
Q=
Quarterly
(depending
on
the
amount
of
use,
Quarterly
procedures
may
need
to
be
performed
more
frequently).
INTERVAL
D W Q PROCEDURE
•Clean dust and dirt from the unit using asoft, clean cloth dampened with anon-abrasive liquid
cleaner. Give particular attention to the display panel, handrails and heart rate grips (if used).
•Clean dust, dirt, oils
or
other contaminants from inside the skate rails (the shuttle tracks), and
on
the shuttle rollers, using asoft, clean cloth and anon-abrasive liquid cleaner.
If
needed, remove
stubborn accumulations
by
scrubbing with asoft-bristle brush (such as atoothbrush). NEVER use
awire brush or any abrasive material to clean the skate rails
or
shuttle rollers.
IMPORTANT: Regularcleaning
of
the skate rails and shuttle rollers is CRITICAL
to
proper
op-
eration
of
the unit. Accumulations
of
dust and dirt
on
the
skate rails
or
shuttle rollers can result
in
rough operation, misalignment
of
the shuttles and excessive wear on the skate rails and shuttle
rollers.
•Vacuum the floor under and around the unit. MAKE SURE that the unit is at its maximum eleva-
tion when vacuuming (or move the unit to another location).
•Check the display panel and handrails to ensure they are securely attached to the unit. Retighten
the screws as needed.
•Inspect the Sport Utility Display panel for evidence
of
wear. Contact STAR TRAC
Customer
Support
if
replacement
of
the Sport Utility Display panel is necessary.
•Check each shuttle for misalignment
or
excessive sideplay. Realign the shuttles as needed (see
Shuttle
Alignment,
page 2.3).
•Check each stride belt for proper tension. Adjust the stride belt tension as needed (see
Adjusting
Stride
Belt
Tension,
page 2.4).
•Check the crank belt for proper tension. Adjust the crank belt tension as needed (see
Adjusting
Crank
Belt
Tension,
page 2.5).
2.2
Elliptical
Edge Service Manual
Shuttle
..
Alignment
0_0
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Misaligned shuttles can cause rough operation, excessive noise during use, and uneven or early wear
of
the skate
rails and shuttle rollers.
The center rollers
on
each shuttle are equipped with eccentric cams which allow the shuttles to
be
adjusted to re-
move sideplay.
Tools
Required:
Flat head screwdriver
Check
the
shuttle
alignment:
1. Grasp the shuttle with one hand, and rock the shuttle from side to side
on
the skate rail.
2.
There should
be
little or no evidence of movement (sideplay). The shuttle rollers should fit snugly inside the
skate rails.
3.
Ifexcessive sideplay
is
noted, realignment
of
the shuttle(s)
is
necessary.
Realign the shuttle(s):
1. Grasp the shuttle with one hand, and rock the shuttle from side to side
on
the skate rail. Determine whether one
or both sides
of
the shuttle show signs
of
excessive sideplay.
2.
Using flat head screwdriver, rotate the shuttle center roller screw aquarter turn clockwise. Recheck the shuttle
for sideplay.
3.
If sideplay has increased, adjust the roller screw counterclockwise. If sideplay has decreased, continue
to
adjust
the roller screw, aquarter turn at atime, until sideplay has been removed.
Elliptical
Edge Service Manual 2.3
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Check and adjust the tension
of
each stride belt separately.
Tools Required:
Phillips head screwdriver
1-in. open-end wrench
Check the stride belt tension:
Stride Belt Adjustment
1. Hold the skate rail with one hand so it does not move.
2. With your other hand, try to move the shuttle back and forth along the skate rail.
3.
If
the shuttle DOES NOT move, stride belt tension does not need to be adjusted.
If
the shuttle DOES move,
stride belt tension must be adjusted.
Adjust stride belt tension:
1. Using Phillips head screwdriver, remove the four Phillips head screws from the rear shroud filler panel.
2. Remove the panel from the rear shroud.
3. Using 1-in. open-end wrench, adjust the stride belt pulley nut clockwise, as needed, to increase stride belt ten-
sion.
Recheck the shuttle for movement along the skate rail. Continue
to
adjust the stride belt pulley nut until proper
stride belt tension is obtained.
5. Position the rear shroud filler panel
on
the rear shroud.
6. Using Phillips head screwdriver, secure the filler panel to the rear shroud with the four Phillips head screws.
2.4 Elliptical Edge Service Manual
Crank Belt-·Adjustment·"
Tools
Required:
Phillips head screwdriver
9/16-in. open-end wrench
Belt tensioner gauge
Remove
the
front
shroud:
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1. Using Phillips head screwdriver, remove the eight Phillips head screws from the front shroud.
2. Lift the front shroud offthe unit.
Check
the
crank
belt
tension:
1. Using belt tensioner gauge, check that crank belt tension is
80
pounds.
2.
If
abelt tensioner gauge is not available, check the crank belt tension
by
pressing down hard on top
of
the belt,
midway between the transmission idler pulley and the crank pulley. The belt should deflect between 3/8-in.-1/2-
in.
(9.5-12.5 mm).
3.
If
crank belt tension is less than
80
pounds, the crank belt must be adjusted.
Re-tension
the
crank
belt:
1. Using 9/16-in. open-end wrench, loosen the transmission idler tension nut to allow adjustment
of
the transmis-
sion idler tension bolt.
1. Using 9/16-in. open-end wrench, tighten the transmission idler tension bolt
to
increase crank belt tension.
2.
Using belt tensioner gauge to check crank belt tension, continue
to
tighten the transmission idler tension bolt
to
achieve
80
pounds tension.
•
If
abelt tensioner gauge is not available, check the crank belt tension
by
pressing down hard on top
of
the
belt, midway between the transmission idler pulley and the crank pulley. The belt should deflect between
3/8-in.-1/2-in. (9.5-12.5 mm).
3. Once the correct crank belt tension
is
obtained, tighten the transmission idler tension nut SECURELY using
9/16-in. open-end wrench.
Install
the
front
shroud:
1. Install the front shroud
in
position
on
the unit.
2. Using Phillips head screwdriver, secure the front shroud to the unit with the eight Phillips head screws.
Elliptical
Edge
Service
Manual 2.5
Section 3
Diagnostics
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The Elliptical Edge contains several customizing and diagnostics features. The customizing feature allows you to
tailor unit operation to suit your particular needs. Diagnostics features let you view accumulated data related to ma-
chine usage, and check critical operating parameters as an aid
in
maintenance and troubleshooting.
These features include:
•
Diagnostic
LEOs -Provide and indication
of
the operating status
of
the Load Control Board (LCB) and the al-
ternator.
•
Display
Maintenance
Mode -Displays start-up and shut-down service messages as aresult
of
self-test
or
wh:m scheduled periodic maintenance is required.
•
Display
Settings
Mode
-Lets you modify certain operating and display settings for the unit.
•
Service
Settings
Mode
-Displays accumulated statistical data related to machine usage.
•
Service
Messages -Display during machine use ifcertain electrical failures
or
out-of-tolerance conditions are
detected.
•
System
Measurements
Mode
-Lets you monitor critical electrical parameters under both idle and in-use condi-
tions.
Contents
Diagnostic LEDs :................................................................................ 3.2
Display Maintenance Mode 3.3
Display Settings Mode 3.4
Service Settings Mode 3.6
Service Messages :............................................................................................................................................ 3.7
System Measurements Mode
_~.................................................................................................
3.8
Elliptical Edge Service Manual
3.1
DiagnosticLEDs
The Load Control Board (LCB) is equipped with three diagnostic LEOs. These LEOs provide indications
of
the operating status
of
the LCB and the alternator.
The LCB diagnostic LEOs function as follows:
LED FUNCTION
D2
This Led provides asteady series
of
flashes, at 20-per-second, indicating communication between the
LCB and the display panel is functional.
If
this LED
is
offor flashes erratically, replacement
of
the LCB,
the display panel
or
the communication cable may be required.
D3
This LED provides asteady series
of
flashes, at one-per-second, indicating the LCB microprocessor is
functional and the loop circuit is operating.
If
this LED is
off
or flashes erratically, replacement
of
the LCB
may be required.
D13 This LED is normally off.
If
alternator output voltage exceeds
19
volts, the LED lights steady on. This con-
dition will also cause the "Needs Service" message
to
display (see Display Maintenance Mode for details).
NOTE:
The
diagnostic LEOs provide a
general
indication
of
certain equipment malfunctions. Refer
to
Section
4,
Troubleshooting
to
aid
in
locating the mostlikely cause
of
the problem.
3.2 Elliptical Edge Service Manual
Display Maintenance Mode
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The Elliptical Edge displays start-up or shutdown service messages
if
adisplay code is detected during use, or when
periodic maintenance is due.
Service Messages at Start-up
The unit performs aself-test at the beginning
of
every workout. The self-test is initiated as soon as operation
of
the
unit begins, and continues throughout the duration
of
the workout.
If
afailure
in
an electronic circuit or component is
detected, one
of
the following messages will display:
Key Down One
or
more keys on the keypad(s) are stuck in the depressed (on) position; maintenance
service is required. Call Star Trac Customer Support for assistance.
Needs Service Self-test has detected
an
electronic component failure; maintenance service is required.
Call Star Trac Customer Support for assistance. Specific service messages describing the
equipment malfunction
or
failure can be accessed and viewed using the Service Settings
feature. Additional troubleshooting information is provided
in
Section 4.
Service Message at Shutdown
The Elliptical Edge displays a"Time for Service" message when aperiodic (preventive) maintenance procedure is
due. This message displays for
2-3
seconds at the end
of
aworkout session. Call Star Trac Customer Support for
assistance. Preventive maintenance procedures are outlined
in
Section
2.
Elliptical Edge Service Manual 3.3
Display
Settings
Mode
The Display Settings Mode lets you view and modify several unit settings, which affect the way the machine oper-
ates during aworkout. Use the keypad
to
enter the Display Settings Mode, view the current settings and make any
desired changes.
To enter the Display Settings Mode:
1. Press and hold the "Enter", "0" and "1" keys at the same time.
2
•.
While continuing to' hold the"Enter" and "0" keys; release the "1" key. The unit
will
beep once, and the message
"Display Settings" will show
in
the upper information display.
3. Release the "Enter" and "0" keys.
Once the unit is in the Display Settings Mode, use the keypad to select and enter changes to unit settings:
KEY FUNCTION
"Scroll" Key Press the "Scroll" key
to
scroll through the display settings and select the setting you wish to
view
or
change (for each setting, the current value is displayed
in
the upper information win-
dow). Pressing and holding the "Scroll" key will scroll continuously through the available set-
tings.
"Up-Down Arrow" Use the "Up-Down Arrow" keys to scroll through the available values for the setting and to se-
Keys lect anew value. When anew value for the setting has been selected, press the "Scroll" key to
save the new value and advance to the next setting.
NOTE:
To
return display settings
to
their original values afterchanges have been made and
saved, you must MANUALLYre-enter the factory-default settings.
"Enter" Key Press the "Enter" key to exit the Display Settings Mode and return to the standard operating
mode.
3.4 Elliptical Edge Service Manual
Display Settings Mode
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The following display settings may be changed using the keypad as previously described:
SETIING
DESCRIPTION DEFAULT VALUE
Maximum
Work
Time Sets the maximum workout time, in minutes. 60 minutes
Heart Rate Enables/disables the Polar heart rate pickup Polar
Units Sets the units display to English or Metric: English
•English -distance is displayed
in
tenths
of
amile; speed is
displayed in miles-per-hour; weight is displayed
in
pounds
•Metric -distance
is
displayed
in
tenths
of
akilometer; speed is
displayed
in
kilometers-per-hour; weight is displayed in kilo-
grams.
Weight Sets the weight displayed as default when apreset program is 155
selected. This value
is
adefault only; users are prompted to enter
their actual weight (used for calculating total calories burned).
NOTE: When setting metric units, weight must be set
at
70
kg.
Elliptical Edge Service Manual 3.5
Service Setting's·
The Elliptical Edge records and stores usage data which may be used as
an
aid
in
maintaining the unit and diag-
nosing malfunctions. The Service Settings Mode lets you view this usage data, as well as software version numbers
and the serial number and date
of
manufacture for the unit.
To
enter
the
Service Settings Mode:
1. Press and hold the "Enter", "0" and "2" keys at the same time.
2. While continuing to hold the "Enter" and "0" keys, release the "2" key.
The
unit will beep once, and the message
"Service Settings" will show
in
the upper information display.
3. Release the "Enter" and "0" keys.
Once the unit is
in
the Service Settings Mode, use the keypad to view service settings, service messages,
or
system
measurements:.
The following stored data may be viewed while
in
the Service Settings Mode:
ITEM DESCRIPTION
Display Version Version
of
software currently installed
in
the display.
LCB Version Version
of
software currently installed
in
the Load Control Board.
Serial# Serial number
of
the unit.
Manufacture Date Unit manufacture date (displayed as DDMMYY).
Workout Hours Total number
of
operating hours accumulated
on
the unit to date.
Workout Distance Total number
of
distance units accumulated
on
the machine to date. Distance units are
displayed
in
either miles or kilometers (depending on the "Units" selection (English
or
Met-
ric) chosen
in
"Display Settings".
Battery Hours Total number
of
hours the battery has been used under power (displayed
in
thousands
of
hours). Need to reset to zero when battery replaced.
Last Keystrokes Displays the last five keys pressed prior to asoftware or system failure.
3.6 Elliptical Edge Service Manual
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