Star Trac 2000 series User manual

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STAR TRAC
SERVICE MANUAL
VERSION 1.0
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~Jr=I,BYUNISEN, INC._
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Copyright 1993, Unisen, Inc. All rights reserved, including those to reproduce this book or part
thereof
in any form without first obtaining written permission from Unisen, Inc.
Every effort has been made to keep the information current; however, periodically changes are made to
the information herein, and these changes will
be incorporated into new editions of this publication. All
product names and logos are trademarks
of their respective owners. Printed in the USA, 01093.
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FOR ADDITIONAL SUPPORT
Customer Service
Unisen, Inc.
14352 Chambers Road
Tustin, California 92680
Telephone: 714 I669 -1660
Fax: 714 I838 -6286
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Hotline Telephone:
Technical Assistance:
Sales Assistance:
800 I535 -4634
800 I503 - 1221
800 I228 -6635
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NOTE: For faster service, please have your STAR TRAC Model and Serial
Numbers available.

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ACKNOWLEDGEME TS
We wish to extend thanks to the entire STAR TRAC Customer
Service team for their support. And, aspecial thanks to Dennis Vega
and Sandy Sather for their valuable technical assistance.
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•CONTElVl'S
TABLE OF CONTENTS
PAGE NUMBER
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How TO USE TIllS MA AL 7
CHAPTER 0E: PREvE TlVE MAl TE A CE 9
DAILY 10
WEEKLY 11
BnNEEKLY 12
MONTI-U.Y 13
CHAPTER Two: DIAG OSTIC TEST 15
ACTIV AT GMOTOR TEsT MODE 16
ACTIVA TI GDlSPLAY TEsT MODE 25
CHAPTER THREE: TROUBLESHOOTI G ERROR CODES 27
SPEED ERRORS 28
ELEVATlO ERRORS 38
FS ERRORS 52
CPU ERRORS 55
No DISPLAY POWER 57
CHAPTER Fo R: I CREASING MECHA leAL UPTIME 59
Ru GBELT TROUBLESHOOTING 60
DRIVE MOTOR TROUBLESHOOTING 65
HEAD- AND TAll..ROLLER TROUBLESHOOTING 68
TREADMILL VmRA TIO TROUBLESHOOTING 69
TREADMll...L STATIC AND SHOCKING TROUBLESHOOTING 71

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CO!'ffENTS
PAG£ NUMBeR
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CHAPTER FIVE: REPLACEMENT PROCEDURES
72
DISPLAYCABLE
74
EMERGENCY STOP SWITCH
78
ELEVATION MOTOR
81
MOTOR BELT
85
ELEVATION SENSOR
87
LIMIT SWITCH
89
RPM SENSOR
92
MOTOR CONTROL BoARD
95
FLYWHEEL
98
MOTOR PULLEY
101
HANDRAILS 104
SUK DECK
106
RUNNING BELT
110
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ELEVATION CANS
115
INDEX 117
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How TO USE TIns MANuAL
This service manual is intended to assist in preventive maintenance, troubleshooting,
and replacing worn parts for the STAR TRAC 2000 and 3000 Series Treadmills.
STAR TRAC MODELS
2000P Series
~1~0
STAR TRAC Programmable
2000S Series STAR TRAC Simple
2000J Series
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\STAR TRAC Jogger
2000W Series STAR TRAC Walker
3000P Series STAR TRAC Programmable
3000S Series STAR TRAC Simple
3000J Series ST
AR TRAC Jogger
3000W Series ST AR TRAC Walker
In Chapter One: Preventive Maintenance, you will find the recommended
maintenance guide for your treadmill.
Keep~ng aregular preventive maintenance
schedule increases the treadmill uptime and runners' enjoyment.
In
Chapter Two: Diagnostic Test you will learn how to acti ate the Motor Test
Mode and Display Test Mode to prevent problems and service your treadmill.
Correcting problems and troubleshooting error codes are covered
in Chapter Three:
Troubleshooting Error Codes.
Chapter Four: Increasing Mechanical ptime provides hints and tips for preventing
and troubleshooting common mechanical problems.
Chapter Five: Replacement
Procedures details with text and illustrations how to replace the worn parts.
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Chapter Four: Increasing echanical Uptime provides hints and tips for preventing
and troubleshooting common mechanical problems. Chapter Five: Replacement
Procedures details with text and illustrations how to replace the worn parts.
DIRECTIO AL ORlE TATIO
The directions used in this manual are from the runner's viewpoint. The display panel
is the front
of the treadmill. The right, left and rear are as viewed by the runner.
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Front
Left
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STAR TRAC SERVICE MA UAL
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Right
Back
PAGE 8
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CHAPTER ONE:
PREVENTIVE MAINTENANCE
•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. In addition,
the more the treadmill is
in use, the stricter you should adhere to the preventive
maintenance schedule.
NOTE: If any unusual problems, such as error codes and blown circuit breakers,
occur, please refer to Chapter Three: Troubleshooting Error Codes.
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PAGE 9
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DAILY PREVENTIVE MAINTENANCE
You should perform the following maintenance on adaily basis.
•Use acloth and diluted all-purpose cleaner to remove any dust, dirt,
and other substances from the main part
of the treadmill. Wipe the
display panel, console, handrails, and motor cover. Avoid using cleaner
under the running belt.
•To ensure the longevity
of the running belt, clean under the running
belt with asoft, dry cloth.
To clean, slide the cloth between the running belt and the deck from
one side
of the frame to the other side. You may need aruler or rod to
slide towel under the running belt.
Then, holding the edges
of the cloth, pull the cloth from the headroller
to the tailroller.
NOTE: Do NOT clean the running belt by activating the treadmill. Do
NOT place feet or any weight on the running belt when cleaning the
treadmill.
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You should perform the following maintenance on aweekly basis.
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Check the running belt for alignment and tension.
NOTE: Do NOT automatically tighten the belt daily. For additional
infonnation on how to verify belt alignment
or correct abelt that has
slipped or mistracked, please refer to Chapter Four: Increasing
Mechanical Uptime.
Verify power cord is not under the treadmill. If the power cord is
placed under the treadmill, it may become pinched
or bind up the
elevation screws. This results
in error codes or treadmill damage.
WEEKL YPREVENTIVE MAINTENANCE
Elevate the treadmill and vacuum the floor under the treadmill. Be
careful not to bump the elevation switches as you sweep.
•Inspect the deck and running belt surfaces for unusual wear.
Check the deck for worn areas where the underlying fiber board
or soft
spots are visible. Inspect the underside center
of the running belt for a
worn, glazed appearance.
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PAGE 11
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•Walk on the deck surface.
If any portion feels soft, replace the deck.
NOTE: For information on replacing aworn deck or belt, please refer
to Chapter Five: Replacement Procedures. •
• If you have a3000 Series, check the subdeck and weardeck screws. If
loose, tighten them.
BIWEEKLY PREVENTIVE MAINTENANCE
You should perform the following maintenance biweekly or twice amonth basis.
•Vacuum around the motor and electronics by removing the shroud
cover and lifting the motor shroud.
Raise the motor shroud and suspend it from the display neck with the
bungie cord, from your STAR TRAC Treadmill Toolkit. Be sure to
avoid bumping or damaging the RPM disc and sensor, elevation sensor,
limit switches, and wire connections.
NOTE: To raise the motor shroud, use the Phillips screwdriver to
remove the screw in the motor shroud. Gently lift the motor shroud
up
the display handrail. Using the bungie cordfrom the STAR TRAC
Toolkit, hold the motor shroud at the top
of the display handrail.
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PAGE 12
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To replace the motor shroud, remove the bungie cord and Lower the
motor shroud until it touches the frame. Press the sides
of the motor
shroud to the frame and attach the
veLcro fasteners. Using the Phillips
screwdriver, tighten the screw in the center
of the motor shroud.
MONTHLY PREVENTIVE MAINTENANCE
You should perform the following maintenance once amonth.
•Lubricate the elevation screws with asilicon lubricant to prevent rust
accumulation.
•Activate Motor Test Mode and Display Test Mode of Diagnostic Test.
This will diagnose any unforeseen maintenance and error codes.
NOTE: For additionaL information on activating Diagnostic Test,
please refer to Chapter
Two: Diagnostic test.
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CHAPTER Two:
DIAGNOSTIC TEST
The STAR TRAC software program contains aself-diagnostic test mode that precisely
determines the reason for
an error. This chapter outlines how to activate Diagnostic
Test and diagnose the problem.
Diagnostic Test consists
of the Motor Test Mode and Display Test Mode. You will
use the test mode to check the motor, sensors (if they are working and calibrated),
and switches (if they are active and responding). The Display Test Mode checks the
keyboard response and
Quality of the LEDs. The Diagnostic Tests are the best
methods for determining specific failure areas
on the STAR TRAC treadmill.
Remember,
in Diagnostic test, you are in command. Pay attention to the display
panel. The LED lights and readouts show you the exact position and limits
of the
treadmill.
In this chapter, you will learn:
CONTENTS
ACTIVATING MOTOR TEST MODE
ACTIVATING DISPLAY TEST MODE
PAGE NUMBER
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25
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ACTIV ATING MOTOR TEST MODE OF DIAGNOSTIC TEST
Use the Motor Test Mode to check the motor, sensors (if they are working and
calibrated), and switches (if they are active and responding).
In addition, you may be
instructed to activate the Motor Test Mode during preventive maintenance
or
troubleshooting.
To activate Motor Test Mode, please follow these instructions.
If your treadmill does
not respond, please refer
to Chapter Four: Increasing Mechanical Uptime or
contact STAR TRAC customer service.
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Step One Tum the power switch
to the OFF position.
Place the treadmill into the Motor Test Mode.
Step Two
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If you have aJogger, Programmable, or Simple with number
keys, simultaneously press key number 8, while turning the
power switch
to ON. •
• If you have aWalker or Simple with no number keys,
simultaneously press the -(minus) key, while turning the power
switch
to ON.
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•Step Three Verify the display panel reads:
Verify the running belt
is not moving.
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If you have a2000 Series treadmill from 1990 or earlier, verify
the display panel reads:
If the running belt is not moving, proceed to the next step.
If the running belt begins moving, then:
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To raise the motor shroud, use the Phillips screwdriver
to remove the screw holding the motor shroud to the
frame. Gently raise the motor shroud up the display
handrail.
Using the bungie cordfrom the STAR TRAC
Toolkit, hold the motor shroud at the top
of the display
handrail.
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Step Four
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2
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•Adjust the
VR2 potentiometer, located on the motor
control board by using asmall, flat screwdriver to slowly
tum the screw on the VR2 potentiometer counter-
clockwise until the running belt quits moving. •
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Step Five Verify the threshold adjustment works correctly by increasing the speed
of the running belt.
•Press the +(Plus) key
or fast key to change the display readout
under Distance from 3to 18.
• If you have an older 2000 Series (1990 or earlier), press the fast
key to change the display readout under Distance from 2to 16.
NOTE: At this point, the belt should be moving slowly at approximately
one inch per second. Look
for a smooth. movement of the belt without
hesitation orjerking motions.
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