Star Trac 8 SERIES Reference manual

Service Bulletin
Page 1
637-4301 Rev. D
Rev. D
This document explains how to troubleshoot and resolve treadmill elevation
errors. Follow the steps below to assess where a potential issue may be hap-
pening.
As a user inclines the treadmill, the MCB sends VAC to power the elevation motor. The power being
sent depends on the input voltage (i.e. 110 VAC treadmills have a 110 VAC elevation motor and 220
VAC treadmills have a 220 VAC elevation motor). The MCB also sends 5 VDC to the elevation sensor
(potentiometer), mounted on the elevation motor, for positioning feedback.
Elevation related errors
• The “Elevation Stall”code is triggered by the display when the elevation motor has been commanded to move
but the display does not sense any movement.
• The “Elevation Lost” code is triggered by the display when there is no elevation motor detected.
• The “Elevation Range” code is triggered by the display when the elevation incline number is far below or above
the Elevation 0% and Elevation Max setting numbers.
• Embedded “Error 38” and “Error 41” is triggered when incline is out of range and “Error 42” is triggered when
incline is stuck.
Tools Required
• Phillips Head Screwdriver
• Multimeter
Warning: the following procedure requires the power to be on.
Please exercise caution when working around live electrical components
Treadmill Elevation Troubleshooting
Applies to: 8 Series, E-Series, and S-Series Treadmills

Service Bulletin
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637-4301 Rev. D
Incorrect Elevation Range Set In Console
1. Enter Maintenance Mode in the console and select Incline / Elevation Calibration.
New Parameters
Updated 1.05 Display software, for 8-series LCD displays and 1.6 Translator Board software, for E and
8-Series 15” Embedded displays, elevation parameters are outlined below:
8-TRx: 20% Elevation 8-TR: 15% Elevation
Min. Elevation 228 Min. Elevation 228
Max. Elevation 11 Max. Elevation 55
Old Parameters
Previous software revisions for E & S Series treadmill LED displays do not aect elevation parameters.
The old values are listed below:
E-TRx: 20% Elevation E-TR, S-TRc, S-TRx: 15% Elevation
Min. Elevation 230 Min. Elevation 230
Max. Elevation 38 Max. Elevation 70
Please note that the embedded console incline should not exceed 1024 at 0% elevation, or go below 25 at 20%.
If this is the case, verify the potentiometer Ohm range is set properly and re-run an incline calibration.
2. Exit out of the Incline / Elevation Calibration and Maintenance Mode. Test the treadmill for functionality.
Potentiometer out of Range (Error Code 38 & 41) Procedure
An Error Code 38 is an elevation range error. If the incline number, during elevation calibration, goes above 1024 at 0%
or below 25 at max incline, an error of code 38 will be displayed. When the treadmill is rebooted, it will boot right into
Error Code 38 and the Service Menu cannot be accessed.
1. Turn o the treadmill and remove the motor shroud so the
elevation motor is visible

Service Bulletin
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637-4301 Rev. D
2. Remove the screw holding the cap to the motor
3. Remove the cap to expose the elevation potentiometer (pot)
4. Unplug the elevation motor from the Motor Control Board
(MCB). Set the multi-meter to measure Ohms (Ω). Insert the
multi-meter leads; one in the orange wire, one in the blue
wire
5. Loosen the two screws holding the elevation pot.
a. If the unit is at max elevation, turn the pot count-
er-clockwise until the screws are completely to
the right side of the pot slots. Tighten the screws.

Service Bulletin
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637-4301 Rev. D
b. If the unit is stuck at 0% elevation, turn the pot
clockwise until the screw is completely to the left
side of the pot slots. Tighten the screws.
6. Check the multi-meter.
a. If the unit is at the max elevation, the value must be between 500-600 ohms.
b. If the unit is at 0%, the value must be between 9.4 – 9.5 k ohms.
7. If the pot is turned all the way to the right or left and the ohm values are not within the necessary range, go
to Step 8. If the values are within the range, go to Step 9..
8. Remove both screws holding the pot in place. Gently wiggle
the pot to pull it out. Once the pot is pulled out, gently turn
the center shaft of the pot to get the desired Ohm value.
9. Put the pot back in the motor. Be careful to not twist it. Once
the pot is in place, verify that the Ohm value is still in the
desired range. Install the two screws and tighten the pot in
place.

Service Bulletin
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637-4301 Rev. D
10. Turn the treadmill on. If the Error Code 38 does not appear,
go directly to the last step. If the Error Code 38 continues, use
the FISP Uploader to reinstall the translator board software.
(Connection shown)
Note: (E-TR & E-TRx Only) Ensure you are installing the prop-
er version of software for that model (see Service Bulletin:
637-1343). Installing the wrong version will cause the speed
calculation to be incorrect.
Once the translator board software has been uploaded,
reboot the treadmill.
11. Once the treadmill has booted up, enter the “Service Menu” to run the elevation calibration program. Once
complete, reinstall the elevation motor cap and motor shroud. The unit is now operational.

Service Bulletin
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637-4301 Rev. D
Elevation Stall Troubleshooting
1. Enter maintenance mode by pressing “0” + “2” +
“OK” at the same time.
2. Use the elevation buttons to scroll to “Elevation
Calibration” then press “OK”.
3. Use the elevation keys to raise/lower the unit. If the unit responds, power cycle the unit and see if error
reoccurs. If error happens again, or if the unit doesn’t move during this step, go on to the next step, otherwise
perform PM and make sure the elevation motor is lubricated.
4. Remove motor shroud. Verify the elevation LED’s
illuminate while raising or lowering. If lights do
not toggle, replace the Comm cable from lower
board to the display.

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637-4301 Rev. D
5. Check the fuses on the control board. If either are
damaged/blown, replace and retest.
6. Make sure the elevation screw is lubricated, and there are no obstructions preventing the frame from rising.
7. Verify the power to the elevation motor using a multimeter.
a. Place red meter probe in black wire
of pin 4 located at connector J5. Place
black meter probe to AC1 on the
MCB. At rest the voltage should read
either 110v or 220v (depending on
your model)
When pressing elevation down the
voltage should drop to 0v or 1v.
b. Place red meter probe in red wire of
pin 5 located at connector J5. Place
black meter probe to AC1 on the
MCB. At rest the voltage should read
either 110v or 220v (depending on
your model)
When pressing elevation down the
voltage should drop to 0v or 1v.

Service Bulletin
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637-4301 Rev. D
8. If voltage changes on meter, but elevation motor does not move, replace the elevation motor. If the voltage
does not change, replace the MCB.
Ribbon / Data Cable Damage
1. Power the treadmill o.
2. Ensure the ribbon / data cable is fully connected to the MCB and console. Disconnect and reconnect if neces-
sary.
3. Inspect the ribbon / data cable for any cuts, tears, or visible damage, power the machine on and test for func-
tionality.
4. Test for continuity for each pin on the cable.
5. Alternately, use a new or known-good ribbon / data cable, routed outside the machine from MCB to Console to
test for functionality.