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StarTrac Elliptical Edge, Service Manual

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Precautions

I N C . _

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

Summary of Contents for Elliptical Edge

Page 1: ...n 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 wil...

Page 2: ...and lists tools and materials required Section 2 Preventive Maintenance Schedules Outlines periodic preventive maintenance checks and services provides detailed procedures for specific maintenance ta...

Page 3: ...ocedure 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...

Page 4: ...nformation available 1 STAR TRAC model 2 STAR TRAC serial number 3 Problem statement symptom After Hours Voicemail Direct CALL TOLL FREE 1 800 486 4736 When placing a call please have the following in...

Page 5: ...ement 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...

Page 6: ...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...

Page 7: ...Elliptical Edge Overview JI I BYUNISEN INC _ 1i1IlC THIS INFORMATION TO BE PROVIDED UPON RECEIPT OF THEORY OF OPERATION SOURCE DATA AND BLOCK DIAGRAM Elliptical Edge Service Manual 1 7...

Page 8: ......

Page 9: ...maintenance normal wear and tear may cause cumulative effects such as misalign ment and early replacement of parts This section provides a list of factory recommended preventive maintenance requiremen...

Page 10: ...wire brush or any abrasive material to clean the skate rails or shuttle rollers IMPORTANT Regular cleaning of the skate rails and shuttle rollers is CRITICAL to proper op eration of the unit Accumula...

Page 11: ...nce of movement sideplay The shuttle rollers should fit snugly inside the skate rails 3 If excessive sideplay is noted realignment of the shuttle s is necessary Realign the shuttle s 1 Grasp the shutt...

Page 12: ...sion 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 Usin...

Page 13: ...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 inc...

Page 14: ......

Page 15: ...Mode Displays start up and shut down service messages as a result of self test or wh m scheduled periodic maintenance is required Display Settings Mode Lets you modify certain operating and display se...

Page 16: ...ble may be required D3 This LED provides a steady series of flashes at one per second indicating the LCB microprocessor is functional and the loop circuit is operating If this LED is off or flashes er...

Page 17: ...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 T...

Page 18: ...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 infor...

Page 19: ...English English distance is displayed in tenths of a mile speed is displayed in miles per hour weight is displayed in pounds Metric distance is displayed in tenths of a kilometer speed is displayed in...

Page 20: ...nts 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 c...

Page 21: ...cation failure has occurred between the upper display and the Load Control Board LCB Communications cable or LCB replacement may be required No Alternator Output The alternator is not producing an out...

Page 22: ...dicates a low battery charge or a damaged battery Output voltage above 7 7 volts indicates a fault in the Load Control Board Alternator Voltage Measures and displays alternator output voltage while th...

Page 23: ...eatures This section contains troubleshooting information for mechanical problems which may occur as a result of normal usage of the Elliptical Edge Troubleshooting information is presented in chart f...

Page 24: ...justment 1 Adjust the shuttle s eccentric roll movement or sideplay on skate ers see Shuttle Adjustment rail page 2 3 2 The shuttle rollers are worn 1 Adjust the shuttle s eccentric roll ers see Shutt...

Page 25: ...crank shaft screws see Crank Bearings Re placement page 5 22 Shuttle makes noise as it move 1 There is dirt or debris build up on 1 Clean the shuttle rollers see along skate rail the shuttle rollers...

Page 26: ......

Page 27: ...ot ing There are no parts which are to be replaced as a part of scheduled preventive maintenance Contents Display Panel Replacement 5 2 Communication Cable Replacement 5 3 Display Power Cable Replacem...

Page 28: ......

Page 29: ...cable from display panel connector J4 and the display power cable from display panel connector J7 by grasping and pulling the ca ble connectors 3 Remove the display panel Install the display panel 1...

Page 30: ...lips head screws from the front shroud 2 Lift the front shroud off the unit Disconnect the communication cable from the LeB 1 CAREFULLY disconnect the communication cable from LCB connector J1 by gras...

Page 31: ...communication cable should route smoothly and easily through the display neck DO NOT force the cable through the neck 3 Remove the tape and separate the new communication cable from the old communica...

Page 32: ...s head screws from the front shroud 2 Lift the front shroud off the unit Disconnect the display power cable from the LeB 1 CAREFULLY disconnect the display power cable from LCB connector J2 by graspin...

Page 33: ...display power cable should route smoothly and easily through the display neck DO NOT force the cable through the neck 3 Remove the tape and separate the new display power cable from the old display p...

Page 34: ...the cables from the LeB 1 CAREFULLY disconnect the following cables from the LCB by grasping and pulling the cable connectors See Diagram D Disconnect the battery cable from LCB connector J3 Disconnec...

Page 35: ...new cable harness and the red and black battery cables along the frame Use the 20 tie straps to secure the cable harness and battery cables to the frame at the locations noted during removal 2 Using...

Page 36: ...ccess to the LCB Remove the LeB 1 CAREFULLY disconnect the following cables from the LCB by grasping and pUlling the cable connectors See Diagram E Disconnect the communication cable from LCB connecto...

Page 37: ...curing the LCB upper bracket to the frame Install the bottom Phillips head screw securing the LCB lower bracket to the frame Tighten the three screws firmly DO NOT OVERTIGHTEN 2 CAREFULLY connect the...

Page 38: ...connectors 2 Using Phillips head screwdriver remove the two screws securing the battery to the frame remove the battery See Diagram F Diag F Install the battery 1 Position the new battery on the frame...

Page 39: ...shuttle completely forward on the skate rail 2 Using 3 16 in hex head socket wrench remove the four screws from underneath the shuttle securing the footpad to the shuttle Remove the footpad 3 Using 3...

Page 40: ...e two Allen screws engage the flats on the crank arm shaft STRIDE BELT PULLEY 5 o I NOTE You may need to adjust the shuttle to remove excess side play see Section 2 for details 5 13 7 Using 5 32 in Al...

Page 41: ...arm shaft as needed until the flats on the shaft are aligned with the holes in the crank arm 7 Using 5 32 in Allen wrench install the two Allen screws in the crank arm TIGHTEN THE SCREWS SECURELY 8 I...

Page 42: ...the rear shroud off the unit Remove the skate rail 1 Slide the shuttle completely forward on the skate rail 2 Using 3 16 in hex head socket wrench remove the four screws from underneath the shuttle se...

Page 43: ...EFULLY pull the belt tension anchor pin out from the belt tension pulley See Diagram M I I Diag M L REMOVE Diag L I I I REMOVE 8 Using 7 16 in hex head socket wrench and 3 16 in Allen wrench remove th...

Page 44: ...10 Using 1 2 in hex head socket wrench and 1 2 in open end wrench remove the front stride belt pulley and bolt from inside the skate rail See Diagram P ST OE BELT PULLEY o Diag P 11 Pull the stride b...

Page 45: ...belt pulley in the stride belt Using 1 2 in hex head socket wrench and 1 2 in open end wrench secure the front stride belt pulley to the skate rail with the bolt TIGHTEN THE SOLT SECURELY 10 Install...

Page 46: ...pin in the belt tension pulley through the loop in the stride belt Install the two cotter pins in the belt tension anchor pin 22 Place the footpad in position on the shuttle Using 3 16 in hex head soc...

Page 47: ...ove the rear shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the rear shroud 2 Lift the rear shroud off the unit Remove the stride belt 1 Using needle nose pliers C...

Page 48: ...remove the rear stride belt pulley and bolt from inside the skate rail See Diagram T Diag T 5 Using 3 16 in hex head socket wrench remove the four screws from underneath the shuttle securing the footp...

Page 49: ...ert the stride belt into the skate rail from the rear end and route the stride belt through the skate rail MAKE SURE the belt is straight when installed in the skate rail See Dia gramW Diag W 2 Instal...

Page 50: ...6 in hex head socket wrench and 3 16 in Allen wrench secure the belt guide bracket to the frame with the two bolts TIGHTEN THE BOLTS SECURELY 11 Slide the shuttle back along the skate rail and align t...

Page 51: ...ps head screwdriver remove the eight Phillips head screws from the rear shroud 2 Lift the rear shroud off the unit Remove the transmission assembly NOTE If needed GENTLY tap the transmission pulley wi...

Page 52: ...and GENTLY slide the alternator pulley and key off the transmission shaft BE CAREFUL not to lose the alternator pulley key See Diagram Y 3 Using 9 16 in hex head socket wrench and 9 16 in open end wr...

Page 53: ...EN THE ALLEN SCREWS 5 Insert the transmission assembly through the crank belt and position the transmission assembly in place on the frame MAKE SURE the crank belt is properly positioned on the transm...

Page 54: ...ar shroud 2 Lift the rear shroud off the unit Remove the skate rails from the crank arms 1 Using 5 32 in Allen wrench remove the two Allen screws from the crank arm 2 CAREFULLY slide the crank arm sha...

Page 55: ...rnal retainer ring pliers remove the two retainer rings from the grooves on the crank shaft 3 CAREFULLY remove the crank pulley and the two crank pulley keys from the crank shaft BE CAREFUL not to los...

Page 56: ...n screws to 34 in Ibs 7 Using 3 16 in Allen wrench tighten the two crank arm Allen screws securing the crank arms to the crank shaft to 80 in Ibs Re tention the transmission pulley 1 Using 9 16 in ope...

Page 57: ...llow block Allen screws to 34 in Ibs 7 Using 3 16 in Allen wrench tighten the two crank arm Allen screws securing the crank arms to the crank shaft to 80 in Ibs Re tention the transmission pulley 1 Us...

Page 58: ...4 N 25 110 1823 Nul Hex 1 2 13 X 5 16 LOCK NUT FOR ADJ 4 N 26 020 6057 Guide Shuttle Belt 2 N 27 130 1650 Idler El 1 N 28 020 6004 Adjustment Idler Slide et 1 N 29 110 3101 Bolt 3 8 16 X 2 0hhcs all T...

Page 59: ...Page 1a ET FRAME ASSY ell...

Page 60: ...n 8 Pos In line 1 N 7 721 0013 Assy Battery therm et 1 N 8 721 0032 Assy Batltherm 1 N 9 220 0155 Cable Ext Power mcb 1 N 10 721 0034 Assy Cable fitlinx et 1 N 11 140 0058 Tape Shielding die Cut 1 0 O...

Page 61: ...Page 2a ELECTRICAL KIT ET w o z...

Page 62: ...6025 Shroud Front b et 1 N 7 020 6071 Handelbar Rear Shroud et 1 N 8 N A 9 140 3132 Fastener U type 10 24 9 N 10 110 3106 Screws 10 24 X 1 5 Pphms 8 N 11 110 3108 Screw 5 16 18 X 1 00 Pphms 4 N 12 110...

Page 63: ...Page3a SHROUD KIT ET...

Page 64: ...Block 1 0 id 2 N 4 140 3144 Key 0 25 sq X 1 25 1 N 5 140 3145 Key 0 25 SqX 0 75 2 N 6 140 3147 Snap Ring 925id 2 N 7 110 3104 Bolt 1 4 20 X 75 Shes 2 N 8 110 3093 Screw 1 4 20x 25 set self Loc 2 N 9...

Page 65: ...Page 4a CRANK ASSY ET...

Page 66: ...1 Pillow Block 3 4 2 N 3 140 3146 Key 3 16 X 1 4 X 1 20 2 N 4 130 1639 Pulley 8j 6 0 Od X 75 Id 1 N 5 130 1640 Pulley 10j 1 230d X 75id 1 N 6 110 3093 Screw 1 4 20x 25 set selt Loc 1 N 7 110 3105 Scre...

Page 67: ...Page Sa Transmission Assy ET...

Page 68: ...02 Pcba Display lower eUcv 1 N 8 110 0020 Screw 4 40x1 4 Phil Pan 5 N 9 110 0250 Screw 6 32 X 1 2 Rhms 3 N 10 120 3002 Washer 6 5 N 11 120 3021 Standoff 8 32 X 1 125 m f 7 N 12 721 0027 Cable Disp Br...

Page 69: ...Page 6a EEDIS YKIT...

Page 70: ...racket Handrail attach et 2 N 6 110 3090 Screw 8 32 Hbhcs 8 N 7 110 3091 Screw 1 3 20x2 25 shcs 4 N 8 110 3092 Screw 5 16 18x 875 Bhscs 8 N 9 140 0054 Gasket Emi W adhesive Back 0 N 10 721 0010 Assy C...

Page 71: ...Page Sa RAIL ASSEMBLY KIT...

Page 72: ...1 Plate Capture belt et 1 N 6 020 6040 Plate Connecting belt et 1 N 7 130 1648 Belt Shuttle Rail et 1 N 8 110 1515 Bolt 5 16 18 X 1 75 1 N 9 110 1871 Nut 5 16 18 1 N 10 120 0480 Washer 5 16 18 Flat Cu...

Page 73: ...8 Pl 4 PER BRACKET 14 FOR UPPER BRACKET NOTSHOWN I 2 4 Pl 2 PER BRACKET 0 llJ Q CD D1 r z o r f m f...

Page 74: ......

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