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Section 1

Introduction

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

Содержание Elliptical Edge

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 14: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 26: ......

Страница 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...

Страница 28: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 63: ...Page3a SHROUD KIT ET...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 69: ...Page 6a EEDIS YKIT...

Страница 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...

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

Страница 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...

Страница 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...

Страница 74: ......

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