Section 1 Introduction
Contents
1. STAR mur Section 1 MAC 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 STAR use INC NTE JARAC 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 a general overview ofthe 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 detaile2. 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 1 2 in open end wrench connect the following wires to the alternator terminals TIGHTEN THE WIRE CONNECTION SECURELY e Connect the two red wires to the alternator B terminal e Connect the black wire to the alternator E terminal e Connect the yellow wire to the alternator EXC terminal e Connect the white wire to the alternator P terminal e Connect the green wire to the alternator S terminal Connectthe cable harness to the LCB 1 CAREFULLY connect the following cables to the LCB MAKE SURE the connectors are properly aligned when reconnecting DO NOT force the connectors e Connect the battery cable to LCB connector J3 e Connect the alternator load resistor cable to LCB connector J4 e Connect the external power cable to LCB connector J5 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 STAR u INC MN Load Control Board Replacement SIRAC Tools Required Phillips head screwdriver Remove the front shroud panel 1 Using Phillips head screwdriver remove one Phillips head screw from the front shroud panel Remove the front shroud panel to gain access to the LCB Remove t
3. e System Measurements Mode Lets you monitor critical electrical parameters under both idle and in use condi tions Contents Diagn sti LEDS O o e treet 3 2 Display Maintenance Mode 3 3 Display Settings Mode 3 4 Service Settings Mode 3 6 Service Messages O 3 7 System Measurements Mode She Snarest 3 8 Elliptical Edge Service Manual 3 1 STAR INC M MAIC 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 a steady series of flashes at 20 per second indicating communication between the LCB and the display panel is functional If this LED is off or flashes erratically replacement of the LCB the display panel or the communication cable may be required functional and the loop circuit is operating If this LED is off or flashes erratically replacement of the LCB D3 This LED provides a steady series of flashes at one per second indicating the LCB microprocessor is may be required 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 ofcertain equipment malfunctions Refer to Section 4 Troubleshoot
4. 75id 6 110 3098 Screw 1 4 20x 25 setseltLloc N Screw 10 32x 25 set patch 99 721 0008 Assy Transmissionet aq Product Support Phn 800 503 1221 Revsion Date 3 12 99 Do Not Duplicate or Di 1 5 Transmission Assy ET ET 4600 STAR UN SEN INC _ TRAC DISPLAY KIT ET 020 6021 2 Housing Displaygreyet Ji nl 4 1050 1734 Keypad CentereUcv CN 6 715 3320 01 Peba Displayupperelev NI 8 1110 0020 Screw 4 40x1 4 Phil Pan 5 N 9 110 0250 Screw 6 32 X 1 2 Rhms 99 7 4600 MUS Kit DisplayeUcvusametGry 1 Y 99 7 4620 GUS Ki Disp poleUcvusagrey ily 99 7 4620 MUS Assy Display greY et 1 yY_ 99 7 4630 MUSj Kit Disp c p HreUcvusagy lily Product Support Phn 800 503 1221 Revsion Date 3 12 99 Page 6 Do Not Duplicate or Dir ut EE DISPLAY KIT N ET 4600 STAR UHISEN INC _ Page 7 TRAC NECK HANDRAIL KIT ET P ECC EA Ta 6 103080 sem 822 Hm Je T n E roses Seren 1petrs Bnscs fel gt 1an00s4 Gasket Emi Wadhesve Back ON Product Support Phn 800 503 1221 Revsion Date 3 12 99 Do Not Duplicate or Distribut RAIL ASSEMBLY KIT ET 4600 STAR UHISEN INC _ TRAC RAIA El 1 1721 0015 Weldment Raitt CN 6 020 6040 Plate Connectingbeltet a nl 8 110 1515 Bolt 5 16 18 X 1 75 if nl 9 14101871 Nutsie t8 Pip n Washer Lock 1 4 Split 99 721 00
5. Allen wrench secure the belt guide bracket to the frame with the two bolts TIGHTEN THE SOLTS SECURELY 18 Slide the shuttle back along the skate rail and align the four holes in the rear of the shuttle with the four holes in the capture plate 5 18 Elliptical Edge Service Manual Skate Rail Replacements NOTE lt may be nec essary to adjust stride belt tension following skate rail replacement see Section 2 for de tails NOTE You may need to adjust the shuttle to remove excess side play see Section 2 for details STAR Y UXISEN ING EN TRAC 19 Using 3 16 in hex head socket wrench secure the shuttle to the capture plate with the four screws TIGHTEN THE SCREWS SECURELY 20 Route the free end of the stride belt around the belt tension pulley and insert through the pulley opening 21 Insertthe belt tension anchor 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 socket wrench install the four Allen screws from underneath the shuttle to secure the footpad to the shuttle TIGHTEN THE SCREWS SECURELY Install the rear shroud 1 Install the rear shroud in position on the unit 2 Using Phillips head screwdriver secure the rear shroud to the unit with the eight Phillips head screws Install the front shroud 1 Install the front shroud i
6. as needed until the flats on the shaft are aligned with the holes in the crank arm Using 5 32 in Allen wrench install the two Allen screws in the crank arm TIGHTEN THE SCREWS SECURELY Elliptical Edge Service Manual ET 4600 STR UHtSEN INC _ TRAC ET FRAME assy 1 72100232 Frame Paintedets grey if nl 2 721 0002 Assy Cranket SANA Assy Roller rear et Assy Rail et 5 721 0003 Assy Transmission et 6 020 6051 Shaft Pulley tension Fer ven ep 8 020 6049 Spacer 1 Id X 1 5 Od X 161 2 o oroso spaces tuxtsooxzet fl 10 7020 6050 Shaft Beltcapture 2 20 110 1871 Nutsi6 18 1614 35 110 3097 Screw 1 4 20X2751 Shes_ 1 81 36 110 3098 Nut 1 4 20Nyloo 37 120 0410 Washer Flat 1 4 o doel 4 0206075 Wheel 2 000 X sad 2 e fico ESA EE IO NES 110 1515 Bolt 5 16 18 X 1 75 44 130 1647 Roller 312id X 1 10 Od X 80 as hets ave Push Cape tr el 46 1100477 Screw 1 4 20X 75hes af nl 4 110 3103 Bom 112 18X 20 nes n WASHER FLAT 1 2 X 10 X7 8 0 0 033 a al Eso 101820 Nut Heavy texte n3 a 51 120 2540 Washerlock3 8 CN I 53 110 3109 Screw 10 24x 5shes feln 54 1200350 Lock Washer 1 0 Split Jf af nl Page 1 ET FRAME ASSY FE ND LER SL SN SY ye EA ET 4600 Page 2 STR UN SEN ING TRAC ELECT KIT ET EDE rae ong A ENE 5 1103026 Sorew 10 2075 NT 6 240 6846 Conn 8 Pos
7. shaft key slots Using a straight edge ruler line up the crank belt with the transmission idler pulley by ad justing the position of the crank pulley on the crank shaft as needed Using 7 64 in Allen wrench tighten the two crank pulley Allen screws to 80 in Ibs Using 5 64 in Allen wrench tighten the two pillow block Allen screws to 34 in Ibs 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 open end wrench tighten the transmission idler tension bolt to increase crank belt tension Using belt tensioner gauge to check crank belt tension continue to tighten the transmis sion idler tension bolt to achieve 80 pounds tension e Ifa belt tensioner gauge is not available check the crank belt tension by pressing down hard on top ofthe 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 Once the correct crank belt tension is obtained tighten the transmission idler tension nut SECURELY using 9 16 in open end wrench Install the skate rails on the crank arms 1 Install one nylon washer on the crank arm shaft CAREFULLY insert the crank arm shaft through the skate rail then install the remaining nylon washer on the crank arm shaft Insert the crank arm shaft through the crank arm Rotate the crank arm shaft
8. 2 for details Install the shuttle 10 Slide the new shuttle on from the front of the skate rail Slide the shuttle along the skate rail and align the holes in the back of the shuttle with the holes in the captive plates Using 3 16 in hex head socket wrench secure the shuttle to the capture plates with the four screws TIGHTEN THE SCREWS SECURELY Install one nylon washer on the crank arm shaft CAREFULLY insert the crank arm shaft through the skate rail then install the remaining nylon washer on the crank arm shaft Insert the crank arm shaft through the crank arm Rotate the crank arm shaft as needed until the flats on the shaft are aligned with the holes in the crank arm Using 5 32 in Allen wrench install the two Allen screws in the crank arm TIGHTEN THE SCREWS SECURELY Install the front stride belt pulley through the stride belt and rail Using in socket head and a in open end wrench secure the front stride belt pulley to the skate rail with the bolt TIGHTEN THE SOLT SECURELY Insert the belt tension anchor pin in the belt tension pulley through the loop in the stride belt Install the two cotter pins in the belt tension anchor pin Place the footpad in position on the shuttle Using 3 16 in hex head socket wrench install the four Allen screws from underneath the shuttle to secure the footpad to the shuttle TIGHTEN THE SCREWS SECURELY Install the front shroud 1 2 Install the front shr
9. Allen wrench secure the display panel to the frame with the seven Allen screws Tighten the Allen screws firmly DO NOT OVERTIGHTEN Elliptical Edge Service Manual STAR UNISEN INC EE Communication Cable Replacement TRAC Tools and Materials Required Phillips head screwdriver 3 32 in Allen wrench Tape Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the front shroud 2 Lift the front shroud off the unit Disconnectthe communication cable from the LeB NOTE DO NOT pull on the wires when dis connecting the com munication cable from the LeB 1 CAREFULLY disconnect the communication cable from LCB connector J1 by grasping and pUlling the cable connector See Diagram 8 DISCONNECT JI Remove the display panel 1 Using 3 32 in Allen wrench remove the seven Allen screws from the back of the dispic panel BE SURE to support the display panel after the Allen screws have been removed Elliptical Edge Service Manual 5 3 STR UNISEX INC NENE Im lC Communication Cable Replacement NOTE Use one hand to support the display panel during removal NOTE DO NOT pull on the wires when dis connecting the cables from the display panel NOTE To prevent the display power cable from falling through the display neck opening tape the display power cable to the top ofthe display neck NOTE Use one hand to support the disp
10. Crank Bearings 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 Communication Cable Replacement Display Power Cable Replacement Tie Straps Cable Harness Replacement 1 6 Elliptical Edge Service Manual STAR iss INC Elliptical Edge Overview IMG THIS INFORMATION TO BE PROVIDED UPON RECEIPT OF THEORY OF OPERATION SOURCE DATA AND BLOCK DIAGRAM Elliptical Edge Service Manual 1 7 STAR mc Sec ticn 2 TRAC 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 a list 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 2 1 Elliptical Edge Service Manual oT RAC Preventive Maintenance Chart The Preventive Maintenance Chart lists the scheduled maintenance tasks for the Elliptical Edge The chart lists the time inter
11. Injine fa e 721 0032 Assy Batttherm mn o 220 0155 Cable ExtPowerimeb I m 12 140 0057 Tie Mount 3 4 w aomlic Adhes 6 m Product Support Phn 800 503 1221 Revsion Date 3 12 99 Do Not Duplicate or DistribL ET 4600 Page 3 STAR ING TRAC SHROUD KIT ET 1 72100232 Frame Pantecetsgrey lm a 020 5024 Shroud Frontaet ln 6 020 6025 Shroud Frontbet fn E OG o 140012 Fastener pe Woes fn io 110 3106 S rews i024Xisepnms en 1 110 3108 Seem 5116 18 x 1 00 Pphms IN Product Support Phn 800 503 1221 Revsion Date 3 12 99 Do Not Duplicate or Distribu Pagesa SHROUD KIT ET a STAR UHISEN INC _ TRAC CRANK ASSY ET mm Pillow Block 1 0 id 4 140 3144 Key 0 25 sq X 1 25 5 140 3145 Key 0 25 SqX 0 75 2 nl ET 4600 6 140147 Snap Ring od SS 7 1103104 Bok 1 4 20X 75 Shes 2 2 TNT e 110 3093 Screw 1 4 20x28 setseliloo 2 mn o 020 6001 Pulley Grankcast an os 721002 Assy crank Tan Product Support Phn 800 503 1221 Revsion Date 3 12 99 Page 4 Do Not Duplicate or Distrib CRANK ASSY ET ET 4600 STAR viser INC Page TRA TRANSMISSION ASSY ET Item Part Qt EHE 020 4621 Shaft Transmission et RARE 2 130 1651 Pillow Block 34 fN 3 1403146 Key 3 16 X 1 4 X 1 20 4 130 1639 Pulley 8j 6 0 Od X 751d Tt TN Pulley 10j 1 230d X
12. O 51 in tip diameter Remove the front 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 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 shaft and two nylon washers out of the skate rail BE CAREFUL not to lose the two nylon washers Remove the crank assembly 1 Using 9 16 in open end wrench loosen the transmission idler tension nut and bolt so the crank belt is completely loose 2 Using 3 16 in Allen wrench loosen the two crank arm Allen screws GENTLY slide the two crank arms and keys off of the crank shaft BE CAREFUL not to lose the crank arm keys See Diagram Al Elliptical Edge Service Manual ST EE Crank Bearings Replacement IRAC NOTE Ifnecessary GENTLY tap the crank pulley to aid in remov ing the crank pulley from the crank shaft NOTE Ifnecessary GENTLY tap the crank pulley keys into place with a rubber mallet Elliptical Edge Service Manual Loosen the crank belt from the crank pulley Using 9 16 in hex head socket wrench and 9 16 in open end wrench remove the four bolts washers and nuts securing the crank assembly to the frame CAREFULLY remove the crank assembly from the frame See Diagram 81 Disassemble the crank assembly Using 5 64 in Allen wrench loosen the All
13. Using Phillips head screwdriver secure the filler panel to the rear shroud with the four Phillips head screws 2 4 Elliptical Edge Service Manual STAR UNISEN INC MN Crank Belt Adjustment IRAC Tools Reguired Phillips head screwdriver 9 16 in open end wrench Belt tensioner gauge Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the front shroud 2 Lift the front shroud off the unit Check the crank belt tension 1 Using belt tensioner gauge check that crank belt tension is 80 pounds 2 Ifa belt 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 Ifcrank 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 e Ifa belt tensioner gauge is not available check the crank belt tension by pressing down hard on top of the belt midway between t
14. 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 3 Install the rear stride belt pulley in the stride belt Using 1 2 in hex head socket wrench and 1 2 in open end wrench secure the read stride belt pUlley to the skate rail with the bolt TIGHTEN THE SOLT SECURELY 4 Slide the shuttle forward on the skate rail until the shuttle rests against the front stride belt pulley 5 Using needle nose pliers CAREFULLY pull the section of the stride belt with the three Elliptical Edge Service Manual STAR un INC Stride Belt Replacement TRAC holes out through the access hole in the side of the skate rail 6 Assemble the capture plates on the stride belt aligning the holes in the capture plates with the holes in the stride belt 7 Using 1 8 in Allen wrench secure the capture plates to the stride belt with the three Allen screws Insert the stride belt and capture plate back inside the skate rail 8 Remove any extra slack from the stride belt by GENTLY pulling the stride belt out the rear ofthe skate rail MAKE SURE the stride belt is tight around both the front and rear stride belt pulleys 9 Insert the exposed end of the stride belt through the groove in the belt gUide bracket 10 Using 7 16 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 BOLT
15. key onto the transmission shaft Using 3 32 in Allen wrench tighten the two Allen screws on the alternator pulley Pull the alternator belt into place on the alternator pulley Re tension the transmission pulley 1 Using 9 16 in open end wrench tighten the transmission idler tension bolt to increase crank belt tension Using belt tensioner gauge to check crank belt tension continue to tighten the transmis sion idler tension bolt to achieve 80 pounds tension e Ifa belt 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 Once the correct crank belt tension is obtained tighten the transmission idler tension nut SECURELY using 1 2 in open end wrench Install the front shroud 1 2 Install the front shroud in position on the unit Using Phillips head screwdriver secure the front shroud to the unit with the eight Phillips head screws Elliptical Edge Service Manual T STAR vener INC EEE NOTE Remove ONLY ONE skate rail ata time 5 27 Crank Bearings Replacement Tools Required Phillips head screwdriver 9 16 in socket wrench 9 16 in open end wrench 7 64 in Allen wrench 5 64 in Allen wrench 3 16 in Allen wrench Rubber mallet Belt tensioner gauge External Retainer Ring Pliers 13 32 1 in with
16. 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 ofthe 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 STAR mswano Shuttle Alignment oI RAC 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 side play Tools Required Flat head screwdriver Check the shuttle alignment 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 If excessive side play 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
17. 15 Stride Belt Replacement 5 2 Transmission Bearings Replacement 5 24 Crank Bearings Replacement 5 27 Elliptical Edge Service Manual 5 1 TRAC NOTE Use one hand to support the display panel during removal NOTE DO NOTpull on the wires when dis connecting the cable from the display panel NOTE Use one hand to support the display panel during installa tion NOTE The cable con nectors are keyed to ent improper con ion 5 2 Display Panel Replacement Tools Required 3 32 in Allen Wrench Remove the display panel 1 3 Using 3 32 in Allen wrench remove the seven Allen screws from the back of the display panel BE SURE to support the display panel after the Allen screws have been removed CAREFULLY disconnect the communication cable from display panel connector J4 and the display power cable from display panel connector J7 by grasping and pulling the ca ble connectors Remove the display panel Install the display panel 1 Place the display panel in position on the unit BE SURE to support the display panel until the Allen screws have been installed CAREFULLY connect the communication cable and power cable to the display panel MAKE SURE the connectors are properly aligned when reconnecting DO NOT force the connectors e Connect the communication cable to display panel connector J4 e Connect the display power cable to display panel connector J7 Using 3 32 in
18. 16 AssyRalet fe n Product Support Phn 800 503 1221 Revsion Date 3 12 99 Page 8 Do Not Duplicate or Distrib BZ afeg 8 4 PER BRACKET 14 FOR UPPER BRAG NOT SHOWN E 13 114 TVYYONVH SEE DETAIL B
19. S SECURELY 11 Slide the shuttle back along the skate rail and align the four holes in the rear of the shuttle with the four holes in the capture plate 12 Using 3 16 in hex head socket wrench secure the shuttle to the capture plate with the four screws TIGHTEN THE SCREWS SECURELY 13 Route the free end ofthe stride belt around the belt tension pUlley and insert through the pulley opening 14 Insertthe belt tension anchor pin in the belt tension pUlley through the loop in the stride belt Install the two cotter pins in the belt tension anchor pin NOTE lt may be nec essary to adjust stride belt tension following belt replacement see Section 2 for details 15 Place the footpad in position on the shuttle Using 3 16 in hex head socket wrench install the four Allen screws from underneath the shuttle to secure the footpad to the shuttle TIGHTEN THE SCREWS SECURELY NOTE You may need to adjust the shuttle to remove excess side play see Section 2 for details Install the rear shroud 1 Install the rear shroud in position on the unit 2 Using Phillips head screwdriver secure the rear shroud to the unit with the eight Phillips head screws Elliptical Edge Service Manual 5 23 STAR Y UNISEN INC AN sIRAC Transmission Bearings Replacement NOTE Ifneedead GENTL Y tap the transmission pulley with a rubber mallet to remove from the ansmission shaft 5 24 Tools Required Phillips
20. assembly in place on the frame Using 9 16 in hex head socket wrench and 9 16 in open end wrench secure the crank assembly to the frame with the four bolts washers and nuts TIGHTEN THE NUTS SECURELY GENTLY slide the two crank arms onto the crank shaft aligning the key slots in the crank arm with the key slots in the crank shaft Insert the two crank arm keys into the crank shaft key slots Using a straight edge ruler line up the crank belt with the transmission idler pulley by ad justing the position of the crank pUlley on the crank shaft as needed Using 7 64 in Allen wrench tighten the two crank pulley Allen screws to 80 in Ibs Using 5 64 in Allen wrench tighten the two pillow block Allen screws to 34 in Ibs 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 Using 9 16 in open end wrench tighten the transmission idler tension bolt to increase crank belt tension Using belt tensioner gauge to check crank belt tension continue to tighten the transmis sion idler tension bolt to achieve 80 pounds tension Ifa belt 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 Once the correct crank belt tension is obtained tighten th
21. ator belt as needed NO PROCEDURE RECEIVED FOR ALTERNATOR BELT RETENSIONING Replace the alternator belt NO PROCEDURE RECEIVED FOR ALTERNATOR BELT RE PLACEMENT 4 2 Elliptical Edge Service Manual STAR ro INC MRE Crank Belt Adjustment TRAC SYMPTOM PROBABLE CAUSE SUGGESTED REMEDY Crank pulley makes excessive noise The crank pulley is loose on the 1 Tighten the crank pulley Allen during use crank shaft screws see Crank Bearings Re placement page 5 22 Shuttle makes noise as it move There is dirt or debris build up on Clean the shuttle rollers see along skate rail the shuttle rollers Preventive Maintenance Chart page 2 2 There is dirt or debris build up in Clean the skate rails see Pre the skate rail tracks ventive Maintenance Chart page 2 2 Elliptical Edge Service Manual 2 3 STAR mo Section 5 TRAC Parts Replacement This section contains parts replacement procedures for assemblies and components of the Elliptical Edge which are authorized for in field replacement Parts should be replaced ONLY when indicated by diagnosis and troubleshoot 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 53 Display Power Cable Replacement 5 5 Cable Harness Replacement 5 7 LCB Replacement 5 9 Battery Replacement 5 11 Shuttle Replacement 5 12 Skate Rail Replacement 5
22. ce Manual STAR u INC ME Tools and Materials ARAC The following tools and materials are required to perform adjustment and parts replacement proceudres for the Ellip tical Edge TOOUMATERIAL 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 STAR oa INC EEE IRNAC Tools and Materials
23. ck the al ternator output voltage e Pedal the unit at a speed above 1 5 miles per hour e Alternator output voltage should range between 11 5 13 5 volts Voltages outside this range indicate a fault in the Load Control Board Wall Power Measures and displays the voltage delivered to the unit from an optional external wall powered power pack while the unit is idle An acceptable power pack voltage will range between 11 0 18 0 voltage The power pack should be replaced ifthe voltage is outside this range Load Voltage Measures and displays the voltage generated across the workout loading resistor while the unit is in use To measure the load voltage Pedal the unit at a speed above 1 5 miles per hour Load voltage should range between 1 0 10 0 volts Voltages outside this range indi cate a fault in the Load Control Board A lower voltage indicates a high resistance which is normal 3 8 Elliptical Edge Service Manual STAR sn non Section 4 MAC Oo Troubleshooting The Elliptical Edge incorporates built in self test and diagnostic features which assist in diagnosing electrical system problems Section 3 Diagnostics contains the procedures for using these self test and diagnostic features This section contains troubleshooting information for mechanical problems which may occur as a result of normal usage ofthe Elliptical Edge Troubleshooting information is presented in chart form The Troubleshooting Chart identifies sympt
24. crank arm shaft and two nylon washers out of the skate rail BE CAREFUL not to lose the two nylon washers See Diagram Q Elliptical Edge Service Manual 5 17 STAR UNISEX INC MENS 1 IMG Skate Rail Replacement 14 CAREFULLY slide the skate rail off the frame by pushing the skate rail forward and off the front end 15 Slide the shuttle off of the skate rail Reinstall the skate rail 1 Slide the shuttle onto the skate rail 2 Slide the skate rail on from the front of the frame engaging the skate rail with the rollers attached to the rear of the frame 3 Install one nylon washer on the crank arm shaft CAREFULLY insert the crank arm shaft through the skate rail then install the remaining nylon washer on the crank arm shaft NOTE MAKE SURE 4 the two Allen screws engage the flats on the 5 Rotate the crank arm shaft as needed until the flats on the shaft are aligned with the crank arm shaft holes in the crank arm 6 Using 5 32 in Allen wrench install the two Allen screws in the crank arm TIGHTEN THE SCREWS SECURELY 7 Using 1 2 in hex head socket wrench secure the skate rail to the rear frame with two NOTE When installing bolts TIGHTEN THE SOLTS SECURELY the stride belt in the skate rail the punched 8 Insert the stride belt into the skate rail from the rear end and route the stride belt through Insert the crank arm shaft through the crank arm vesunthe belt face the skate rail MAKE SURE
25. d 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 a Symptom 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 STAR aos INC TRAC Precautions 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 TRAC Product Support Assistance PRODUCT SUPPORT DEPARTMENT STAR TRAC Product Support Department sets the industry standard in Customer Service and Technical Assis tance world wide Prov
26. d viewed from the Service Settings Mode To view Service Messages e On entering the Service Settings Mode press the S key while in service settings Service message will dis play in the upper information display e Press the Scroll key to view service messages if any have been set Pressing and holding the Scroll key will advance through all service messages e Press the Enter key to exit Service Messages and return to the Service Settings Mode The following service messages may be set by the self test function DEFINITION No Communication A communication 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 output voltage the unit will not provide a load workout to the user Alternator load resistor or alternator cable harness replace ment may be required Alternator Field Open The alternator field has an open circuit Alternator alternator cable harness or LCB replacement may be required No Load The alternator is working but the unit is not providing a load workout to the user Al ternator cable harness or LCB replacement may be required Low Battery The battery charge voltage is low This may be a result of low usage The battery can be recharged either by operating the machine by connecting the external wall powered power pack and the machine is in use for several h
27. e transmission idler tension nut SECURELY using 9 16 in open end wrench Install the skate rails on the crank arms Install one nylon washer on the crank arm shaft CAREFULLY insert the crank arm shaft through the skate rail then install the remaining nylon washer on the crank arm shaft Insert the crank arm shaft through the crank arm Rotate the crank arm shaft as needed until the flats on the shaft are aligned with the holes in the crank arm Using 5 32 in Allen wrench install the two Allen screws in the crank arm TIGHTEN THE SCREWS SECURELY Elliptical Edge Service Manual STR UXISEN INC ES 1 TRAC NOTE MAKE SURE the crank beltis prop erly positioned before tightening the crank pulley screws NOTE Install ONLY ONE skate rail ata time 5 29 5 Crank Bearings Replacement Using 5 64 in Allen wrench tighten the pillow block Allen screws just until snug against the crank shaft DO NOT OVERTIGHTEN THE SCREWS Install the crank assembly 1 Insertthe crank assembly through the crank belt and position the crank assembly in place on the frame Using 9 16 in hex head socket wrench and 9 16 in open end wrench secure the crank assembly to the frame with the four bolts washers and nuts TIGHTEN THE NUTS SECURELY GENTLY slide the two crank arms onto the crank shaft aligning the key slots in the crank arm with the key slots in the crank shaft Insert the two crank arm keys into the crank
28. en screws on the two pillow blocks GENTLY slide the two pillow blocks off of the crank shaft Using external retainer ring pliers remove the two retainer rings from the grooves on the crank shaft CAREFULLY remove the crank pulley and the two crank pulley keys from the crank shaft BE CAREFUL not to lose the two crank pulley keys Assemble the crank assembly 1 Install the crank pUlley on the crank shaft aligning the two keyways in the crank pulley with the keyways in the crank shaft GENTLY insert the two crank pulley keys into the crank shaft key slots DO NOT force the keys into place Using external retainer ring pliers install the two retainer rings in the grooves on the crank shaft on either side of the crank pulley Install the two pillow blocks on the crank shaft with the Allen screws facing outward to ward the ends of the crank shaft MAKE SURE the Allen screws in the pillow blocks align with the flats on the crank shaft 5 28 STAR Y UNISEN INC HE IRAC NOTE MAKE SURE the crank belt is prop erly positioned before tightening the crank pulley screws NOTE Install ONLY ONE skate rail ata time 5 29 1 1 1 Crank Bearings Replacement 5 Using 5 64 in Allen wrench tighten the pillow block Allen screws just until snug against the crank shaft DO NOT OVERTIGHTEN THE SCREWS Install the crank assembly Insert the crank assembly through the crank belt and position the crank
29. eplacement Using 3 32 in Allen wrench loosen the Allen screws in the transmission shaft pillow blocks and gently slide the pillow blocks of the transmission shaft Using 3 32 in Allen wrench loosen the Allen screw or the transmission idler pUlley and gently slide the transmission idler pulley of the transmission shaft BE CAREFUL not to lose the transmission idler pulley key Install the transmission assembly 1 Install the transmission idler pulley key on the transmission shaft then GENTLY slide the transmission idler pulley onto the transmission shaft Using 3 32 in Allen wrench tighten the Allen screw on the transmission idler pulley firmly DO NOT OVERTIGHTEN THE ALLEN SCREW Install the two pillow blocks on the transmission shaft with the Allen screws facing out ward toward the ends ofthe transmission shaft MAKE SURE the Allen screws in the pillow blocks align with the flats on the transmission shaft Using 3 32 in Allen wrench tighten the pillow block Allen screws firmly DO NOT OVERTIGHTEN THE ALLEN SCREWS 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 transmission idler pulley Using 9 16 in hex head socket wrench and 9 16 in open end wrench secure the trans mission assembly to the frame with the four bolts and nuts TIGHTEN THE NUTS SECURELY GENTLY slide the alternator pUlley and
30. ex head socket wrench remove the four screws from underneath the shuttle securing the footpad to the shuttle Remove the footpad 6 Using 3 16 in hex head socket wrench remove the four screws at the rear of the shut tle securing the shuttle to the capture plates 7 Using needle nose pliers CAREFULLY pull the section ofthe stride belt containing the capture plates out through the access hole in the side of the skate rail Elliptical Edge Service Manual 5 21 STAR unex INC _ eI RAC NOTE When installing the stride belt in the skate rail the punched holes in the belt face up the arrows point to the rear ofthe skate rail 5 22 Stride Belt Replacement 8 Using 1 8 in Allen wrench remove the three Allen screws from the top capture plate and separate the capture plates from the stride belt See Diagram U POINTS TOWARD FRONT OF WELDED RAIL 9 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 V STRIDE BELT PULLEY 10 Pull the stride belt out through the back of the skate rail Install the stride belt 1 Insertthe 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 Y YA Diag W 2 Install the front stride belt pUlley in the stride belt Using 1 2 in
31. eys 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 wenn O O 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 a software or system failure 3 6 Elliptical Edge Service Manual STAR UNISEN INC IMA K Service Messages IMG The Elliptical Edge self test function monitors the electronics while a workout is in progress If a malfunction or failure in a monitored circuit occurs during a workout the Needs Service message displays as described in Display Maintenance Mode and a specific service message is set Service message can be accessed an
32. f the shut tle securing the shuttle to the capture plates 4 Using needle nose pliers CAREFULLY pull the two cotter pins out from the belt tension pulley at the rear of the unit See Diagram G 5 Using needle nose pliers CAREFULLY pull the belt tension anchor pin out from the belt tension pulley See Diagram H Elliptical Edge Service Manual 5 12 STAR ue INC RR IRAC Shuttle Replacement a Fe NOTE Adjust the posi tion ofthe skate rail as E needed to allow removal 6 Using 1 2 in hex head socket wrench and 1 2 in open end wrench remove the front ofthe crank arm shaft stride belt pulley and bolt from inside the skate rail See Diagram I STRIDE BELT PULLEY NOTE MAKE SURE the two Allen screws engage the flats on the crank arm shaft NOTE You may need to adjust the shuttle to remove excess side play see Section 2 for details 7 Using 5 32 in Allen wrench remove the two Allen screws from the crank arm See Dia gram J 5 CAREFULLY slide the crank arm shaft and two nylon washers out of the skate rail BE CAREFUL notto lose the two nylon washers 6 Slide the shuttle forward and off of the skate rail 5 13 Elliptical Edge Service Manual STAR UNISEN INC M Shuttle Replacement oI RAC NOTE MAKE SURE the two Allen screws engage the flats on the crank arm shaft NOTE You may need to adjust the shuttle to remove excess side play see Section
33. he Allen screws firmly DO NOT OVERTIGHTEN Connectthe communication cable to the LCB 1 CAREFULLY connect the communication cable to LCB connector J1 MAKE SURE the connector is properly aligned when reconnecting DO NOT force the connector 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 STR UNISEN INC MEN Display Power Cable Replacement o TRAC NOTE DO NOT pull on the wires when dis connecting the com munication cable from the LeB Tools and Materials Required Phillips head screwdriver 3 32 in Allen wrench Tape Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips 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 grasping and pulling the cable connector See Diagram C DISCONNECT J2 Remove the display panel 1 Using 3 32 in Allen wrench remove the seven Allen screws from the back of the disp panel BE SURE to support the display panel after the Allen screws have been removi Elliptical Edge Service Manual 5 5 STAR UNISEX INC EM TRA 0 NOTE Use one hand to support the display panel during removal NOTE DO NOT pull o
34. he LeB NOTE DO NOT pull on the wires when dis connecting the cables from the LeB 1 CAREFULLY disconnect the following cables from the LCB by grasping and pUlling the cable connectors See Diagram E e Disconnect the communication cable from LCB connector J 1 e Disconnect the display power cable from LCB connector J2 e Disconnect the battery cable from LCB connector JS e Disconnect the alternatorlload resister cable from LCB connector J4 e Disconnect the external power cable from the connector J5 e Disconnect the Fitlinxx cable from LCB connector J6 Elliptical Edge Service Manual 5 9 STAR BY UNISEX ING INMI TRAC NOTE Use one hand to support the LCa when removing the bottom Phillips head screw from the LCa NOTE Use one hand to support the LCa while installing the three Phillips head screws NOTE The cable connectors are keyed to prevent improper con nection 5 10 Load Control Board Replacement 2 Using Phillips head screwdriver remove the two top Phillips head screws securing the LCB to the frame 3 Using Phillips head screwdriver remove the bottom Phillips head screw securing the LCB to the frame Remove the LCB Install the LeB 1 Support the new LCB in position on the frame Using Phillips head screwdriver install the top two Phillips head screws securing the LCB upper bracket to the frame Install the bottom Phillips head screw securing the LCB lower bracket to
35. he new battery on the frame Using Phillips head screwdriver install the two Phillips head screws through the battery to secure the battery to the frame TIGHTEN THE SCREWS FIRMLY 2 Connect the lead wires to the battery NOTE When installing the battery make sure the negative termi nal is positioned at the top e Connect the black lead wire to the top battery terminal marked e Connect the red lead wire to the bottom battery terminal marked 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 Philli head screws Elliptical Edge Service Manual 5 11 Shuttle Replacement NOTE Remove and install ONL Y ONE shuttle ata time STAR UNISEN INC el RAC Tools Required Phillips head screwdriver Needle nose plier Flat head screwdriver in Hex head socket 3 16 in socket wrench 5 32 in Allen wrench Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the front shroud 2 Lift the front shroud off the unit Remove the shuttle 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 securing the footpad to the shuttle Remove the footpad 3 Using 3 16 in hex head socket wrench remove the four screws at the rear o
36. he 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 STAR Section 3 RAC Oo Diagnostics 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 a result of self test or when scheduled periodic maintenance is required e 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 e Service Messages Display during machine use if certain electrical failures or out of tolerance conditions are detected
37. head screwdriver 9 16 in socket wrench 9 16 in open end wrench 3 32 in Allen wrench Rubber mallet Belt tensioner gauge Remove the front 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 transmission assembly 1 Using 9 16 in open end wrench loosen the transmission idler tension nut and bolt so the crank belt is completely loose See Diagram X LOOSEN LOOSEN Elliptical Edge Service Manual STAVA use nc mem Transmission Bearings Replacement TRAC 2 Loosen the alternator belt from the transmission pulley Using 3 32 in Allen wrench loosen the two Allen screws on the alternator pulley and GENTLY slide the alternator pulley and key off the transmission shaft BE CAREFUL not to lose the alternator pulley key See Diagram Y LOOSEN 3 Using 9 16 in hex head socket wrench and 9 16 in open end wrench remove the four bolts and nuts securing the transmission shaft pillow blocks to the frame CAREFULLY remove the transmission assembly from the frame See Diagram Z Elliptical Edge Service Manual 5 25 STR UNISEX ING BE 0 NOTE Support the free end ofthe crank belt to keep it from fal ling inside the frame NOTE Ifneeded back offthe transmis sion idler tension nut to allowproper adjust ment ofthe transmis sion idler pulley 5 26 4 Transmission Bearings R
38. iding superior product support and customer service is at the very heart of STAR TRAC s business philosophy This commitment to service has been a major contributor to STAR TRAC s success and growth in the worldwide fitness equipment industry Technical Assistance When purchasing a part 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 a call please have the following information available 1 STAR TRAC model 2 STAR TRAC serial number 3 Problem statement symptom After Hours Voicemail Direct e CALL TOLL FREE 1 800 486 4736 When placing a call 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 STAR TRAC model STAR TRAC serial number Problem statement symptom Return phone fax number and contact name Purchase order or reference number Part description and quantity Ship to bill to NO a Fo N gt 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 a list of Product Sup port Procedures and Bulletins 1 4 Elliptical Edge Servi
39. ing to aid in locating the most likely cause ofthe problem 3 2 Elliptical Edge Service Manual STAR sen INC MAG Display Maintenance Mode o The Elliptical Edge displays start up or shutdown service messages if a display code is detected during use or when periodic maintenance is due Service Messages at Start up The unit performs a self test at the beginning of every workout The self test is initiated as soon as operation ofthe unit begins and continues throughout the duration of the workout If a failure 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 a periodic preventive maintenance procedure is due This message displays for 2 3 seconds at the end of a workout session Call Star Trac Customer Support for assistance Preventive maintenance procedures are outlined in Sec
40. lay a during instal a NOTE The cable connectors are keyed to prevent improper connection NOTE The cable connectoris keyed to prevent improper con nection 5 4 2 CAREFULLY disconnect the communication 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 communication cable 1 Tape one end of the new communication cable to the bottom LCB end of the old com munication cable 2 Using the old communication cable as a routing guide GENTLY pull the new communi cation cable up through the display neck The 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 communication cable Install the display panel 1 Place the display panel in position on the unit BE SURE to support the display panel until the Allen screws have been installed 2 CAREFULLY connect the communication cable and power cable to the display panel MAKE SURE the connectors are properly aligned when reconnecting DO NOT force the connectors e Connect the communication cable to display panel connector J4 e Connect the display power cable to display panel connector J7 3 Using 3 32 in Allen wrench secure the display panel to the frame with the seven Allen screws Tighten t
41. n position on the unit 2 Using Phillips head screwdriver secure the front shroud to the unit with the eight Phillip head screws Elliptical Edge Service Manual 5 19 STAR us INC HR IRAC Stride Belt Replacement NOTE Remove and install ONL YONE stride belt ata time 5 20 Tools Required Phillips head screwdriver 7 16 in socket or open end wrench 1 2 in socket wrench 1 2 in open end wrench 3 16 in Allen wrench 1 8 in Allen wrench Needle nose pliers Remove 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 CAREFULLY pull the two cotter pins out from the belt tension pulley at the rear of the unit 2 Using needle nose pliers CAREFULLY pull the belt tension anchor pin out from the belt tension pulley See Diagram R Elliptical Edge Service Manual Stride Belt Replacement STAR UNISEN INC NR 3 Using 7 16 in hex head socket wrench and 3 16 in Allen wrench remove the top two bolts from the belt guide bracket Once the bolts are removed CAREFULLY dislodge the stride belt from the groove in the guide bracket See Diagram Se FRONT VIEW 4 Using 1 2 in hex head socket wrench and 1 2 in open end wrench remove the rear stride belt pulley and bolt from inside the skate rail See Diagram T 5 Using 3 16 in h
42. n the wires when dis connecting the cables from the display panel NOTE To prevent the communication cable from falling through the display neck opening tape the communica tion cable to the top of the display neck E Use one hand support the display panel during installa tion NOTE The cable connectors are keyed to prevent improper connection NOTE The cable connector is keyed to prevent improper con nection 5 6 Display Power Cable Replacement 2 CAREFULLY disconnect the communication 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 power cable 1 Tape one end of the new display power cable to the bottom LCB end of the old display power cable 2 Using the old display power cable as a routing guide GENTLY pull the new display power cable up through the display neck The 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 power cable Install the display panel 1 Place the display panel in position on the unit BE SURE to support the display panel until the Allen screws have been installed 2 CAREFULLY connect the communication cable and power cable to the display panel MAKE SURE the connectors are p
43. oms of problems which may occur lists the most probable cause s for the problem and provides suggested remedies to return the unit to operating condition Contents Troubleshooting Chart 42 Elliptical Edge Service Manual 4 1 TRAC SYMPTOM Shuttle is loose forward and back ward movement on skate rail Shuttle is loose up and down movement or sideplay on skate rail Front of skate rail falls rapidly with little or no resistance Troubleshooting Chart PROBABLE CAUSE The stride belt is worn or has stretched The clutch bearing is slipping The shuttle out of adjustment The shuttle rollers are worn The crank belt is loose or worn The alternator belt is loose or worn SUGGESTED REMEDY Adjust the stride belt tension see Stride Belt Adjustment page 2 4 Replace the stride belt see Stride Belt Replacement page 5 18 Replace the transmission as sembly see Transmission Bear ings Replacement page 5 20 Replace the transmission shaft see Transmission Bearings Re placement page 5 20 Adjust the shuttle s eccentric roll ers see Shuttle Adjustment page 2 3 Adjust the shuttle s eccentric roll ers see Shuttle Adjustment page 2 3 Replace the shuttle see Shuttle Replacement page 5 13 Re tension the crank belt as needed see Crank Belt Adjust ment page 2 5 Replace the crank belt NO PROCEDURE RECEIVED FOR CRANK BELT REPLACEMENT Retension the altern
44. oud in position on the unit Using Phillips head screwdriver secure the front shroud to the unit with the eight Phillips head screws Elliptical Edge Service Manual 5 14 STAR us INC EE Skate RaiLReplacement el RAC Tools Required Phillips head screwdriver 7 16 in socket wrench 1 2 in socket wren 1 2 in open end wrench 3 16 in Allen wrench 5 32 in Allen wrench 1 8 in Allen wrench Needle nose pliers NOTE Remove and instafl ONLY ONE skate rail ata time Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the front shroud 2 Lift the front shroud off the unit Remove 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 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 securing the footpad to the shuttle Remove the footpad 3 Using 3 16 in hex head socket wrench remove the four screws at the rear of the shut tle securing the shuttle to the capture plates 4 Using needle nose pliers CAREFULLY pull the section ofthe stride belt containing the capture plates out through the access hole in the side of the skate rail 5 Using 1 8 in Allen wrench remove the three Allen screws from the top ca
45. ours With the machine not in use the recharging ofthe battery will take 24 hours to reach full charge NOTE Ifthe Low Battery message is set frequently battery replacement or charging system service may be required Elliptical Edge Service Manual 3 7 TRAC System Measurements Mode The System Measurements Mode leis you measure critical voltages in the battery alternator circuits under both idle and operating conditions To enter the System Measurements Mode e On entering the Service Settings Mode press the 8 key while in service settings Measurements will dis play in the upper information display e Press the Scroll key to view the system measurements available e Press the Enter key to exit the System Measurements Mode and return to the Service Settings Mode Once the unit is in the System Measurements Mode use the Arrow Keys to select the desired system measure ment The following voltage measurements may be taken while in the System Measurements Mode MEASUREMENT DESCRIPTION Battery Voltage Measures and displays battery output voltage while the unit is idle Output voltage for a normal battery should range between 6 2 7 7 volts e Output voltage below 6 2 volts indicates a low battery charge or a damaged battery e Output voltage above 7 7 volts indicates a fault in the Load Control Board Alternator Voltage Measures and displays alternator output voltage while the unit is in use To che
46. pture plate and separate the capture plates from the stride belt See Diagram K POINTS TOWARD FRONT OF WELDED RAIL Elliptical Edge Service Manual 5 15 IRAC Skate Rail Replacement 6 Using needle nose pliers CAREFULLY pull the two cotter pins out from the belt tension pulley at the rear ofthe unit See Diagram L 7 Using needle nose pliers CAREFULLY pull the belt tension anchor pin out from the belt tension pulley See Diagram M REMOVE m 8 Using 7 16 in hex head socket wrench and 3 16 in Allen wrench remove the top two bolts from the belt guide bracket Once the bolts are removed CAREFULLY dislodge the stride belt from the groove in the guide bracket See Diagram N 5 16 Elliptical Edge Service Manual STAR UNISEN INC ME s IRAC Skate Rail Replacement o 9 Using 1 2 in hex head socket wrench and 1 2 in open end wrench remove the rear stride belt pulley and bolt from inside the skate rail See Diagram O T Diag O 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 STRIDE BELT PULLEY Diag P NOTE Adjust the posi tion ofthe skate rail as 11 Pull the stride belt out through the back ofthe skate rail needed to allow re 5 movalofihe Crank anh 12 Using 5 32 in Allen wrench remove the two Allen screws from the crank arm shaft 13 CAREFULLY slide the
47. roperly aligned when reconnecting DO NOT force the connectors e Connect the communication cable to display panel connector J4 e Connect the display power cable to display panel connector J7 3 Using 3 32 in Allen wrench secure the display panel to the frame with the seven Allen screws Tighten the Allen screws firmly DO NOT OVERTIGHTEN Connect the display power cable to the LCB 1 CAREFULLY connect the display power cable to LCB connector J2 MAKE SURE the connector is properly aligned when reconnecting DO NOT force the connector 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 STAR UNISEN INC EE Cable Harness Replacement IRAC NOTE DO NOT pull on the wires when discon necting the cables from the LeB Tools Required Phillips head screwdriver 1 2 in open end wrench Needle nose clippers Tie straps 20 req d Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the front shroud 2 Lift the front shroud off the unit Disconnect the cable harness from the LeB 1 CAREFULLY disconnect the following cables from the LCB by grasping and pulling the cable connectors See Diagram D e Disconnect the battery cable from LCB connector JS e Disconnect the alternatorlload resis
48. the belt is straight when installed in the skate rail p the arrows point to e rearofthe skate 9 Install the front stride belt pulley in the stride belt Using 1 2 in hex head socket wrench rall 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 the rear stride belt pulley in the stride belt Using 1 2 in hex head socket wrench and 1 2 in open end wrench secure the read stride belt pulley to the skate rail with the bolt TIGHTEN THE SOLT SECURELY 11 Slide the shuttle forward on the skate rail until the shuttle rests against the front stride belt pulley 12 Using needle nose pliers CAREFULLY pull the section of the stride belt with the three holes out through the access hole in the side of the skate rail 13 Assemble the capture plates on the stride belt aligning the holes in the capture plates with the holes in the stride belt 14 Using 1 8 in Allen wrench secure the capture plates to the stride belt with the three Allen screws Insert the stride belt and capture plate back inside the skate rail 15 Remove any extra slack from the stride belt by GENTLY pulling the stride belt out the rear of the skate rail MAKE SURE the stride belt is tight around both the front and rear stride belt pulleys 16 Insert the exposed end of the stride belt through the groove in the belt guide bracket 17 Using 7 16 in hex head socket wrench and 3 16 in
49. the frame Tighten the three screws firmly DO NOT OVERTIGHTEN 2 CAREFULLY connect the following cables to the LCB MAKE SURE the connectors are properly aligned when reconnecting DO NOT force the connectors e Connect the communication cable to LCB connector J1 e Connect the display power cable to LCB connector J2 Connect the battery cable to LCB connector J3 e Connect the alternator load resistor cable to LCB connector J4 e Connect the external power cable to LCB connector J5 Connect the Fitlinxx cable to LCB connector J6 Install the front shroud panel 1 Position the front shroud panel on the front shroud 2 Using Phillips head screwdriver secure the front shroud panel to the front shroud with one Phillips head screw Elliptical Edge Service Manual STAR UNISEN INC ZI s C Battery Replacement Tools Required Phillips head screwdriver Remove the front shroud 1 Using Phillips head screwdriver remove the eight Phillips head screws from the front shroud 2 Lift the front shroud off the unit Remove the battery NOTE DO NOT pull on the wires when dis connecting from the battery 1 CAREFULLY disconnect the black and red lead wires from the battery terminals by grasping and pulling the wire connectors 2 Using Phillips head screwdriver remove the two screws securing the battery to the frame remove the battery See Diagram F Install the battery 1 Position t
50. tion 2 Elliptical Edge Service Manual 3 3 STAR UNISEN INC INN of RAC Display Settings Mode The Display Settings Mode lets you view and modify several unit settings which affect the way the machine oper ates during a workout 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 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 a new value When a new 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 after changes have been made and sa
51. tor cable LCB connector JA e Disconnect the external power cable LCB connector J5 Disconnect the cable harness from the alternator 1 Using 1 2 in open end wrench disconnect the following wires from the alternator termi nals e Disconnect the two red wires from the alternator B terminal e Disconnect the black wire from the alternator E terminal Elliptical Edge Service Manual 5 7 0 STAR Y UNISEN INC INN NOTE Note the loca tion ofthe 20 tie straps to aid in reinstallation NOTE The cable connectors are keyed to prevent improper connection 5 8 Cable Harness Replacement e Disconnect the yellow wire from the alternator EXC terminal e Disconnect the white wire from the alternator P terminal e Disconnect the green wire from the alternator S terminal 2 Using needle nose clippers cut and remove the 20 tie straps securing the cable harness to the frame remove the cable harness 3 Separate the red and black battery cables from the cable harness Remove the load resistor 1 Using Phillips head screwdriver remove the two Phillips head screws securing the load resistor to the frame remove the load resistor Install the load resistor 1 Using Phillips head screwdriver secure the new load resistor to the frame with two Phil lips head screws TIGHTEN THE SCREWS SECURELY Connectthe cable harness to the alternator 1 Reroute the new cable harness and the red and black
52. val 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 HOP PROCEDURE Clean dust and dirt from the unit using a soft clean cloth dampened with a non 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 a soft clean cloth and a non abrasive liquid cleaner If needed remove stubborn accumulations by scrubbing with a soft bristle brush such as a toothbrush NEVER use a wire brush or any abrasive material to clean the skate rails or shuttle rollers IMPORTANT Regular cleaning ofthe skate rails and shuttle rollers is CRITICAL to proper op eration ofthe unit Accumulations ofdust 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
53. ved you must MANUALLY re enter the factory default settings Enter Key Press the Enter key to exitthe Display Settings Mode and return to the standard operating mode 3 4 Elliptical Edge Service Manual STAR ne Display Settings Mode TRAC The following display settings may be changed using the keypad as previously described SETIING DESCRIPTION DEFAULT VALUE Enables disables the Polar heart rate pickup Sets the units display to English or Metric English e 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 kilometers per hour weight is displayed in kilo grams Sets the weight displayed as default when a preset program is 155 selected This value is a default 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 TrRnC 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 enterthe Service Settings Mode 1 Press and hold the Enter 0 and 2 k
54. whether one or both sides of the shuttle show signs of excessive sideplay 2 Using flat head screwdriver rotate the shuttle center roller screw a quarter turn clockwise Recheck the shuttle for side play 3 If sideplay has increased adjust the roller screw counterclockwise If side play has decreased continue to adjust the roller screw a quarter turn at a time until sideplay has been removed Elliptical Edge Service Manual 25 STR INC EEE RAC Stride Belt Adjustment 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 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 Ifthe 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
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