StarTrac Elliptical Edge Service Manual

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Section 1

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.

How to Use the Manual

Precautions

Product Support Assistance

Tools and Materials

Elliptical Edge Overview

Elliptical Edge Service Manual

Introduction

Contents

1.2

1.3

1.4

1.5

1.7

1.1

Table of Contents

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Summary of Contents for StarTrac Elliptical Edge

Page 1 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.
Page 2 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 of the Elliptical Edge, outlines safety precautions to be ob- served when performing maintenance or repair, and lists tools and materials required.
Page 3 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. When disconnecting cable connectors, ALWAYS pull on the connector itself, NEVER the wires. Elliptical Edge Service Manual...
Page 4 Part description and quantity. 7. Ship to/bill to. 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. Elliptical Edge Service Manual...
Page 5 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...
Page 6 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 Tape Communication Cable Replacement Display Power Cable Replacement Tie Straps Cable Harness Replacement Elliptical Edge Service Manual...
Page 7 I N C . _ Elliptical Edge Overview THIS INFORMATION TO BE PROVIDED UPON RECEIPT OF THEORY OF OPERATION SOURCE DATA AND BLOCK DIAGRAM. Elliptical Edge Service Manual...
Page 9 Sec,ticn 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.
Page 10 Preventive Maintenance Chart The Preventive Maintenance Chart lists the scheduled maintenance tasks for the Elliptical Edge. The chart lists the time interval 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.
Page 11 Using flat head screwdriver, rotate the shuttle center roller screw a quarter turn clockwise. Recheck the shuttle for sideplay. If sideplay has increased, adjust the roller screw counterclockwise. If sideplay has decreased, continue to adjust the roller screw, a quarter turn at a time, until sideplay has been removed. Elliptical Edge Service Manual...
Page 12 Recheck the shuttle for movement along the skate rail. Continue to adjust the stride belt pulley nut until proper stride belt tension is obtained. Position the rear shroud filler panel on the rear shroud. Using Phillips head screwdriver, secure the filler panel to the rear shroud with the four Phillips head screws. Elliptical Edge Service Manual...
Page 13 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. Using Phillips head screwdriver, secure the front shroud to the unit with the eight Phillips head screws. Elliptical Edge Service Manual...
Page 15 Section 3 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.
Page 16 "Needs Service" message to display (see Display Maintenance Mode for details). NOTE: The diagnostic LEOs provide general indication of certain equipment malfunctions. Refer to Section 4, Troubleshooting to aid in locating the most likely cause of the problem. Elliptical Edge Service Manual...
Page 17 Display Maintenance Mode 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 of the unit begins, and continues throughout the duration of the workout.
Page 18 NOTE: To return display settings to their original values after changes have been made and saved, you must MANUALL re-enter the factory-default settings. "Enter" Key Press the "Enter" key to exit the Display Settings Mode and return to the standard operating mode. Elliptical Edge Service Manual...
Page 19 Sets the weight displayed as default when a preset program is 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...
Page 20 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.
Page 21 Service Messages 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 and viewed from the Service Settings Mode.
Page 22 Pedal the unit at a speed above miles-per-hour. • 1.0-10.0 Load voltage should range between volts. Voltages outside this range indi- cate a fault in the Load Control Board. A lower voltage indicates a high resistance which is normal. Elliptical Edge Service Manual...
Page 23 Section 4 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 of the Elliptical Edge.
Page 24 CRANK BELT REPLACEMENT) 1. Retension the alternator belt as 2. The alternator belt is loose or worn. needed (NO PROCEDURE RECEIVED FOR ALTERNATOR BELT RETENSIONING) 2. Replace the alternator belt (NO PROCEDURE RECEIVED FOR ALTERNATOR BELT RE- PLACEMENT) Elliptical Edge Service Manual...
Page 25 Clean the shuttle rollers (see along skate rail the shuttle rollers. Preventive Maintenance Chart, page 2.2) 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...
Page 27: Table Of Contents
I N C . _ Parts Replacement This section contains parts replacement procedures for assemblies and components of the Elliptical Edge which are ONLY authorized for in-field replacement. Parts should be replaced when indicated by diagnosis and troubleshoot- ing. There are no parts which are to be replaced as a part of scheduled preventive maintenance.
Page 29: Display Panel Replacement
.ion. • Connect the display power cable to display panel connector J7. 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. Elliptical Edge Service Manual...
Page 30: Communication Cable Replacement
Diag.B Remove the display panel: 1. Using 3/32-in. Allen wrench remove the seven Allen screws from the back of the displt.' panel. BE SURE to support the display panel after the Allen screws have been removed. Elliptical Edge Service Manual...
Page 31 Install the front shroud: connector is keyed to prevent improper con- nection. 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...
Page 32: Display Power Cable Replacement
Diag. C Remove the display panel: Using 3/32-in. Allen wrench, remove the seven Allen screws from the back of the displ- panel. BE SURE to support the display panel after the Allen screws have been remov\. Elliptical Edge Service Manual...
Page 33 Install the front shroud: connector is keyed to prevent improper con- nection. 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...
Page 34: Cable Harness Replacement
Disconnect the cable harness from the alternator: 1. Using 1/2-in. open-end wrench, disconnect the following wires from the alternator termi- nals: • Disconnect the two red wires from the alternator B terminal. • Disconnect the black wire from the alternator E terminal. Elliptical Edge Service Manual...
Page 35 Connect the external power cable to LCB connector J5. Install the front shroud: 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...
Page 36 Disconnect the battery cable from LCB connector J3. • Disconnect the alternatorlload resister cable from LCB connector J4. • Disconnect the external power cable from the connector J5. • Disconnect the Fitlinxx cable from LCB connector J6. Diag. E Elliptical Edge Service Manual...
Page 37 Connect the Fitlinxx cable to LCB connector J6. Install the front shroud panel: Position the front shroud panel on the front shroud. Using Phillips head screwdriver, secure the front shroud panel to the front shroud with one Phillips head screw. Elliptical Edge Service Manual 5.10...
Page 38: Battery Replacement
Connect the red (+) lead wire to the bottom battery terminal marked (+). Install the front shroud: Install the front shroud in position on the unit. Using Phillips head screwdriver, secure the front shroud to the unit with the eight head 5.11 Elliptical Edge Service Manual...
Page 39: Shuttle Replacement
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. Using needle nose pliers, CAREFULLY pull the belt tension anchor pin out from the belt tension pulley. See Diagram H. " \LJ=0. 5.12 Elliptical Edge Service Manual...
Page 40 CAREFULLY slide the crank arm shaft and two nylon washers out of the skate rail. BE CAREFUL notto lose the two nylon washers. Slide the shuttle forward and off of the skate rail. Elliptical Edge Service Manual 5.13...
Page 41 Allen screws (from underneath the shuttle) to secure the footpad to the shuttle. TIGHTEN THE SCREWS SECURELY. Install the front shroud: 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. 5.14 Elliptical Edge Service Manual...
Page 42: Skate Railreplacement
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 K. Diag. K Elliptical Edge Service Manual 5.15...
Page 43 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. ---- F RONT VIEW Diag. N Elliptical Edge Service Manual 5.16...
Page 44 13. CAREFULLY slide the crank arm shaft and two nylon washers out of the skate rail. BE shaft. CAREFUL not to lose the two nylon washers. See Diagram Q. Diag.Q Elliptical Edge Service Manual 5.17...
Page 45 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: Slide the shuttle onto the skate rail. 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.
Page 46 Using Phillips head screwdriver, secure the rear shroud to the unit with the eight Phillips head screws. Install the front shroud: Install the front shroud in position on the unit. Using Phillips head screwdriver, secure the front shroud to the unit with the eight PhilliPI' head screws. Elliptical Edge Service Manual 5.19...
Page 47: Stride Belt Replacement
Stride Belt Replacement 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: install ONL Y ONE stride belt at time. 1.
Page 48 Using needle nose pliers, CAREFULLY pull the section of the stride belt containing thL capture plates out thrqugh the access hole in the side of the skate rail. Elliptical Edge Service Manual 5.21...
Page 49 Stride Belt Replacement 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 Diag. U 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.
Page 50 Install the rear shroud play (see Section details). Install the rear shroud in position on the unit. Using Phillips head screwdriver, secure the rear shroud to the unit with the eight Phillips head screws. 5.23 Elliptical Edge Service Manual...
Page 51 Using 9/16-in. open-end wrench, loosen the transmission idler tension nut and bolt so the GENTL Y tap the crank belt is completely loose. See Diagram X. transmission pulley with rubber mallet to remove from the "ansmission shaft. LOOSEN LOOSEN Elliptical Edge Service Manual 5.24...
Page 52 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...
Page 53: Transmission Bearings Replacement
SECURELY using 1/2-in. open-end wrench. Install the front shroud: 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. 5.26 Elliptical Edge Service Manual...
Page 54 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 External Retainer Ring Pliers (13/32-1-in. with O.51-in. tip diameter) Remove the front shroud: Using Phillips head screwdriver, remove the eight Phillips head screws from the rear shroud.
Page 55 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 Elliptical Edge Service Manual...
Page 56: Crank Bearings Replacement
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. 5.29 Elliptical Edge Service Manual...
Page 57 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. 5.29 Elliptical Edge Service Manual...
Page 58 ET 4600 Page: UHtSEN.INC._ ET FRAME ASSY. Part Item Descrlptlon Core Number 721-0023-2 Frame, Painted,et,s-grey Assy, Crank,et 721-0002 721-0006 Assy, Roller,rear,et Assy, Rail,et 721-0016 Assy, Transmission,et 721-0003 020-6051 Shaft, Pulley,tension 721-0030 Assy, Pulley/roller,tension 020-6049 Spacer, 1 Id X 1.5 Od X 1.61 Spacer, 1 Id X 1.5 Od X 2.2 L 020-6048 020-6050...
Page 59 ET FRAME ASSY Page 1a...
Page 60 ET 4600 Page: INC._ UN/SEN. ELECT. KIT, ET Part Item Description Core Number 721-0023-2 Frame, Painted,et,s-grey 721-0022 Assy, Mcb 721-0012 Assy, Cable Mcb/res,et 020-6054 Brace, Bracket,mcb,et 110-3026 Screw 10 - 24 X .75" 240-6846 Conn, 8 Pos, In-line - 721-0013 Assy, Battery/therm,et 721-0032 Assy, Batltherm...
Page 61 ELECTRICAL. KIT Page 2a...
Page 62 Page: ET 4600 lNC._ UNlSEN, SHROUD KIT, ET Part Item Description Core Number 721-0023-2 Frame, Painted,et,s-grey 020-6026 Shroud, Rear,et 020-6027 Shroud, Cheeks,et Shroud, Front-a,et 020-6024 020-6023 Shroud, Collar,et 020-6025 Shroud, Front-b,et Handelbar, Rear Shroud,et 020-6071 140-3132 Fastener, U-type, #10-24 110-3106 Screws, 10-24 X 1.5 Pphms 110-3108 Screw, 5/16-18 X 1.00 Pphms...
Page 63 SHROUD KIT ET Page3a...
Page 64 ET 4600 Page: CRANK ASSY. ET Part Item Description Core Number 020-4620 Shaft, Crank Pulley,et 020-6002 Crank Arm, Et 130-1671 Pillow Block, 1.0"id 140-3144 Key, 0.25 "sq X 1.25" Key, 0.25" SqX 0.75'! 140-3145 140-3147 Snap Ring, .925id 110-3104 Bolt, 1/4-20 X .75 Shes 110-3093 Screw, 1/4-20x.25,set,self Loc 020-6001...
Page 65 CRANK ASSY ET Page 4a...
Page 66 ET 4600 Page: INC._ UHISEH. TRANSMISSION ASSY. ET Part Item Description Core Number 020-4621 Shaft, Transmission,et 130-1651 Pillow Block, 3/4" 140-3146 Key, 3/16 X 1/4 X 1.20 130-1639 Pulley, 8j,6.0 Od X .75 Id Pulley, 10j,1.230d X'.75id 110-3093 Screw, 1/4-20x.25,set,selt Loc 110-3105 Screw, 10-32x.25,set,patch 721-0003...
Page 67 Transmission Assy. ET Page Sa...
Page 68 ET 4600 Page: UN/SEN, lNC._ DISPLAY KIT ET Part Item Description Core Number 020-6021-2 Housing, Display,grey,et 020-6022-2 Housing, Display,rear,greY,et 050-1733 Keypad, Lelft,eUcv 050-1734 Keypad, Center,eUcv 050-1735 Keypad, Right,eUcv 715-3320-01 Pcba, Display,upper,eUcv 715-3320-02 Pcba, Display,lower,eUcv 110-0020 Screw,4-40x1/4 Phil Pan 110-0250 Screw, 6-32 X 1/2" Rhms 120-3002 Washer #6 120-3021...
Page 69 Page 6a...
Page 70 Page: ET 4600 NECK I HANDRAIL KIT, ET Part Item Description Core Number 721-0018-01 Assy, Rail,lt,et 721-0018-02 Assy, Rail,rt,et 721-0024·2 Neck, Painted,et,s-grey 020-6074 Plate, Cover,back,disp,s-grey 020-5035 Bracket, Handrail,attach,et 110-3090 Screw, 8-32 Hbhcs 110-3091 Screw, 1/3-20x2.25,shcs 110-3092 Screw, 5/16-18x.875, Bhscs 140-0054 Gasket, Emi, W/adhesive Back 721-0010 Assy, Cable Display,power,et...
Page 71 RAIL ASSEMBLY KIT Page Sa...
Page 72 ET 4600 Page: RAIL ASSY. ET Part Item Description Core Number 721-0015 Weldment, Rail,et 120-3018 Spacer, 5/16id X 5/80d X .3321 130-1667 Bearing, Roller,5/8id X 13/16 130-1647 Roller, .312id X 1.10 Od X .80 Plate; Capture,belt,et 020-6040 Plate, Connecting,belt,et 130-1648 Belt, Shuttle Rail,et 110-1515 Bolt,5/16-18 X 1.75"...
Page 73 8 Pl 4 PER BRACKET 14 FOR UPPER BRACKET NOT SHOWN} 4 Pl 2 PER BRACKET...