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Star Trac TR 4500 - page 1
Section 1: Introduction W elcome to the world of STAR TRAC. In your hands is the STAR TRAC TR 4500 Service Manual. This manual is desig ned to be easy to use, providing detailed instruct ions on how to service and maintain the TR 4500. W e highly recomm end that you read all the applicable sect ions of t he service manual prior t o serving the trea ...
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Star Trac TR 4500 - page 2
How To Use This Manual • This Service Manual has been written to assist and instr uct the repair technician on k ey components f or q uick and ef f icient diagnosis of service problems. • To assist in f inding t he applicable sections in the Ser vice M anual. Each Section has a t able of contents to help locat e specific sympt oms and topics. T ...
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Star Trac TR 4500 - page 3
Precautions 1. Always make sure that the tr eadmill is turned of f and unplug ged bef ore star ting any work, unless otherwise noted, or when necessary for voltag e testing . 2. Read each section thr ough f or NO TES bef ore star ting any work. 3. To pull apar t electr ical connectors, pull on the connector it self , not the wires. 4. W hen replaci ...
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Star Trac TR 4500 - page 4
Product Support Asistance PRODUCT SUPPORT DEPA RTMENT STAR TRAC Product Support Department sets the industr y standard in Customer Service and Technical Assistance W or ld W ide. Providing superior product support and customer ser vice is at the very heart of STAR TRAC’ s business philosophy. This commit ment to ser vice has been a major contribu ...
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Star Trac TR 4500 - page 5
Tools and Equipment Equipment Functi on Philips Head Screwdriver #2 Shroud Mo tor Con trol Bo ard Assemb ly Side Bed Cover and End Caps Auto-Tra nsformer Smal l Slo tted Scre wdri ver 3 /32” M otor Co ntrol P otentio meters (M AX SPD ) & (IRC OMP ) Bungee Cord 28” Suspend Motor Shroud on Display Rail 5/32” Hex Allen key Handrail assem bly ...
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Star Trac TR 4500 - page 6
Treadmill Overview • DC POWER SUPPLY The MCB provides pow er to t he display assembly. Establishes a ref erence voltag e and potentiamet er position f rom the elevation mot or • RUNNING BELT MO TOR DRIVE CONTROL Tak es Alternat ing Curr ent and converts it to Pulse W idth Modulation (PW M) to p owe r the Dri ve M otor. Motor voltage f eedback a ...
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Star Trac TR 4500 - page 7
Section 2: Preventive Maintenance Schedules Perf orming regular preventive maintenance on all Star Tr ac treadmills is st rongly recom mended. W ithout preventive maintenance, norm al wear and tear may cause cumulative ef fect s, such as misalignm ent and early replacement of part s. T his may result in downtime. For this reason, we highly r ecomme ...
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Star Trac TR 4500 - page 8
Preventive Maintenance Chart Mai ntenance Clean Inspect Lubricate Replace Daily Using a liquid non-abrasive cleaner, wipe down the following: display board handrails, shroud, heart rate grip s. Note: Do not spray d irectly onto the display board or heart grip s. Inspect f or wear and tear on ex- terior part s regularl y, especially under the runnin ...
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Star Trac TR 4500 - page 9
Quarterly Waxing The tr eadmill is designed with an autom atic prom pt, which will display RE W AX across the display screen every 2,000 miles or 3,000 k ilomet ers. T he procedure below explains step-by- step how to apply w ax and clear the RE W AX prompt . Note: Apply wax powder while belt and deck are still warm (f ro m 5 to 15 minutes of use) f ...
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Star Trac TR 4500 - page 10
Section 3: Diagnostics The STAR TRAC 4500 Treadm ill series contains diagnost ic and customizing m odes. I n these modes you are able to check accumulat ed data about t he past usage of the t readmill, test its motor and display controls, and investigate display code messages. For these reasons, your treadmill is eq uipped wi th a ; • Manager Mod ...
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Star Trac TR 4500 - page 11
Manager Mode Aft er having used you Star Trac 4500 treadmill f or several workouts, you may wish to specially customize your treadmill by changing some of its set tings. To engage Manager Mode: 1. Press and hold the “ 0 ”, “ 1 ” & “ START ” k eys toget her. W hile holding the “ 0 ” & “ START ” k eys down, release the “ ...
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Star Trac TR 4500 - page 12
Manager Mode The f ollowing parameter s may be changed using t he previous keys: Parameters Low est Value Highest Value Option 1 Option 2 Default Value Meaning UNITS --- --- English Metric English English= units of lbs., miles, hours, minutes Me tric= uni ts of kg., km, hours, minutes. MN SPD 0.1 2.5 English=0.5 Metric=1.0 0.5 Minimum speed in MP H ...
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Star Trac TR 4500 - page 13
Maintenance Mode Maintenance M ode includes all of the item s of Manager Mode, plus additional dat a that is autom atically saved to properly troubleshoot in case of a problem . To eng age Maintenance Mode: 1. Press and hold the “ 0 ”, “ 2 ” & “ START ” k eys toget her. W hile holding the “ 0 ” & “ START ” k eys down, re ...
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Star Trac TR 4500 - page 14
Maintenance Mode The f ollowing parameter s may be changed using t he previous keys: Parameters Low est Value Highest Value Option 1 Option 2 Default Value Meaning UNITS --- --- English Metric English English= units of lbs., miles, hours, minutes Me tric= uni ts of kg., km, hours, minutes. MN SPD 0.1 2.5 English=0.5 Metric=1.0 0.5 Minimum speed in ...
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Star Trac TR 4500 - page 15
Maintenance Mode Parameters Low est Value Highest Value Option 1 Option 2 Default Value Meaning HRT CON --- --- ON OFF OFF OFF= H eart Co ntrol disable ON= Heart Contr ol enabled HRT --- --- CNT DN POLAR CONT ACT BOTH CNT DN POLAR CONT ACT BOTH CNT DN CNT DN= Manual countdown heart rate POLAR, CO NTACT or BOTH ( Polar & Contact) 10 REV 22.0 74. ...
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Star Trac TR 4500 - page 16
Maintenance Mode Parameters Low est Value Highest Value Option 1 Option 2 Default Value Meaning KEY DN 0 255 -- - --- 0 Number of t imes the Stop Switch was dow n or disconnected on power-up since last reset. NO RPM 0 255 -- - --- 0 Number of t imes the display did not detect a RMP signal. SP CNG 0 255 --- --- 0 Number of t imes a sudden change in ...
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Star Trac TR 4500 - page 17
Maintenance Mode Parameters Low est Value Highest Value Option 1 Option 2 Defaul t Value Meaning LSTRES 0 2 --- --- 0 Disp lay s 1 = Unit was resetting to 0%. 0 = Unit f inished resettin g to 0% prior to the display code. LSTSSP 0 255 --- --- 0 Displays the speed prior to t he display code. LSTPWM 0 255 --- --- 0 Displays the PW M number prior to t ...
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Star Trac TR 4500 - page 18
Motor Test Mode Motor Test Mode allows the treadmill t o calibrate bot h elevation and running belt speed. Verif ies RPM Sensor f eedback, Dr ive Motor and MC B response, and verif ies Elevation Motor range ( count). Also burns in the mot or, by way of the contr ols and displays of the t readmill. ***Caution*** : Do not stand on the running belt wh ...
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Star Trac TR 4500 - page 19
Calibration ***Caution*** : Do not stand on the running belt while performing these test. A utomatic Speed Calibration: In this mode m inimum and maximum speed is automatically calibrat ed. Calibrat ion lasts less than 3 minutes; belt will be in motion during t his test. Auto-calibra tion should be done every time MN, MX SPD & UNITS paramet ers ...
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Star Trac TR 4500 - page 20
Display Test Mode Display Test Mode allows y ou to test the light -emitt ing diodes (LEDs) , 15- segment displays, and t he watchdog timer of t he Display Control Panel by way of its own controls and displays. It also allows EPROM version to be displayed. To enter Display Test Mode: ***Caution*** : Do not stand on the running belt while performing ...
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Star Trac TR 4500 - page 21
Heart Rate Test Heart Rate T est Mode tests t he heart rat e calculation and display capability of the t readmill if it is equipped with contact rings or Polar w ireless heart r ate chest st rap reception capabilit y. To enter Heart Rate Test Mode: 1. Press and hold the “ 0 ”, “ 1 ” & “ START ” k eys toget her (or the “0” , “2 ...
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Star Trac TR 4500 - page 22
Section 4: Troubleshooting Should the STAR TRAC 4500 Treadmill experience a problem or a display code appear, the f ollowing procedures will help determine the precise reason f or the pr oblem. Included ar e flow charts br eaking down each indiv idual display code with problem statement s and solutions. Con tents 4.1 110v MCB Lay out 4.3 220v MCB L ...
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Star Trac TR 4500 - page 23
110v MCB LED Layout The Following LEDs w ill help diagnose if the MCB has failed or causing intermittent problems. ** CAU TION ** AC L E D - I ndicates that AC power has been applied to the MCB. It does Several of t he f ollow- not give indication of voltage level, if t his LED is not lit and t he tread- ing tr oubleshooting m ill does not power up ...
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Star Trac TR 4500 - page 24
110v MCB LED Layout NOTE : Engage Mo tor MOTOR LED - I ndicates the presence of accept able voltage to the m otor. Test Mode and If t his LED is not lit one of t he following condit ions exists: manually push on 1. Veri fy AC v oltage is b eing ap plie d. the running belt to 2. Verif y that MTR1/MTR2 wires are connected to t he MCB. verify RPM feed ...
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Star Trac TR 4500 - page 25
220v MCB LED Layout The Following LEDs w ill help diagnose if the MCB has failed or causing intermittent problems. ** CAU TION ** AC P W R - I ndicates that AC power has been applied to the MCB. It does Several of t he f ollow- not give indication of voltage level, if t his LED is not lit and t he ing tr oubleshooting t readmill does not power up, ...
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Star Trac TR 4500 - page 26
220v MCB LED Layout NOTE : Engage M otor RPM SENSOR - Indicates input sig nal f rom t he RPM Sensor to the MCB. Test Mode and If t his LED is not f lashing dur ing operat ion, verif y the following manually push on 1. RPM sensor disconnected fr om connector J3 at the MCB. the running belt to 2. RPM sesnor gap m isaligned. verify RPM feedback. 3. RP ...
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Star Trac TR 4500 - page 27
Calibration Troubleshooting The f ollowing steps help troubleshoot in case Auto-Calibrat ion procedures f ail to g ive the correct reading or r esponse. Symptom: A uto-Calibration fluctuates. 1. Verif y line voltage f or suf ficient voltage supply. • If wall voltage is less than 10% than what is requir ed, this will cause speed fluct uation. 2. V ...
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Star Trac TR 4500 - page 28
Calibration Troubleshooting Symptom: Will not Calibrate to MA X speed. 1. Verif y line voltage f or suf ficient voltage supply. • If wall voltage is less than 10% than what is requir ed, this will cause speed fluct uation. 2. Verif y unit is on a dedicated circuit break er. • Treadmills shar ing t he same circuit line will cause intermit tent p ...
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Star Trac TR 4500 - page 29
Manual Calibration The f ollowing procedure allows the tr eadmill to m anually calibrate Minimum and Max imum speeds, only in the case Auto-Calibration is not funct ioning corr ectly. Symptom: Will not calibrate to MN or MX speed, in the A uto-Calibration Mode. **CAU TION** 1. Eng age T EST MODE. Press and hold t he “ 0 ”, “ 1 ” & “ S ...
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Star Trac TR 4500 - page 30
No Display Power The f ollowing steps help troubleshoot in case the display board f ails to power up, during or bef ore regular operation. 110v UNIT 1. Lift and suspend the m otor shroud. **CAU TION** The f ollowing steps 2. Verif y if LED AC is lit . AC LED indicates t hat AC power is being applied t o are perf ormed with the MCB, does not indicat ...
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Star Trac TR 4500 - page 31
No Display Power The f ollowing steps help troubleshoot in case the display board f ails to power up, during or bef ore regular operation. 220v UNIT 1. Lift and suspend the m otor shroud. **CAU TION** The f ollowing steps 2. Verif y if LED AC is lit . AC LED indicates t hat AC power is being applied t o are perf ormed with the MCB, does not indicat ...
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Star Trac TR 4500 - page 32
Elevation Motor NOTE: A ctiv atio n of t he thermal protection break - er does not cause damage to the elevation actuator or other treadmill com pon- ents. The f ollowing procedure explains the elevation system T hermal Prot ection and limitat ions. Symptom: Elevation sy stem shuts-off when used consistently . 1. The St ar Tr ac Model 4500 elev ati ...
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Star Trac TR 4500 - page 33
Elevation Motor ** CAU TION ** Do not stand on the running belt while perform ing these steps. NOTE: Several of the f ollowing steps req uire dealing with “live” voltage. Have the treadmill t urned off and unplug g- ed when check- ing wire connec- tions. NOTE: The pot- entiometer values can be read in Motor Test Mode, 240 = 0%, 57 = 15% for 110 ...
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Star Trac TR 4500 - page 34
Elevation Troubleshooting ** CAU TION ** Do not stand on the running belt while perform - ing these st eps. NOTE: These ran- ges were chosen to optim ize the output voltag e to the elevation motor w ithi n an acceptable operating range, while still using the present manuf acturing tolerances of the transf ormer manufact urer. 220v treadmill Incline ...
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Star Trac TR 4500 - page 35
Speed Troubleshooting Note: This s ym- ptom may be easily fixed by veri fying certain val ues i n the Config ure Mode. Note: For each value changed the “EN TER” key must be pressed to be saved. . Symptom: Treadmill appears/feels faster/slower than other STAR TRAC treadmills. 1. Engag e Maintenance Mode by holding down the “0”, “2” and ? ...
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Star Trac TR 4500 - page 36
Speed Troubleshooting Note: Th is sy m- ptom may be easily fixed by veri fying certain val ues i n the Config ure Mode. Note: For each value changed the “EN TER” key must be pressed to be saved. Note: All 110v units are desig n- ed to reach a maximum speed of 10. 0 MPH. 220v units set in metr ic will reach a max imum 20.0 KM/PH. Note: W all vol ...
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Star Trac TR 4500 - page 37
Speed Troubleshooting ** CA UTION ** Running belt will be moving at hig h speed during Step 1 & 3. ** CA UTION ** W hen checking motor brushes have the treadmill turned of f and unplugged. Note: Brushes should show a smooth patt ern of wear, cracks or unusual wear will cause motor to jerk , replace if brushes if neded. Symptom: Treadmill jerks ...
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Star Trac TR 4500 - page 38
Heart Rate Troubleshooting ** CAUT ION ** Do not stand on the running belt while perfo rming these steps. Before any troublesh ooting is performed, v eri fy that the hear t rate grips are bei ng used and maintai ned prop erly. Symptom: Intermittent or erratic hear t rate re ading. 1. User failing to grip al l four ring s completely with both left a ...
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Star Trac TR 4500 - page 39
Heart Rate Troubleshooting Symptom: No Heart Rate reading. 1. Engage HEA RT RA TE TEST. Turn th e power switch “on” while pressing key “5” simultaneously on the display. All th e display LEDs will light up when engaged. • Press the HEART key once, EPROM ver- sion will be displayed. HEART key twice, displ ay s Heart/ S eeking H R. • Grip ...
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Star Trac TR 4500 - page 40
Heart Rate Troubleshooting 5. Connect Heart Rate Board st raight t o the display input. • By-pass the Combiner Board, insert t he heart rate w ires strai ght to the disp lay. See Diagram #3 & 3a. Af ter connect ion has been repeat step 1. REPLA CE: Combiner Board if Heart Rat e register s. If no Heart Rat e is reg istered go t o step 6. NOTE: ...
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Star Trac TR 4500 - page 41
Polar Heart Troubleshooting ** CAU TION ** Do not stand on the running belt while perform - ing these st ep. NOT E : Secure the chest strap transmi tter as high under t he pectoral muscle (breast) as is comf ortable and allow normal breathing . NOT E: W et the electrodes (t he two grooved rectang ular areas) thor ou- ghly w ith w ater. NOT E: Verif ...
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Star Trac TR 4500 - page 42
Display Cable The f ollowing symptoms indicates a f ault y or pinched display cable. Symptom: No d isplay pow er related. **CAU TION** 1. No display power, treadm ill elevation bottoms out during start -up. Do not stand on 2. No display power, MCB LED +11 remains lit on 110v units. MCB LED Display the running belt remains lit on 220v units. while p ...
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Star Trac TR 4500 - page 43
Drive Motor The foll owi ng sympto ms indica tes a faulty driv e motor. Symptom: Tripping the ON/OFF sw itch breaker. **CAU TION** 1. Disconnect t he drive motor belt. Do not stand on 2. Run t he drive motor for ten minutes at a high speed ( 6 MPH/ 10 KPH). If the the running belt ON/O FF switch trips, verif y if t he MCB LED I-LIMIT lig hts up (11 ...
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Star Trac TR 4500 - page 44
Head / Tail Roller Note : Do not remove all the was as it is req uired to lubricate both t he running belt and deck. You may need to replace the head or tail roller if t he fo llowing symptoms ar e observed. Sy mptom: Thumping, knocki ng noise as the runni ng belt goes over the roller. Verify the follow ing: • Delron end caps are l oosening. • ...
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Star Trac TR 4500 - page 45
Drive Belt Troubleshooting The drive belt t ension may requir e tight ening if a slipping pr oblem occur s on the drive pulley. Sy mptom: Running belt slips w hen runni ng or w alki ng. 1. Loosen the f our motor mount kep nuts and washer using a 5/16 “ w rench. 2. Adjust the drive belt tensi on by turning the motor mount adjustment (socket head c ...
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Star Trac TR 4500 - page 46
Running Belt Troubleshooting Note: For op timal To prevent belt problems f rom occur ring, verify the running belt is proper ly perf ormance during the adjust ed and working sm oothly by perform ing the f ollowing steps: lifet ime of the tr eadmill, running belt adjust- 1. Feel the underside cent er of the running belt, f or g laze. Glaze is ments ...
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Star Trac TR 4500 - page 47
Running Belt Tracking Note: The running belt If t he running belt is not center ed on the tailr oller and is either t o f ar lef t or may mis-track due to right , adjust track ing using t he following steps: : the style of t he walker or runner. 1. Turn t readmill on. I ncrease speed to 3. 0 mph (5.0 k ph). Note: The running belt 2. Adjust tr ackin ...
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Star Trac TR 4500 - page 48
Running Belt Tension Note: Prior to making The running belt tension may need to be adjust ed over time to k eep the any adjustments to t he the belt f rom slipping with each jog ging st ep or at hig h speeds. Use the running belt tension, f ollowing procedure f or t esting belt tension. verify the drive mot or belt is properly 1. Acceler ate the r ...
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Star Trac TR 4500 - page 49
Running Deck The following procedure will help determine and properly adjust the deck bumpers. Sy mptom: Running deck squeaks w hen r unning. 1. W hen properly l ocated, the side bumpers (tw o on each side) bear against the delrin rods in the frame rail s. The rear bumpers bear against the steel posts at the end of the frame rails. If the bumpers a ...
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Star Trac TR 4500 - page 50
Running Deck Sy mptom: Running deck squeaks w hen r unning (conti nued). Correcti ng the problem: 1. Position the deck w ith the rear bumper s properly aligned w ith the steel posts. W ith a pencil, make a mar k on the deck adjacent to each of the four delrin rods( as seen from the top of the side rails). 2. Reach under the running deck, shift the ...
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Star Trac TR 4500 - page 51
Isolating Noise NOTE: Verify that the treadmill is level before isolating any specif ic compo nent NOTE: Ensure all assembly screws are tight: 1. Handrail s. 2. Displ ay board. 3. Mot or shro ud. NOTE: W hen doing the stethoscope method, be careful of body placement. Ensure all lo ose items (hair , clothing , jewelry etc) are secure and aw ay from ...
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Star Trac TR 4500 - page 52
Leveling NOTE: If a leveling foot does not make contact with the f loor or if it lif ts upwards as w eight is applied to one corner of the deck, t his will cause the running belt t o mis-track. To ensure proper tracking of the running belt, treadmill leveling should be verified. Sy mptoms: • Running belt tr avels to one side. • Treadmill vib ra ...
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Star Trac TR 4500 - page 53
Vibration NOTE: F or complete leveling procedure, see the f ollowing page. NOTE: W hen check ing motor brushes, the treadmill m ust be turned of f and unplugged. A treadmill v ibrates during use if the floor or leveling feet are uneven or w hen assembly bol ts are loose. Sy mptom: Unit vibr ates w hil e runni ng. 1. Verif y the treadmill is on an e ...
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Star Trac TR 4500 - page 54
Static Shock **CAU TION** W hen checking m otor brushes, always turn the treadmill of f and unplug. The treadmill may cause a slight shock from the display panel or handrails, due to a faulty gr ound wir e or a worn r unning belt and deck. Sy mptom: Slight shock fr om handrail s or w hen using the displ ay panel. 1. Check the line cord and plug pro ...
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Star Trac TR 4500 - page 55
Display Codes Chart ** CAU TION ** Do not stand on the running belt, while perform ing these steps. NOTE: Tr eadmill should be turned off and un- plugged f r om t he wall w hen looking under the mot or shroud. NOTE: Contact STAR T RAC Product Support Department at 1-800-501-1221 or throug h our we b site at h ttp:// www.s t a rt r a c .c o m Please ...
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Star Trac TR 4500 - page 56
Definition: "KEY STUCK" Possible Cause: Damaged or shorted key/keypad. Note 1: This code may occur when a user tried entering "Test Mode" or "Display Test Mode" using the wrong key. Look for any indentations on any of the keys. The plus or fast key are used most often and may cause this error. Note 2: Press and hold th ...
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Star Trac TR 4500 - page 57
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Star Trac TR 4500 - page 58
Definition: "RPM LOSS" Possible Cause: Damaged or misaligned RPM sensor. Note 1 : Press and hold the "0", "1," & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Then press and release the 8 key. Or manually hold the 8 key and simultaneously turn ...
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Star Trac TR 4500 - page 59
Code: NO RPM Flowchart If no appearant damage is visable. Manually toggle the display cable for possible intermittent connection. If the PWM LED does not flash or intermittently respond, replace the display cable. STOP Process 1A Does display read RPM feedback ? Engage automatic speed calibration. See (note 4) Stop Replace RMP Sensor Stop YES NO No ...
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Star Trac TR 4500 - page 60
Code: NO RPM Flowchart Check the following connections; drive motor to choke/filter to MCB. Stop 1B Replace the choke/filter system. Re-engage Test Mode. Bring speed command 3 back up to 50. Does the running belt move ? By-pass the choke/filter from the MCB and drive motor. Does the running belt move ? Stop Replace the MCB NO YES NO Re-engage Auto- ...
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Star Trac TR 4500 - page 61
Definition: "SUDDEN SPEED CHANGE." Possible Cause: RPM pick-up misaligned. Note 1: Press and hold the "0", "1", & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANC, then press and release the "8" key. Or, manually hold the "8" key ...
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Star Trac TR 4500 - page 62
Code: SP CNG Flowchart Manually toggle the display cable for possible intermittent connection. If the PWM LED does not flash or intermittently respond when cable is toggled, replace the display cable. 1A Stop 1B LED responds ? NO Replace the M.C.B. YES Stop Check motor brushes, for unusual wear. See (note 5) Diagram #3 Note 5: Turn the treadmill of ...
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Star Trac TR 4500 - page 63
Code: SP CNG Flowchart Engage automatic speed calibration. See (note 6) STOP 1C Does display read RPM feedback ? Engage automatic speed calibration. Then clear all error codes, see (note 8) Stop Replace RPM sensor, or Hall effect depending on style.Then clear all error codes, see (note 8) Stop YES NO 1D Diagram #3 Diagram #4 Note 6: To engage autom ...
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Star Trac TR 4500 - page 64
Code: SP CNG Flowchart Does display read RPM feedback ? Engage automatic speed calibration. Stop Replace the RPM sensor or Hall Effect, depending on style. Then clear all error codes, see (note 8) Stop YES NO Exit "Test Mode" by pressing the stop key. Re-engage "Engineering Mode" and clear all error codes. See (note 8) Note 8: E ...
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Star Trac TR 4500 - page 65
Definition: "ELEVATION LOST BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Press and release the " ...
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Star Trac TR 4500 - page 66
Definition: "ELEVATION RANGE BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE/. Press and release the &quo ...
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Star Trac TR 4500 - page 67
Code: EL RNG Flowchart Disconnect the elevation motor belt and manually bring down the elevation until display read 240. 1A Re-connect the elevation belt. Re-ingage regular mode. Verify if elevation is operating correctly. If elevation is working see (note 4) If display code continues contact Unisen. Stop Bring the treadmill down to physical 0% 240 ...
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Star Trac TR 4500 - page 68
Definition: "ELEVATION STALL BEYOND 0% or 15% RANGE" Possible Cause: Out of range elevation count or elevation system malfunctioned. Note 1: Press and hold the "0", "2" & "START" keys down at the same time, then release the "1" key. The display will read: MAINTENANCE. Press and release the " ...
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Star Trac TR 4500 - page 69
Code: EL STL Flowchart 1A Note 4: Diagram #2 Place your (red) meter probe into the black wire of pin 4, located at connector J5. Then place your (black) meter probe to AC1 on the M.C.B. Voltage should read +/-110v. or +/-220v depending on model. When pressing the elevation "DOWN" key, the voltage should drop down to 0v or 1v. This would i ...
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Star Trac TR 4500 - page 70
Section 5: Parts Replacement Should the S T AR TR AC 4500 T readmill experience a problem requiring replacement of a specific part, the following procedures will help and instruct in the replacement of major parts. Contents 5.1 – 5 Drive Motor Replacemen t 5.13 – 15 A uto-transf ormer Replace ment 5.6 – 9 Elevation Motor Replacement 5.16 – ...
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Star Trac TR 4500 - page 71
Drive Motor Replacement ** CAUT ION ** Alw ays turn the power switch to the off position. Unplug the treadmill power cord fro m the power outlet. Tools: • Running Belt Drive Motor • Philips-head scr ewdriver • Bungee cord, approx. 24 inches • Needle nose pli ers • 5/16-in sock et and torque sock et wrench t o measure 110 in/lb. • 1/8-in ...
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Star Trac TR 4500 - page 72
Drive Motor Replacement Remove Motor 1. Loos en the 5/16-inch nut that locks the mo tor alignment screw, th en unscrew the screw several turns. 2. Loos en the four 5/1 6-inch mot or mount n uts so that t he motor slides freel y on the fr ame. See Diagram A below . 5.2 ...
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Star Trac TR 4500 - page 73
Drive Motor Replacement 3. U sing a 1/8-i nch Allen w rench, loose n the tw o set screw s in the motor pulley. 4. Slide the motor towards the rear of the trea dmill l to give sla ck to the motor drive b elt. 5. Slip the dr ive belt o ff the motor pul ley, then remove the pulley and the locki ng key. 6. Remove the four mo tor mount nuts, then lift t ...
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Star Trac TR 4500 - page 74
Drive Motor Replacement Diagram B. Check and Adjust Belt Tens ion 1. Pl ace a tension g auge ont o the cent er of the belt an d check tension . The gaug e should indi cate 90 inc h-pounds. 2. If y ou have n ot tensio n gauge, press dow n on top of t he belt, midway between pulley s, very hard wi th your thum b. The belt should de flect betw een 3/8 ...
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Star Trac TR 4500 - page 75
Drive Motor Replacement 5. R echeck pulley alignment and bel t tension. 6. W hen align men t and t ensio n are c orre ct, t ighten all fo ur mo tor moun t nu ts u sing a socket torq ue wrench set at 75 inch- pounds. 7. Lock t he mot or adjustmen t screw by tighteni ng the locking n ut agai nst the frame . 8. Loos en the s et screw at t he mot or pu ...
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Star Trac TR 4500 - page 76
Elevation Motor Replacement ** CAUT ION ** Alw ays turn the power switch to the off position. Unplug the treadmill power cord fro m the power outlet. Tools: • Replacement el evation mot or • Philips-head scr ewdriver • Pliers • Tap nuts, ½-inch (2) • A llen w rench, 9/64 in. • Socket wrench with 17-mm sock et • Shop hammer • Large ...
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Star Trac TR 4500 - page 77
Elevation Motor Replacement Diagram A 4. Sl ide the idler pulley in its slot to loosen the elevati on driv e belt, the n remov e the belt from the i dler pull ey. 5. U sing an All en wrench, l oosen the scr ews aroun d the dr ive pull ey, then re move the pulley from the el evation motor sh aft. 6. At th e Motor Control Boar d, disconn ect the el e ...
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Star Trac TR 4500 - page 78
Elevation Motor Replacement Replacement the Elev ation Motor 1. Position the elev ation motor in its m ount. Be sure to hold the motor’s electrical cable clos ely ag ainst the motor t o prevent its bei ng pinched between t he motor a nd the treadm ill frame . 2. R eplace and tighten the four screw s that hold the el evation mot or to th e motor p ...
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Star Trac TR 4500 - page 79
Elevation Motor Replacement 6. Tig hten Allen scr ews i n the drive pul ley, taking care to pr eserve th e alignment achieved i n the pr eceding step . 7. Pl ace the dr ive belt ov er the i dler pul ley. 8. Sl ide the idler pulley tightly against the b elt, then fi nger tig hten the mou nting scr ew on the idl er pull ey shaft. 9. M anipulate t he ...
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Star Trac TR 4500 - page 80
Side Bed Cover Replacement ** CAUT ION ** Alw ays turn the power switch to the off position. Unplug the treadmill power cord fro m the power outlet. Tools: • Si de bed co ver • Philips-h ead screwdriver • Slot-head scr ewdri ver • 1/8-in Alle n wrench • 5/8-in socket and socket w rench w ith ratchet • Plastic-hea d hammer • W ooden bl ...
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Star Trac TR 4500 - page 81
Side Bed Cover Replacement 4. Star ting at the raised cor ner o f the flang e, lift upw ards and o utwards to free its out er edge fro m the fra me along its length. 5. Lifting the outer edge o f the cover, push the co ver towards the cent er of the trea dmill to clear the cover’s inner fla nge from the frame an d remove from the trea dmill. Inst ...
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Star Trac TR 4500 - page 82
Side Bed Cover Replacement 4. At th e front e nd, pull t he out er flange over the fr ame, then use y our hand or a soft mallet to “pop” the outer flange ov er the frame along its full length. The rear end o f the cover shoul d butt ag ainst the en d cap. See Dia gram C . Diagr am C 5. If th e rear end of the cov er does not meet th e end c ap, ...
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Star Trac TR 4500 - page 83
Autotransformer Replacement The autotr ansformer may be tapped to accommodate line v oltages fro m 195VAC to 250VAC. Fol lowing are procedur es for repl acing a failed a utotransform er. Tools: • Replaceme nt autotrans former • Philips-h ead screwdriver • Slot screw driver Procedure: Li ft motor shroud The drive m otor is located be low the p ...
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Star Trac TR 4500 - page 84
Autotransform er Replacement Replace the A uto transfor mer 1. Posi tion the replacem ent autotr ansfor mer over the four holes in the m otor pla te so th at the connecto r lugs are towards the left -hand side of the treadmill. 2. D rop the four screws r emoved in t he precedi ng step 5 i nto the mounting h oles o f the autotrans former. 3. Reachin ...
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Star Trac TR 4500 - page 85
Autotransformer Repl acment Reconnect the autotran sformer’ s black wi re to termin al AC1 at t he left-rear corner o f the Motor Contr ol Boar d. Connect th e blue w ire to the l ug on th e autotrans former. 1. C onnect the r ed wi re to the sa me lug fro m which it w as remov ed in the pr evious st ep. If there is a question a bout the av ailab ...
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Star Trac TR 4500 - page 86
Heart Grip Replacement ** CAUT ION ** Alw ays turn the power switch to the off position. Unplug the treadmill power cord fro m the power outlet. Tools: • Handgr ip Kit • 1/16 inch Al len wr ench • Light ny lon cord • Isopropyl alcohol Procedure: Remove the Disp lay Panel 1. U sing a 1/16-i nch Allen wrench, r emove th e five screw s from th ...
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Star Trac TR 4500 - page 87
Heart Grip Replacement 3. Li ft the han dgrip cables t o separat e the Velc ro strips on the cable from th e Velcro on the rear o f the panel, then re move the tw o Velcro strips that hold t he two cabl es together. 4. C ut and remov e the cabl e ties from the han dgrip cabl es. 5. Tie a 4- foot length o f strong nylon cor d to each c able, just b ...
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Star Trac TR 4500 - page 88
Heart Grip Replacement Remove the Handgrips 1. Pull and twist the handgrips free of the rail tubin g. If they will not slide off the tubing, use a knif e or sc isso rs to cu t the ru bbe r alon g its le ngth , then slide t he han dgrip s off the tubing . 2. C ontinue to pul l each of the handg rip cables though t he goos eneck and t he display rail ...
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Star Trac TR 4500 - page 89
Heart Grip Replacement Replace Display Panel 1. Posi tion the display pan el over th e display panel mo unt, matching scr ew holes in th e back of the p anel wi th holes in the mount. 2. U sing a 1/16-i nch Allen wrench, r eplace a nd tighten each of the five screw s removed in a previ ous step. Test Treadmill Operation After you h ave complete d r ...
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Star Trac TR 4500 - page 90
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Star Trac TR 4500 - page 91
1 TR 4500 & 3900 Series Deck & Frame Assy Item No Part Number Description Qty Per Core Page: 1 020-4497 Shroud, Motor, black, 45/39/4000Sm 1 N 2 020-4500 Shroud, motor, grey, 45/39/4000Sm 1 N 3 020-4452 End Cap, 45/39/4000, left, black 1 N 4 020-4480 End Cap, 45/39/4000, left, grey 1 N 5 020-4453 End Cap, 45/39/4000, right, black 1 N 6 020- ...
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Star Trac TR 4500 - page 92
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Star Trac TR 4500 - page 93
2 TR 4500 & 3900 Series Elevation Assy Item No Part Number Description Qty Per Core Page: 1 260-0235 Motor, Elevation, 110vac 1 N 2 708-0151 Elevation Can 2 N 3 715-0110 Elevation Screw, drilled 2 N 4 130-0250 Pulley, Elevation, elev motor 1 N 5 110-1415 Axle Push Caps 1/2" 2 N 6 708-0645 Axle 1/2" 1 N 7 020-6266 Sleeve, Elevation Axl ...
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Star Trac TR 4500 - page 94
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Star Trac TR 4500 - page 95
3 TR 4500 & 3900 Series Motor & Electrical Assy Item No Part Number Description Qty Per Core Page: 1 800-3016 Mcb, 110v, 18/35/39/45/4000 1 Y 2 715-3132 Mcb, 220v, 18/35/39/45/4000 1 Y 3 800-3259 Filter Network, 110v 1 N 4 800-3258 Filter Network, 220v 1 N 5 260-0220 Motor, 110v, 2.5hp 3500rpm, mag 1 Y 6 260-0903 Motor, 220v, 2.5hp 3500rpm, ...
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Star Trac TR 4500 - page 96
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Star Trac TR 4500 - page 97
4 TR 4500 & 3900 Series Running Belt Assy Item No Part Number Description Qty Per Core Page: 1 130-1630 Running Belt, (20"x128.5") 1 Y 2 708-0061 Head Roller 1 Y 3 708-0132 Tail Roller 1 Y 4 130-0121 Drive Belt, (280J10) 1 N 5 130-1629 Drive Belt, (285J10) 1 N 6 130-7009 Pulley, drive motor, (10J180) 1.8"dia 1 N 7 130-1628 Pulley ...
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Star Trac TR 4500 - page 98
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Star Trac TR 4500 - page 99
5 TR 4500 & 3900 Series 4500 Handrail Assy Item No Part Number Description Qty Per Core Page: 1 715-3301 Cable, Display, lower m/f, Tr4500 1 N 2 715-3302 Cable, Display, upper m/m, Tr4500 1 N 3 715-3328 Stop Switch, w/cable, 4500 (D04591 and up) 1 N 4 705-1663 Cable, Display to Stop Sw 1 N 5 711-1032 Hand Grip, Contact HR 2 N 6 020-4600 Cap, si ...
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Star Trac TR 4500 - page 100
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Star Trac TR 4500 - page 101
6 TR 4500 & 3900 Series 3900 Handrail Assy Item No Part Number Description Qty Per Core Page: 1 800-0126 Cable, Display, 39/4000/18/35/900-1 1 N 2 110-0685 Screw, 5/16-18 X 6" hex 2 N 3 120-0480 Washer, 5/16, cut 2 N 4 120-0491 Washer, 5/16 x 1.5"od, flat 2 N 5 110-0506 Screw, 1/4-28 x 3/8" Bhss 8 N 6 710-0521 Hand Rail Insert 2 ...
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Star Trac TR 4500 - page 102
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Star Trac TR 4500 - page 103
7 TR 4500 & 3900 Series 4500 Display Assy Item No Part Number Description Qty Per Core Page: 1 715-3279 Display Electronic, Pcb, Tr4500 1 Y 2 050-1722 Keypad Overlay, 4500/4200, left 1 N 3 050-1723 Keypad Overlay, 4500/4200, center 1 N 4 050-1724 Keypad Overlay, 4500/4200, right 1 N 5 020-4576 Lens, small, upper (1" x 6.5") 1 N 6 020- ...
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Star Trac TR 4500 - page 104
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Star Trac TR 4500 - page 105
8 TR 4500 & 3900 Series 3900 Display Assy Item No Part Number Description Qty Per Core Page: 1 705-1635 Display Electronic, Pcb, 3900/3500 1 Y 2 050-1705 Keypad Overlay, 3900/3500 1 N 3 020-4496 Lens, (3" x 8") 1 N 4 020-4492 Display Housing 1 N 5 120-3004 Standoff, 6-32 X 3/8 5 N 6 110-0130 Screw, 6-32 X 1/4 9 N 7 120-3002 Washer, #6 ...
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