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Star Trac Elite CrossTrainer, Service Manual

The Star Trac Elite CrossTrainer is an exceptional fitness machine designed to provide a total body workout. Enhance your exercise routine with this versatile equipment. For detailed instructions and maintenance guidelines, you can conveniently download the comprehensive Service Manual for free from our website, ensuring optimal usage and performance.

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CrossTrainer Service Manual 

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  CrossTrainer Service Manual Rev A 620-7575 

Table of Contents 

Table of Contents .............................................................................................................................................................. 1

Preventive Maintenance.................................................................................................................................................... 2

Settings -  Maintenance Mode .......................................................................................................................................... 3

Diagnostics -  Display Codes ........................................................................................................................................... 5

Diagnostics -  LED Test .................................................................................................................................................... 6

Diagnostics -  Keypad Test............................................................................................................................................... 7

Diagnostics -  Heart Rate Test, Measurements .............................................................................................................. 8

Diagnostics -  UB Calibration ........................................................................................................................................... 9

Trouble Shooting -  Incorrect Model Setting ................................................................................................................ 10

Trouble Shooting - Noises : Pinging ............................................................................................................................. 11

Trouble Shooting - Noises : Bearings ........................................................................................................................... 14

Trouble Shooting - Excess Lateral UB Arm Movement............................................................................................... 17

Part Installation Procedure - Shrouds.......................................................................................................................... 18

Part Installation Procedure -  Keypad ........................................................................................................................... 21

Part Installation Procedure -  LCB, Batt. And UB Board ............................................................................................. 23

Part Installation Procedure – Upper Crank Arm........................................................................................................... 27

CrossTrainer Parts List................................................................................................................................................... 30

Summary of Contents for Elite CrossTrainer

Page 1: ...Pro CrossTrainer Elite CrossTrainer Service Manual ...

Page 2: ... Diagnostics Heart Rate Test Measurements 8 Diagnostics UB Calibration 9 Trouble Shooting Incorrect Model Setting 10 Trouble Shooting Noises Pinging 11 Trouble Shooting Noises Bearings 14 Trouble Shooting Excess Lateral UB Arm Movement 17 Part Installation Procedure Shrouds 18 Part Installation Procedure Keypad 21 Part Installation Procedure LCB Batt And UB Board 23 Part Installation Procedure Upp...

Page 3: ...body arms pedals shrouds and heart rate grips Note Do not spray directly on the display or heart rate grips Spray on the cloth first Weekly Maintenance Perform the following services each week x Vacuum the floor under and around the CrossTrainer Move the unit to another spot if necessary to vacuum thoroughly x Inspect the screws i e display panel mounting screws for security and retighten if neces...

Page 4: ...ngs Increase and Decrease Level Keys Adjust the value of the displayed setting up and down respectively in increments of 1 unit OK Key Updates saves the value of the display setting in the Flash memory and exits Maintenance Mode Maintenance Mode Settings The items that you may display and change Default values set in Serial Number CrossTrainer serial number 0 Date Manufactures date for the CrossTr...

Page 5: ...n since the last reset 0 Auto Pilot Number of times the Auto Pilot program was run since the last reset 0 IHR Pro Number of times the Interval Heart Rate Control program was run since the last reset 0 CHR Pro Number of times the Constant Heart Rate Control program was run since last reset 0 CW Pro Number of times the Constant Watt Control program was run since the last reset 0 Alpine Number of tim...

Page 6: ... One or more keys on the display panel are stuck in the on position for at least 10 seconds This can occur if a user presses keys before the system is turned on Comm Lost Communication between the Load Control Board LCB and the display are lost This can occur if the display cable is not connected securely at install Batt Low Upper body actuator is commanded to work and the battery voltage is less ...

Page 7: ...embly To engage the LED Test 1 Enter the Maintenance Mode see Settings Maintenance Mode 2 Press until LED Test is displayed in the information window 3 Press to enter the LED Test All lights on the display should be on 4 Check for any burned out lights 5 To exit the LED Test press If any of the LED s do not illuminate they may not be functioning and the display electronics should be replaced ...

Page 8: ...pad Test 1 Enter the Maintenance Mode see Settings Maintenance Mode 2 Press until Keypad Test is displayed in the information window 3 Press to enter the Keypad Test 4 Press each key on the display Each time you press a key the information window will display which key has been pressed 5 To exit the keypad test press If any of the keys do not respond they may not be functioning and the display key...

Page 9: ...Polar the display will read TELEMETRY and the heart rate number 5 To exit the heart rate test press Measurements Mode Measurements can be done to verify the voltage of the battery and the UB motor s position voltage feedback To verify the battery voltage 1 Enter the Maintenance Mode see Settings Maintenance Mode 2 Press until Measurements is displayed in the information window 3 Press to enter Mea...

Page 10: ...rate the Upper Body 1 Enter the Maintenance Mode see Settings Maintenance Mode 2 Press until UB Calibration is displayed in the information window 3 Press to enter UB Calibration Mode Manual Calibration 1 For Manual Calibration press 1 2 Press the until the upper body arms stop moving None Position and then press to save 3 Press the until the upper body actuator stops and then press the to save Au...

Page 11: ...lso some programs will not work when the keys are pressed i e When pressing the Total Body program key Warm Up program will start If you experience any of these symptoms engage the Maintenance mode to correct the Model setting Engaging Maintenance Mode 1 Press and hold the and keys together 2 A beep will sound and the MAINTENANCE MODE will display momentarily in the information window 3 Release al...

Page 12: ...dal arm Check the Upper Crank arm Pin 1 Check the gap between the crank arm and leg assemblies right and left There should be no more than 1 8 inch 4 mm gap 2 If there is more than 1 8 inch 4 mm gap replace the crank arm 721 0109 The pin has come loose and shifted This causes the pedal arm to misalign and rub the lower crank disk If the gap between the crank arm and leg assemblies is correct then ...

Page 13: ... the largest adjustable end wrench crescent wrench to twist the base of the pedal arm x Place a piece of paper over the pedal arm to prevent scratching it with the wrench just in front of the foot pedal but before the upward bend x Slide the wrench over the paper and all the way down on the pedal arm Be sure the handle of the wrench points toward the middle of the machine 5 Carefully push down on ...

Page 14: ...al Rev A 620 7575 Trouble Shooting Noises Pinging cont 6 Test ride the machine again to confirm that the problem has been fixed Jump slightly from side to side as you pedal to be sure the pedal arm is adjusted correctly 7 Replace the rear center shroud cover ...

Page 15: ...se while striding this process will help determine if the noise is caused by a bearing Check Pillow Block Bolts 1 Use two 9 16 wrenches or socket to verify that all 4 bolts and nuts on the upper and lower crank assemblies are tight 2 If the bolts are loose tighten them and check to see if the noise has been eliminated 3 If the noise continues proceed with checking the bearings ...

Page 16: ...2 Spray the lube then test the CrossTrainer to see if the noise has disappeared If the noise remains lubricate the other crank bearing If the noise goes away then the bearing is the cause and the upper crank assembly should be replaced part number 721 1057 Lower Crank Bearings 1 Remove the lower disk cap 2 Insert the straw of the lube can into the slit on the lower crank arm through the lower cran...

Page 17: ...hooting Noises Bearings cont 3 Spray the lube then test the CrossTrainer to see if the noise has disappeared If the noise remains lubricate the other crank bearing If the noise goes away then the bearing is the cause and the upper crank assembly should be replaced part number 721 0121 ...

Page 18: ... CrossTrainer should have little to no lateral movement side to side If a CrossTrainer has excessive lateral movement do the following 1 Remove the Upper Body shrouds 2 Use a 5 32 Allen hex wrench and a 3 8 open end wrench to tighten the pinch bolts on the upper body pivot axle Tighten both bolts 3 Test to ensure there is no longer excessive lateral movement ...

Page 19: ... 721 1074 02 x Lower Shroud Lt 721 1072 01 x Lower Shroud Rt 721 1072 02 Tools Needed x 3 32 Allen Hex Key x 5 16 Allen Hex Key x Phillips Head Screwdriver x Flat Head Screwdriver Procedure Remove the Upper Body Shroud 1 Using the 3 32 inch Allen hex key remove the 6 screws from the left upper body shroud panel 2 Carefully remove the UB shroud panel from the frame Utilize the slit in the panel to ...

Page 20: ...e right UB shroud panel Remove the Lower Body Shroud 1 Use the 5 16 Allen hex key to remove the bolt holding the lower linkage arm to the crank Note Weight and movement of leg beam will force the lower linkage to move in the forward direction during removal Either have another person hold the leg beam or pedal in position use a block under the pedal 2 Use the Phillips screwdriver to remove the 2 s...

Page 21: ...ont 3 Use the Phillips screwdriver to remove the 7 screws from the lower shroud 4 Remove the plastic cap from the metal guard disk using the flat head screwdriver 5 Use the Allen hex key to remove the 3 screws on the guard disk Remove disk 6 Repeat step 1 5 on the other side 7 Installation is reversal of removal ...

Page 22: ... back housing off display 2 Remove the fan bracket x Remove the 4 screws from the fan bracket Note Before removing the last screw be sure to have a hold of the fan bracket The fan wire will still be connected to the display electronics x Carefully unplug the fan Do not tug aggressively or you may pull the connector from the display 3 Remove the display electronics x Unplug all the cables from the ...

Page 23: ...hesive is making contact with the display panel Note If the keypad is not properly lined up with the display panel some of the lights may not be visible 3 Install the display electronics x Carefully pull the keypad ribbon cable through the hole on the display electronics x Install the 5 screws that hold the display electronics to the panel x Plug the cables into the electronics Be sure to plug all...

Page 24: ...l Board 721 1045 x Battery 580 0305 x Upper Body Controller Elite only 721 1044 Tools Needed x Short Phillips Head Screwdriver x 1 8 inch Allen Hex Key x Phillips Head Screwdriver Procedure Remove the Upper Body Shroud Panel 6 Using the 3 32 inch Hex key remove the 6 screws from the right upper body shroud panel Note If you are replacing the upper body board remove the left shroud panel 7 Carefull...

Page 25: ...ry to loosen it to service the LCB LCB Replacement Remove the Old LCB 1 Unplug all 6 7 for Elite cables from the LCB 2 Use the short Phillips head screwdriver to remove the 2 screws holding the LCB to the frame Note Be careful not to drop the screws in the frame Install the New LCB 1 Place the new LCB in the frame 2 Use the short Phillips head screwdriver to install the 2 screws to hold the LCB to...

Page 26: ... 3 volts or above x A battery with a marginal charge will be between 6 0 and 6 2 volts x If the battery is less than 6 0 volts do not install Obtain a new battery 2 Plug the wires into the new battery x Red wire plugs into the positive of the battery x Black wire plugs into the negative of the battery Note Incorrect wiring of the battery may cause damage to the system Upper Body Electronic Board R...

Page 27: ...he UB board to the frame 2 Connect the two wires to the board 3 Before installing the UB shroud panel test for functionality Reinstall the LCB Plastic Shield 1 Position the LCB Shield over the electronics and align the holes for the plastic thumb screws 2 Tighten the screws Reinstall the Upper Body Shroud 1 Carefully reinsert the upper body shroud onto the frame 2 Reinstall the 6 screws that hold ...

Page 28: ...y x Torque Wrench foot pounds w 5 16 Allen Hex Driver x inch Cold Chisel x Large Flat Head Screwdriver x Short Punch x 1 8 Allen Hex Key Procedure Remove the Upper Crank Arm 1 Using a 1 8 Allen hex key loosen both of the sets screws on the pedal shaft under the pedal pad 2 Using the short punch or socket gently tap the shaft into the pedal base until it is clear of the collar on the outside 3 Remo...

Page 29: ...use your foot to support the lower end of the leg beam as you pull Remove the shims and wavy washers from the crank pin and set them aside for re use 6 Remove the plastic cap and retaining ring from the center of the upper crank arm Completely remove both of the pinch bolts using a 5 16 Allen hex key 7 Insert a inch cold chisel or a large flat head screwdriver in the slot in the end of the upper c...

Page 30: ...rank arm The crank arm should easily slide on the main shaft assembly 2 Insert and tighten the two pinch bolts to 60 ft lbs with torque wrench and 5 16 hex driver 3 Replace the retaining ring and plastic cap 4 Slide the shim and wavy washer onto the upper crank pin Then slide the leg beam bearing housing on the upper crank pin 5 Replace the e clip and plastic cap 6 Tap the pedal pin back into posi...

Page 31: ...CrossTrainer Service Manual 30 CrossTrainer Service Manual Rev A 620 7575 CrossTrainer Parts List Pro CrossTrainer Elite CrossTrainer ...

Page 32: ...1 2 3 4 5 6 7 8 11 12 13 14 15 17 19 20 21 22 23 24 25 26 18 18 19 19 27 24 18 CrossTrainer Shrouds ...

Page 33: ...sc Cap El6200 11 140 3301 Cap Leg Axle Housing El6200 12 140 3300 Cap Upper Crank El6200 13 050 1816 Label Id Plate 14 050 1956 Label Patents El6100 6200 15 020 6818 Bracket Shroud 1 El6200 17 020 6821 Bracket Shroud 4 El6200 18 110 0286 Screw 8 18x1 1 2 pht ab ph 19 110 3026 Screw 10 24x3 4 Phtcs 20 110 3072 Screw 8 32x3 8 Rhms 21 110 3298 Screw 5 16 18x 75 bhc he ss 22 110 3341 Bolt 8 32x3 8 Bhc...

Page 34: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CrossTrainer Outer Mechanical ...

Page 35: ...uard Disk Plate El6200 7 721 0126 Assy Lower Linkage El6200 8 721 0114 01 Weldment Pedal Base lf el6200 9 721 0114 02 Weldment Pedal Base rg el6200 10 721 0130 01 Assy Shoe Left El6200 11 721 0130 02 Assy Shoe Right El6200 12 120 0510 Washer 1 0 13 120 0411 Washer 1 0 14 140 0940 E clip 3 4 15 120 3293 Washer locking nord lock 1 2 16 110 3291 Screw 1 2 13 1 5 bhc he ss 17 110 3290 Screw 5 16 18 X ...

Page 36: ...IL B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 19 15 15 15 32 33 34 35 37 38 39 40 41 42 35 35 36 36 25 24 22 18 15 18 19 15 16 15 CrossTrainer Pro Frame Inner Mechanical ...

Page 37: ...5 16 18 19 110 1830 Nut 3 8 16 Hex nyloc 20 110 3304 Nut 7 16 Locknut Nylon 21 721 1082 Assy Elect Plate El6200 22 110 3292 Screw 5 16 18x2 5 bhc he ss 23 120 3279 Spacer 1 3 8x1 3 4x 340 Nylo 24 140 3309 Ring Retaining Ext 1 250 25 110 3297 Bolt 3 8 16x1 75 Shc hk cs b 26 120 3294 Spacer 1 3 8x1 3 4x 220 Nylo 27 110 3312 Screw 3 8 16x3 25 hhc he cs z 28 120 3278 Washer 5 16x 50 Ss 29 110 0686 Bol...

Page 38: ...DETAIL C C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 9 10 8 6 6 6 CrossTrainer Elite Inner Mechanical ...

Page 39: ...sy Pillowblock 6 120 0463 Washer 3 8x1 0 Flat 7 110 3312 Screw 3 8 16x3 25 hhc he cs z 8 110 0575 Screw 1 4 20x1 25 hhc he cs z 9 110 1810 Nut 1 4 20 Kep 10 020 6634 Base Pedal Side Logo El6200 11 110 0601 Screw 3 8 16x4 0 Hhcs 12 120 0341 Washer 10 Flat Sae 13 110 1830 Nut 3 8 16 Hex nyloc 14 110 3311 Screw 10 32x1 75 shc he cs bo 15 110 3314 Nut 10 32 Nyloc ...

Page 40: ...TO FRAME GROUND 7 8 9 10 11 24 25 26 27 1 2 3 4 5 6 12 13 14 15 16 17 18 19 20 21 22 23 CrossTrainer Display Assembly 28 ...

Page 41: ...11 721 0069 Cable Grips Hr Brd 12 718 1116 Harness Assy IR 13 718 1129 Pcb Hr Contact Ub rb Pro 14 721 0033 Phone Jack Assy C Safe NR BK 15 800 3961 Cable Assy Polar Rcvr 16 721 1065 Assy Harness Ground El6200 17 718 5062 IR Assy 18 050 1932 Label Info Center Universal 19 050 1887 Label Logo ST Pro Bike 20 718 1107 Air Vent Assy 21 020 6460 Window Ir Reader 22 110 3163 Screw M3x0 5x8 Pht ph cs zi ...

Page 42: ...1 2 3 4 5 6 7 8 9 9 9 CrossTrainer Control System ...

Page 43: ... 1045 Assy Lcb W heatsink Ub rb el 3 721 1044 Assy Ub Electronics El6200 4 580 0305 Battery 6v Ee Nr PB5k 6k 5 721 1049 Assy Harness Ub Interface 6 721 1046 Assy Harness Battery El6200 7 140 0715 Deck Foam 1 4 p ft top 8 140 3324 Foam Rubber 1 4x3 4 9 110 3026 Screw 10 24x3 4 Phtcs ...

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