Page 2 - INTRODUCTION; USA; Europe
Service Manual: E-TR and E-TRi Service Manual: E-TR and E-TRi 1 INTRODUCTION This is the Service Manual for the Star Trac AC Pro Tread 7600 & 7700. This manual is designed to be easy to use, providing detailed instructions on how to service and maintain the AC treadmills. Star Trac highly recomm...
Page 3 - TABLE OF CONTENTS
Service Manual: E-TR and E-TRi 1 TABLE OF CONTENTS INTRODUCTION .................................................................................................................................................. 1 TABLE OF CONTENTS ........................................................................
Page 6 - PRECAUTIONS - SAFETY; Your safety and the safety of those around you must come first; ELECTRICAL SAFETY
Service Manual: E-TR and E-TRi 4 PRECAUTIONS - SAFETY The 7600 and 7700 treadmills are wired for either 120 VAC nominal or 230 VAC nominal power input. They are equipped with a specific electric cord and plug to permit connection to the proper electric circuit. Make sure that the product is connecte...
Page 7 - EQUIPMENT PLACING
Service Manual: E-TR and E-TRi 5 EQUIPMENT PLACING Star Trac recommends that treadmills be spaced a minimum of 20.0 inches (0.5 m) apart to allow safe and easy ingress and egress. More importantly, there must be at least 48 inches (1.25 m) of free space behind the treadmill. The Pro Series treadmill...
Page 10 - Power Cords
Service Manual: E-TR and E-TRi 8 Power Cords Below are the power cords you will find installed onto a Star Trac treadmill. Note the configuration of the prongs for power and polarization:
Page 11 - PREVENTIVE MAINTENANCE; Overview; over performing maintenance actions only when the system fails.; Determining When to Perform Maintenance
Service Manual: E-TR and E-TRi 9 PREVENTIVE MAINTENANCE Overview Preventive maintenance (PM) is a schedule of planned maintenance actions aimed at the prevention of failures. PM is the best way to preserve and enhance equipment reliability by keeping key components clean and free of debris. PM activ...
Page 12 - Preventive Maintenance Schedule
Service Manual: E-TR and E-TRi 10 Preventive Maintenance Schedule This section provides a comprehensive list of factory recommended PM requirements, along with detailed procedures for performing each task. DAI LY WEEKLY MONT HLY AS NEEDE D Wipe down all surfaces including: Display, handrails shroud ...
Page 14 - Inspect display panel (keypad) for wear
Service Manual: E-TR and E-TRi 12 WEEKLY Clean Elevate the treadmill and vacuum the floor around and underneath. Inspect x Inspect display panel (keypad) for wear x Inspect inside of running belt and top of deck x Inspect all mounting hardware and correct any squeaks or rattles
Page 15 - Unplug the treadmill and remove the; Inspect; Inspect the drive belt for tension and wear.; Lubricate
Service Manual: E-TR and E-TRi 13 MONTHLY Clean x Unplug the treadmill and remove the shroud. Use a portable vacuum with dust attachment to clean any dust, dirt or debris from inside the shroud area. Use extreme caution to not damage any components or knock and connections loose Inspect x Inspect th...
Page 16 - RUNNING BELT; Once a deck surface has been used, it should not be used again.
Service Manual: E-TR and E-TRi 14 RUNNING BELT Once a deck surface has been used, it should not be used again. You must install a new belt and new deck surface together. Most Star Trac decks are double-sided so they can be flipped to utilize both sides. Failure to install a new belt over a fresh dec...
Page 17 - Importance of Running Belt Maintenance; Running Belt “Do Not’s”
Service Manual: E-TR and E-TRi 15 Importance of Running Belt Maintenance The running belt is the most important part of a treadmill. It is what a treadmill is all about. It is the core component that must be maintained to insure many years of continued function. By performing a few maintenance steps...
Page 18 - Cleaning a Running Belt; Bristle; CLEAN BELT SURFACE
Service Manual: E-TR and E-TRi 16 Cleaning a Running Belt The running belt should be cleaned to help prevent dirt build up and maintain a nice appearance for users. To properly clean a running belt you will need: TOOLS & MATERIALS x Clean towel (1) x Paint stick or ruler (1) x Diluted all-purpos...
Page 19 - Running Belt Tension; PARTS REQUIRED; Masking tape and pen or pencil; TOOLS REQUIRED; OR whichever comes first.
Service Manual: E-TR and E-TRi 17 Running Belt Tension Proper running belt tension and tracking are important to maintain the performance and life of the belt. It is recommended to follow this tensioning and tracking procedure whenever the running belt or deck is replaced or as needed. PARTS REQUIRE...
Page 20 - RUNNING BELT RETENSION PROCEDURE; Release tension of running belt by
Service Manual: E-TR and E-TRi 18 RUNNING BELT RETENSION PROCEDURE Fig 1 Step 1: Release tension of running belt by unscrewing the tension screws until the roller touches the finger-guard. The belt should be completely relaxed. (Note: This applies to both left & right finger-guards.) Fig 2 Step ...
Page 22 - Running Belt Alignment
Service Manual: E-TR and E-TRi 20 Running Belt Alignment Fig 7 Step 1: Start the treadmill and set the speed to 3.0 mph (5.0 kmh). Make sure the running belt tracks to the center (see Fig 7). If the running belt shifts or tracks to either side (left or right), follow the appropriate procedure below....
Page 23 - Roller Care & Maintenance; CLEANING; Do not use sandpaper to clean the rollers
Service Manual: E-TR and E-TRi 21 Roller Care & Maintenance The care and maintenance of the head and tail rollers are as important as the care and maintenance of the running belt. Dirt buildup on the rollers can cause noise, rough feelings and unwanted belt tracking. CLEANING Scrape any dirt and...
Page 24 - Applying Wax to a Waxless Running Belt; Parts Required; #2 Phillips screwdriver
Service Manual: E-TR and E-TRi 22 Applying Wax to a Waxless Running Belt While it is generally not necessary to add wax to a waxless style running belt, if the running belt is making unacceptable noises or is experiencing tracking difficulties, adding wax the underside of the belt will improve the g...
Page 25 - The next step involves working near moving parts. BE CAREFUL!; While the treadmill is running, squirt about 5-8 times on the left; at least half; the
Service Manual: E-TR and E-TRi 23 Step 2: x Using the screwdriver, remove the three screws from the left and the three screws from the right finger guards (Fig 4). x Remove both finger guards (Fig 5). Fig 4 Fig 5 CAUTION: The next step involves working near moving parts. BE CAREFUL! Be mindful of lo...
Page 26 - MAINTENANCE MODE; Engaging Maintenance Mode; Press and hold the
Service Manual: E-TR and E-TRi 24 MAINTENANCE MODE The Maintenance Mode allows you to query and modify the settings of the Star Trac product. Engaging Maintenance Mode Press and hold the + + keys. While holding all three keys release the key only. A beep will sound and the display will read “MAINTEN...
Page 27 - Maintenance Mode Keys; WARNING
Service Manual: E-TR and E-TRi 25 Maintenance Mode Keys The following keys are used to search through and modify the Maintenance Settings: INCLINE keys: Display the next and previous parameters. SPEED keys: Adjust the value of the displayed parameter up and down respectively. Some parameters can uti...
Page 28 - DISPLAY PARAMETERS; Parameter Defaults; Parameter
Service Manual: E-TR and E-TRi 26 DISPLAY PARAMETERS Parameter Defaults The following parameters can be accessed by entering the Maintenance Mode. When installing a new display electronic board, it will come with factory default settings. Depending on the model and voltage of unit you are installing...
Page 30 - Parameter Setting Definitions; ACCELERATION
Service Manual: E-TR and E-TRi 28 Parameter Setting Definitions The following are the definitions of each parameter from the Maintenance Mode. UNITS: Sets the conversion for speed, distance and weight between US and Metric measurements. (Conversions: Km = Miles x 1.6 x Lb = Kg x 2.2) MINIMUM SPEED: ...
Page 31 - CHECK MOTOR
Service Manual: E-TR and E-TRi 29 RAIL STOP: Used to turn the side stop switch port on or off on International units. *Note: This parameter should always be ON unless the mechanical stop switch is installed. STOP SWITCH: Sets the type of International stop switch is in use: U.S.A. or International 1...
Page 33 - MAINTENANCE MODE – TEST MODES; DISPLAY TEST; This parameter is used by Star Trac at the factory.
Service Manual: E-TR and E-TRi 31 MAINTENANCE MODE – TEST MODES Within the Maintenance Mode parameters are a few Test Modes that can be used to test various functions of the unit. While in the Maintenance Mode, set the following parameter and use the functions as listed to utilize each parameter. DI...
Page 34 - CALIBRATE SCALE
Service Manual: E-TR and E-TRi 32 CALIBRATE SCALE Press ‘Start’ key Display will enter CALIBRATE SCALE mode and scroll the following: 1 = INPUT SPAN WEIGHT 2 = CAL SPAN WEIGHT 3 = CAL ZERO WEIGHT 4 = VERIFY WEIGHT PRESS STOP TO EXIT Loop Pressing ‘Stop’ will return to MAINTENANCE MODE Press ...
Page 35 - CSAFE TEST; HEART RATE TEST; LAST ERROR LIST
Service Manual: E-TR and E-TRi 33 CSAFE TEST This parameter is used by Star Trac at the factory. HEART RATE TEST The Heart Rate Test mode can be used to simultaneously test the function and response for both the contact and Polar heart rate systems. Press ‘Start’ key Display will read POLAR 0 CONT...
Page 36 - Running belt will move, center number will increase and the
Service Manual: E-TR and E-TRi 34 MAINTENANCE MODE – AUTO CALIBRATION Electrical voltages vary between locations. The treadmill can run through an auto-calibration process to allow the electronics to balance out with the speed control. To run an auto-calibration procedure, do the following: Auto-Cal...
Page 37 - LAST ERROR LIST DEFINITIONS; DEFINITIONS
Service Manual: E-TR and E-TRi 35 LAST ERROR LIST DEFINITIONS DEFINITIONS LAST CODE The last code (Check Speed Sys, Key Down, Elev Stall, etc.) LST CHK Check Sum at time of incident. Check Sum is part of the software language. LAST MTR CURR Motor Current sensed at time of incident. LAST STAT LAST OP...
Page 38 - DFR INFORMATION; Same Codes, Different Meanings; (see “LAST ERROR LIST” in the “MAINTENANCE MODES – TEST MODES” section)
Service Manual: E-TR and E-TRi 36 DFR INFORMATION DFR’s (Drive Fault Records) The AC MCB (Motor Control Board) monitors the drive system and reports any anomalies by triggering what is called a DFR (Drive Fault Record) code. Same Codes, Different Meanings The AC System has the same codes as the DC s...
Page 39 - Uploaders; Uploader kit contains all
Service Manual: E-TR and E-TRi 37 SOFTWARE - DISPLAY The display on the AC Pro Tread contains the software to operate the treadmill. This software may be updated via the “uploaders” or by replacing the display electronics which contains an updated version of the software. Uploaders Uploaders are two...
Page 40 - Uploading Software into the Uploaders; is to upload the software into the uploaders only.; Time Required; minutes; The USB style uploaders do not require a; Tools Required; Phillips head screw driver
Service Manual: E-TR and E-TRi 38 Uploading Software into the Uploaders The following procedure explains how to upload software into the grey uploader boxes. The software may be downloaded from the Star Trac Support Website ( http://support.startrac.com/Software ). Click on the Service Provider tab ...
Page 41 - Obtaining the FISP and Latest Software
Service Manual: E-TR and E-TRi 39 You will need Winzip (or equivalent) installed on your PC. If you do not have a zip file extractor program, you can get a free version from www.winzip.com . Obtaining the FISP and Latest Software 1. Open your web browser and go to the Support Website (*1). Click on ...
Page 43 - Connecting the USB Cable to the PC
Service Manual: E-TR and E-TRi 41 5. In the ‘AVRISP’ folder, right click on ‘Pro_tread-disp_verXX_XX.zip’ then left click on ‘Open with Winzip’. 6. Once extracted, a new window will appear as shown below with 2 files in it. Click and hold in the white space next to the lower file (*1) and drag the s...
Page 44 - Installing the FISP Program on the PC; If a ‘Security Warning’ window appears,
Service Manual: E-TR and E-TRi 42 Installing the FISP Program on the PC 1. In the ‘AVRISP’ folder, open the executable file for the FISP program called ‘fisp_setup.exe’. If a ‘Security Warning’ window appears, click ‘Run’). 2. Click ‘Next’ to run the setup wizard. 3. Make sure you are going to insta...
Page 46 - – Check “SUT0 Fuse” only; FUSE BITS HIGH; – Check “CKOPT; FUSE BITS EXTENDED
Service Manual: E-TR and E-TRi 44 8. The ‘Device’ – ‘Options’ window will appear with several tabs. LOCK BITS - Uncheck all: FUSE BITS – Check “SUT0 Fuse” only FUSE BITS HIGH – Check “CKOPT Fuse” and “JTAG Fuse” only. FUSE BITS EXTENDED – Uncheck all. 9. Once all check boxes are set as above, click ...
Page 48 - Uploading Software into the AC MCB with MCB Uploader
Service Manual: E-TR and E-TRi 46 Uploading Software into the AC MCB with MCB Uploader The following procedure explains how to upload software into the MCB (Motor Control Board) of the AC Pro Treadmill. The software may be downloaded from the Star Trac Support Website http://support.startrac.com . C...
Page 50 - Uploading to the MCB
Service Manual: E-TR and E-TRi 48 Fig 6 Fig 7 Uploading to the MCB 1. Turn the treadmill on at the on/off switch. 2. Turn the treadmill power on. After 2 to 3 seconds the RED led on the uploader should light steady (see Fig 6) 3. Press the RED button once. The Led’s should blink on and off then one ...
Page 52 - PART REPLACEMENT PROCEDURES; Table Of Part Replacement Procedures; Running Belt Tensioning Procedure
Service Manual: E-TR and E-TRi 50 PART REPLACEMENT PROCEDURES Table Of Part Replacement Procedures x Running Belt Tensioning Procedure x Display Panel (Keypad)/Electronics Replacement
Page 53 - Masking
Service Manual: E-TR and E-TRi 51 Running Belt Tensioning Procedure Applies to models: 4500, 4000, 3900, 4200, 5500, 5600, 6500, 6600, 7500, 7600 and 7700 Proper running belt tension and tracking are important to maintain the performance and life of the belt. Star Trac recommends following this tens...
Page 54 - Step 3
Service Manual: E-TR and E-TRi 52 Fig 2 Step 2 Apply a piece of masking tape on the edge of the running belt on both sides. Fig 3 Step 3 Draw a line on each piece of masking tape aligned with the edge of the deck. (Note: Be careful not to move the belt or roller while drawing the lines.) Fig 4 Check...
Page 56 - Step 1; Repeat above steps until the running belt tracks in the center
Service Manual: E-TR and E-TRi 54 Fig 7 Step 1 Start the treadmill and set the speed to 3.0 mph (5.0 kph). Make sure the running belt tracks to the center (see Fig 7). If the running belt shifts or tracks to either side (left or right), follow the appropriate procedure below. If the belt tracks to t...
Page 57 - TROUBLESHOOTING; Table Of Troubleshooting Documents; Check Speed System and Check Motor System
Service Manual: E-TR and E-TRi 55 TROUBLESHOOTING Table Of Troubleshooting Documents x Check Speed System and Check Motor System x Troubleshoot DFR Codes: x Code: 1000000, 100000, 10000 x Code: 4000 x Code: 1000 x Code: 800 & 400 x Code: 200 x Code: 40, 20 & 10 x Remaining Codes x Slipping R...
Page 65 - DFR Remaining Codes
Service Manual – Treadmills: E-Series x P-Series 63 DFR Remaining Codes
Page 66 - Slipping Running Belt; Loose drive belt
Service Manual – Treadmills: E-Series x P-Series 64 Slipping Running Belt Slipping is the term that many people use when a running belt stops moving for a split second, but the motor, possibly the head roller, keeps moving. Possible causes for a slipping running belt: x Loose drive belt x Worn runni...
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Page 68 - SERVICE MANUAL
X Star Trac Fitness x 14410 Myford Road x Irvine, California 92606 x 800-503-1221 Tel x 714-669-1660 Tel x 714-669-0739 Fax X http://support.startrac.com x email: [email protected] Doc: 620-7734 Rev: B SERVICE MANUAL
