SERVICE MANUAL Pro Tread AC 7600 x 7700 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: support@startrac.
Service Manual: E-TR and E-TRi 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 recommends that you read the entire manual prior to performing any maintenance or repair. The information on the following pages will enable you to begin easily, quickly and safely. This is not an Owners Manual.
TABLE OF CONTENTS INTRODUCTION.................................................................................................................................................. 1 TABLE OF CONTENTS ....................................................................................................................................... 1 PRECAUTIONS - SAFETY .................................................................................................................................. 4 ELECTRICAL SAFETY .....
Running Belt “Do Not’s” ...............................................................................................................................................................15 Cleaning a Running Belt ................................................................................................................................................ 16 Running Belt Tension ....................................................................................................................................
DFR Code 1000..............................................................................................................................................................................59 DFR Code 800 & 400.....................................................................................................................................................................60 DFR Code 200............................................................................................................................
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 connected to a dedicated power line having an outlet with the same configuration as that of the plug. NO adapter should be used with this product.
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. m 20.0 o inches (0.5 m) m 20.0 o inches (0.5 m) 5 m 48.0 o inches (1.25 m) m 20.0 o inches (0.5 m) m 48.0 o inches (1.25 m) m 48.0 o inches (1.25 m) m 20.0 o inches (0.5 m) m 20.0 o inches (0.5 m) m 20.0 o inches (0.5 m) m 20.0 o inches (0.
POWER (ELECTRICITY) Objectives If you are not qualified/comfortable working with electricity you should consult a certified electrician.
General Electricity Star Trac refers to the two most common global voltages as: x 110V (or 110VAC) x 220V (or 220VAC) Voltages worldwide can vary. Star Trac products are designed to be stable within most voltages: x For 110V systems the voltage range is: 110 VAC – 125 VAC 50/60hz x For 220V systems the voltage range is: 190 VAC – 250 VAC 50/60hz Electrical Tools MULTIMETER – Used to test voltages, amperages and ohm readings. They can vary on type from digital (as shown to the right) or analog.
Power Cords Below are the power cords you will find installed onto a Star Trac treadmill.
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 activities may include cleaning, vacuuming, visual inspections of key components, lubrication, etc. The better your PM program is, the more dramatically you can increase the life of your product and significantly reduce equipment failures.
Preventive Maintenance Schedule Wipe down all surfaces including: Display, handrails shroud and heart rate grips.
DAILY Clean x Use a 5:1 dilution ratio (5 parts water to1 part Simple Green, Formula 409, Fantastic,or the like).
WEEKLY Clean Elevate the treadmill and vacuum the floor around and underneath.
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 x Inspect the drive belt for tension and wear. Inspect the power cord for pinches and/or broken prongs Lubricate x Wipe and debris from the elevation screws then lubricate. Use a spray lithium grease or a thin coating of grease.
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 deck surface will cause the belt to burn along the center walking area, the edges will curl, electrical components will create so much heat as to begin to fail, and will not be covered under warranty.
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 at regular intervals, you can help to: x x x Increase the life of a running belt Reduce unnecessary down-time Prevent electrical component failures Dirt is an abrasive.
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-purpose cleaner (409, Simple Green, etc.) x Bristle brush CLEANING PROCEDURE: 1. CLEAN BETWEEN DECK & BELT: A. Using the paint stick or ruler, slide a dry towel under the middle of the belt from one side of the frame to the other. B.
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 REQUIRED x Masking tape and pen or pencil x Ruler or tape measurer TOOLS REQUIRED x 1/4” Allen wrench FREQUENCY After: 1,000 Miles (1,600 Km) OR 1 Month. Whichever comes first. x Clean deck with dry cloth and retighten belt using procedure below.
RUNNING BELT RETENSION PROCEDURE 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 fingerguards.) Fig 1 Step 2: Apply a piece of masking tape on the edge of the running belt on both sides. Fig 2 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.
Step 4: Check to make sure that both lines are aligned with the edge of the deck at the same point. (See Fig 4) Fig 4 Step 5: Using a ruler or tape measure, draw a line on each piece of tape parallel to each first line at a distance of 3/8” (9.5mm) from each first line. (See Fig 5) Fig 5 Step 6: You are now ready to begin tensioning the belt. Before beginning, make sure the line on each piece of tape closest to the tail roller is aligned with the edge of the deck on each side.
Running Belt Alignment 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.
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 debris build up from the roller using a plastic scraper or an old credit card. Do not use anything metal or sandpaper, as you will damage the coating on the roller. Vacuum up any debris from the rollers.
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 grip between the belt and the rollers which will reduce the noise and improve the tracking response. This procedure should ONLY be performed by a person that is familiar with waxing of running belts and is physically able to do so.
Step 2: x x Using the screwdriver, remove the three screws from the left and the three screws from the right finger guards (Fig 4). Remove both finger guards (Fig 5). Fig 4 Fig 5 CAUTION: The next step involves working near moving parts. BE CAREFUL! Be mindful of loose clothing, long hair, loose and/or hanging jewelry, etc. Step 3: x x x x x Insert the straw onto the bottle of wax (Fig 6). Start the treadmill at 3.0 mph (5.0 kmh).
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 “MAINTENANCE MODE” momentarily in the information window. Once in the Maintenance Mode release all of the keys. The display will read “UNITS: ENGLISH” (or “UNITS: METRIC”) depending on your settings.
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 utilize the number pad. ALPINE PASS: Sets parameter back to its default factory setting. Note: For parameter “LAST DECK” this key will set the parameter to the current “MILEAGE” value to clear the “REWAX BELT” message.
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 the board into, you may need to adjust your settings by referencing the following chart.
PROGRAM CAPTURES ERROR CAPTURES Parameter NO RAIL STOP KEY DOWN SPEED CHG ELEV STALL ELEV RANGE ELEV LOST CHECK MOTOR SYS CHECK SPEED SYS FUSE BITS ERROR ELEVATION ZERO ELEVATION MAX LAST DECK LAST BELT LAST MOTOR CS AUTO STATUS MODEL 110V Setting 240 70 220V Setting 240 70 HR CALC.
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: Sets the minimum start up speed for the unit. MAXIMUM SPEED: Sets the maximum speed available for the unit. ELEVATION: Turns the elevation (incline) system on or off. TIME: Sets the maximum workout time for the unit.
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 10_REV: Sets the speed and distance calculation value.
ELEVATION ZERO: Sets the value for 0% (zero percent) for the elevation motor sensor. ELEVATION MAX: Sets the value for 15% (maximum incline) for the elevation motor sensor. LAST DECK: This parameter is used for models with a waxable style running belt. If you have a waxless style treadmill and REWAX BELT appears on your display, go to the MODEL parameter and make sure your unit is set for the correct model.
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. DISPLAY TEST The Display Test can be used to test each individual key for function and response, and can also be used to verify led function and display.
CALIBRATE SCALE Press ‘Start’ key Display will enter CALIBRATE SCALE mode and scroll the following: 1 = INPUT SPAN WEIGHT 2 = CAL SPAN WEIGHT Loop 3 = CAL ZERO WEIGHT 4 = VERIFY WEIGHT PRESS STOP TO EXIT Pressing ‘Stop’ will return to MAINTENANCE MODE Unit will read REF WEIGHT = 155 Press ‘1’ key Enter your exact weight *It is advisable to weigh yourself for accuracy just before performing this step. After entering your weight press either the ‘Start’ or ‘OK’ keys.
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.
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-Calibration DO NOT LEAVE THE TREADMILL UNATTENDED WHILE RUNNING THE AUTO-CALIBRATION PROCEDURE AS IT WILL RUN THE BELT TO THE MAXIMUM SPEED SETTING. 1. Enter the Maintenance Mode (see “Engaging Maintenance Mode”). The display will read: 2.
LAST ERROR LIST DEFINITIONS DEFINITIONS LAST CODE LST CHK LAST MTR CURR LAST STAT LAST OPHR LAST ODOM LAST PRGM LAST DFR LAST TIME LAST MSPD LAST PWM LAST SSPD LAST EPOT LAST ELEV The last code (Check Speed Sys, Key Down, Elev Stall, etc.) Check Sum at time of incident. Check Sum is part of the software language. Motor Current sensed at time of incident. Total unit OPER HOURS (Operating Hours) at time of incident. Total unit DISTANCE (mileage) at time of incident.
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 system but the meanings may not necessarily be the same, specifically “CHECK SPEED SYSTEM” and “CHECK MOTOR SYSTEM”.
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 small grey boxes that contain the primary (MC1) and secondary (MC2) software for the display. In order to use these uploaders you must install software onto a computer which allows you to upload the treadmill software into each box.
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 at the top then click on the Latest Product Software link. The Pro Tread Series display uses a flash memory system to store the software that runs the treadmill. To update the software requires the use of two “uploader” boxes and a PC.
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. 4. Move your mouse pointer into the white space but do not hover over a folder. Right click in the white space (*1). Hover your mouse over ‘New’ (*2) to open the window to the right. Click ‘Folder’ (*3) to create a New Folder. Obtaining the FISP and Latest Software 1. Open your web browser and go to the Support Website (*1).
7. Open your web browser in the Latest Product Software section. Click on the latest Display Version of software for the 7000 (7k) treadmills. Extracting (Unzipping) the Zip Files 1. Open the ‘AVRISP’ folder. Right click on ‘fisp_setup.zip’ then left click on ‘Open with Winzip’. 8. When you choose Display Ver X.X / X.X, the following window will appear. Click ‘Save’. 2. If using the free trial of Winzip and you have the screen as below, click on ‘Use Evaluation Version’. 9.
5. In the ‘AVRISP’ folder, right click on ‘Pro_tread-disp_verXX_XX.zip’ then left click on ‘Open with Winzip’. Connecting the USB Cable to the PC 1. On the back of your PC (or on the front on newer PC’s), locate the USB port. Plug the USB cable in to the USB port on the PC. 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 selection box across both files to select them both (*2).
4. Create the Start Menu folder as ‘Fisp’. Installing the FISP Program on the PC 1. In the ‘AVRISP’ folder, open the executable file for the FISP program called ‘fisp_setup.exe’. 5. This is your choice for a desktop icon. If a ‘Security Warning’ window appears, click ‘Run’). 6. Click ‘Install’ to install Fisp on your PC. 2. Click ‘Next’ to run the setup wizard. 7. Click ‘Install’ to install USB driver. 3. Make sure you are going to install into the ‘AVRISP’ folder then click ‘Next’. 8.
5. Under the ‘Device’ drop down menu, choose the ‘Mega128’. Uploading the Software into the Uploader 1. Be sure the upload is plugged in to the USB cable and the USB cable is plugged in to the PC and the Orange led is lit on the uploader. 2. Open the ‘AVRISP’ folder. Open the ‘Fisp’ folder. . PROJECT CHANGE POINT . You will need to upload one program at a time. ‘Primary’ or ‘Secondary’. Follow the next steps to upload the Primary program into the Primary uploader.
10. Click on ‘Load Fisp’ to send software to the uploader. 8. The ‘Device’ – ‘Options’ window will appear with several tabs. LOCK BITS - Uncheck all: 11. You will see a Transferring Date” status window. Click ‘Close’ when prompted. FUSE BITS – Check “SUT0 Fuse” only FUSE BITS HIGH – Check “CKOPT Fuse” and “JTAG Fuse” only. 12. This will complete the programming of the Primary uploader. Return to the Project Change Point to complete the Secondary uploader. . RETURN TO PROJECT CHANGE POINT . 13.
SOFTWARE - MCB 45 Service Manual: E-TR and E-TRi
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. Click on the Service Provider tab at the top then click on the Latest Product Software link. Time Required x 10 minutes Parts Required x Uploader kit part number 800-4043.
6. Unplug JP1 and move it up one pin so it is now connected to the top two pins and the bottom pin is exposed (see Fig 3). 7. Unplug JP2 and move it down one pin so it is now connected to the bottom two pins and the top pin is exposed (see Fig 3). Jumpers in PROGRAM mode Fig 3 8. Plug the uploader cables to the uploader box: x x Plug the power cable into the uploader inserting the small pin connector into the small hole.
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) Fig 6 3. Press the RED button once. The Led’s should blink on and off then one led will remain lit. If the RED led is on, the upload did not work. x Check all connections and verify the jumper settings then repeat the procedure. If the GREEN led is on, the upload was successful, proceed to the next step.
7. Turn the power on at the on/off switch. 8. The LED’s near the jumpers J1 and J2 should be blinking. If they are lit solid: x Turn the power off and verify that the jumpers in the RUN mode positions. (NOTE: Do not move the jumpers with the power on.) If they are blinking, proceed to the next step. 9. Install the motor shroud. 10. Test the treadmill for proper function.
PART REPLACEMENT PROCEDURES Table Of Part Replacement Procedures x Running Belt Tensioning Procedure x Display Panel (Keypad)/Electronics Replacement 50 Service Manual: E-TR and E-TRi
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 tensioning and tracking procedure whenever the running belt or deck are replaced or as needed.
Step 2 Apply a piece of masking tape on the edge of the running belt on both sides. Fig 2 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 3 Check to make sure that both lines are aligned with the edge of the deck at the same point.
Step 4 Using a ruler or tape measure, draw a line on each piece of tape parallel to each first line at a distance of 3/8” (9.5mm) from each first line. (See Fig 5) Step 5 Fig 5 You are now ready to begin tensioning the belt. Before beginning, make sure the line on each piece of tape closest to the tail roller is aligned with the edge of the deck on each side. (See Fig 5) Step 6 Using the 1/4" Allen wrench begin tightening the tensioning screws (see Fig 1).
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.
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 Running Belt 55 Service Manual: E-TR and E-TRi
“Check Speed System” and “Check Motor System” Flowchart for Display Codes: “CHECK SPEED SYSTEM” & “CHECK MOTOR SYSTEM” Start Press 0, 2, and start keys simultaneously Screen will display “Maintenance Mode” Press “Incline – or +“ key until display reads “Last Error List” Press # 4 key Press # 2 key Does the Last Code (4) read Check MO or Check SP? Does the Last Code (2) read Check MO or Check SP? Yes Yes Press “Speed – or +“ key until display reads “Last DFR (4)xxxxxxxx” Press “Speed – or +“ key u
DFR Code 1000000, 100000 and 10000 57 Service Manual: E-TR and E-TRi
DFR Code 4000 58 Service Manual – Treadmills: E-Series x P-Series
DFR Code 1000 59 Service Manual – Treadmills: E-Series x P-Series
DFR Code 800 & 400 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 800 & 400 Solution: DFR Code = 800 DFR Code = 400 Phase Over Current / 12 Blinks Illegal Speed Command / 11 Blinks Possible Causes: Possible Causes: (1) Worn running belt. (2) Dirty running belt (3) Faulty MCB. (1) Pinched or damaged display cable. (2) Bad wire connection to drive system (3) Faulty MCB.
DFR Code 200 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 200 DFR Code = 200 DC Link Bus Under Voltage / 10 Blinks Possible Causes: (1) Low AC voltage from wall. (2) Low AC voltage from EMI filter. (3) Faulty MCB. Solution: __ G1_______ Consult with electrician to fix AC input rail voltage. Note: The AC rail voltage with a load should never drop greater than a 5 volt deferential comparing it with no load. There are many equations to measure for low rail voltage.
DFR Code 40, 20 & 10 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 40, 20 & 10 DFR Code = 40 Phase A Circuit Open / 7 Blinks DFR Code = 20 Phase B Circuit Open / 6 Blinks Solution: __ H1_______ Replace MCB __ H2_______ Replace I/O cable __ H3_______ Reinsert the phase wires into the harness connector. Note: If the wire continues to make a bad connection replace drive motor. DFR Code = 10 Phase C Circuit Open / 5 Blinks Possible Causes: (1) Bad wire connection on drive motor.
DFR Remaining Codes 63 Service Manual – Treadmills: E-Series x P-Series
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 running belt x Loose running belt To identify the cause of a slipping running belt, follow these troubleshooting steps: 1. Lift the motor shroud. 2. With the motor shroud lifted, start walking on the treadmill. Watch the head roller.
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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: support@startrac.
