STAR TRAC FITNESS Pro Tread AC 7600, Service Manual

Page 1: ...tar Trac Fitness 14410 Myford Road Irvine California 92606 800 503 1221 Tel 714 669 1660 Tel 714 669 0739 Fax X http support startrac com email support startrac com SERVICE MANUAL Pro Tread AC 7600 77...

Page 2: ...act the Star Trac Customer Service department during regular hours of operation Star Trac Customer Support contact information USA Hours Monday thru Friday excluding U S holidays Check the support web...

Page 3: ...ring 7 Power Cords 8 PREVENTIVE MAINTENANCE 9 Overview 9 Value of Preventive Maintenance 9 Determining When to Perform Maintenance 9 Preventive Maintenance Cautions 9 Preventive Maintenance Schedule 1...

Page 4: ...ST 33 INFRARED TEST 33 LAST ERROR LIST 33 MAINTENANCE MODE AUTO CALIBRATION 34 LAST ERROR LIST DEFINITIONS 35 DEFINITIONS 35 LAST ERROR LIST BANKS 35 DFR INFORMATION 36 DFR s 36 Same Codes Different M...

Page 5: ...Service Manual E TR and E TRi 3 DFR Code 1000 59 DFR Code 800 400 60 DFR Code 200 61 DFR Code 40 20 10 62 DFR Remaining Codes 63 Slipping Running Belt 64...

Page 6: ...ake sure that the equipment you are working on is turned off and unplugged BEFORE performing any work unless otherwise noted or when necessary for voltage testing When replacing fuses be sure the fuse...

Page 7: ...ly there must be at least 48 inches 1 25 m of free space behind the treadmill The Pro Series treadmill measures 85 5 l by 34 0 w 217 x 86 5cm See the following graph for proper equipment spacing requi...

Page 8: ...VAC o 220V or 220VAC WATT The rate at which an electrical device consumes energy OHM A measurement of resistance o Ohm s Law Current I V R I current V voltage R resistance V I R Depending on what you...

Page 9: ...lug NEMA Configurations U S A 110V Commercial 220V Commercial 110V Home NEMA 5 20 NEMA 6 15 NEMA 5 15 Plug Receptacle Plug Receptacle Plug Receptacle In this configuration the HOT line is in the norma...

Page 10: ...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: ...ome types of PM need to be performed more often than others The frequency of PM depends a great deal on the use and environment of the unit Star Trac has a baseline of procedures that should be perfor...

Page 12: ...and around treadmill 9 Inspect inside surface of running belt and top of deck 9 Correct any display or handrail squeaks and rattles 9 Visually inspect display panel keypad for wear 9 Vacuum inside shr...

Page 13: ...ipe the following areas Do not spray directly onto surfaces o Display Keypad o Heart Rate Grips o Handrails o Shroud o Side Bed Covers o Under Belt Edge Inspect Inspect running belt for proper alignme...

Page 14: ...EEKLY Clean Elevate the treadmill and vacuum the floor around and underneath Inspect Inspect display panel keypad for wear Inspect inside of running belt and top of deck Inspect all mounting hardware...

Page 15: ...e power cord for pinches and or broken prongs Lubricate Wipe and debris from the elevation screws then lubricate Use a spray lithium grease or a thin coating of grease Avoid thin lubricants i e TriFlo...

Page 16: ...from the factory with a Waxless running belt and deck system It is not necessary to regularly wax rewax or lubricate the running belt and deck on these models Wax may be applied to alleviate running...

Page 17: ...ate the layers of the belt resulting in curled edges folded edges and ripples in the center of the walking area Checking for proper running belt tension can help ensure that the running belt is not to...

Page 18: ...side of the frame to the other B Hold the edges of the towel and pull towards the tail roller then pull back towards the head roller C Rotate the running belt around and repeat to completely wipe the...

Page 19: ...Y After 1 000 Miles 1 600 Km OR 1 Month Whichever comes first Clean deck with dry cloth and retighten belt using procedure below After 6 000 Miles 10 000 Km OR 6 Months 12 000 Miles 20 000 Km OR 12 Mo...

Page 20: ...ouches the finger guard The belt should be completely relaxed Note This applies to both left right finger guards Fig 2 Step 2 Apply a piece of masking tape on the edge of the running belt on both side...

Page 21: ...ece of tape closest to the tail roller is aligned with the edge of the deck on each side See Fig 5 Fig 6 Step 6 Using the 1 4 Allen wrench begin tightening the tensioning screws see Fig 1 You will tig...

Page 22: ...ither side left or right follow the appropriate procedure below To move belt back towards the center if it has tracked to the LEFT side To move belt back towards the center if it has tracked to the RI...

Page 23: ...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 th...

Page 24: ...ered Paraffin Wax Part No 140 3180 2 Phillips screwdriver Towel 36 x 12 90cm x 30cm is suggested Plastic drinking straw large diameter S SA AF FE ET TY Y F FI IR RS ST T Caution should be exercised at...

Page 25: ...bottle of wax Fig 6 Start the treadmill at 3 0 mph 5 0 kmh While the treadmill is running squirt about 5 8 times on the left side onto the underside of the running belt Fig 7 and 5 8 times on the rig...

Page 26: ...ad 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 You will n...

Page 27: ...SS 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 OK key Updates saves the...

Page 28: ...N TIME 99 20 99 OPER HOURS 0 0 65535 DISTANCE 0 0 65535 WEIGHT 155 0 350 SERIAL NO 0 0 65535 LANGUAGE ENGLISH ENGLISH DUTCH FRENCH GERMAN PORTUGUESE SPANISH SWEDISH ITALIAN KATAKANA ENTRY UNITS UNITS...

Page 29: ...0 0 65535 LAST BELT 0 0 65535 LAST MOTOR 0 0 65535 CS AUTO STATUS ON OFF ON MODEL PRO AC PRO S PRO PRO ELITE PRO AC PRO ELITE AC HR CALC TIME 30 0 99 MANUAL 0 0 65535 FOREST WALK 0 0 65535 TRAIL 0 0...

Page 30: ...ult an Owners Manual or a certified trainer for definition WATTS Used for workout feedback Consult an Owners Manual or a certified trainer for definition PAUSE Sets the amount of time in seconds that...

Page 31: ...defaulted back to 0 zero during each maintenance session To Reset While on the parameter press the ALPINE PASS key to reset value to 0 then press the OK key or the START key to save the change NO RAIL...

Page 32: ...This aids in your record keeping CS AUTO STATUS An internal calculation setting Leave at default setting MODEL Sets the model that the display electronic board will be used on Note that some features...

Page 33: ...ill enter DISPLAY TEST and await your next command Press 1 key MC1 Vx x CKSM xxxx will display Press Speed Plus key MC2 Vx x CKSM xxxx will display Press Speed Minus key MC1 Vx x CKSM xxxx will displa...

Page 34: ...previous step Pressing Stop will return to MAINTENANCE MODE Press 2 key Display will read PLACE CAL WEIGHT ON WEIGHT PADS PRESS OK TO BEGIN Loop After pressing OK unit will read CALIBRATING X X calibr...

Page 35: ...section in this manual Press Start key Display will enter DISPLAY TEST and await your next command Press Start key Display will cycle thru a self test and display all led s in a sequenced pattern Pres...

Page 36: ...SETTING 1 Enter the Maintenance Mode see Engaging Maintenance Mode The display will read 2 Enter the Motor test mode by pressing the 8 key once The display will read 3 Start the auto calibration proce...

Page 37: ...ST CODE 0 LAST CODE 0 LST CHK 0000000 LST CHK 0000000 LST CHK 0000000 LST CHK 0000000 LST CHK 0000000 LAST MTR CURR 0 LAST MTR CURR 0 LAST MTR CURR 0 LAST MTR CURR 0 LAST MTR CURR 0 LAST STAT 0000 LAS...

Page 38: ...e LAST ERROR LIST in the MAINTENANCE MODES TEST MODES section Scroll the parameters until you come to the LAST DFR There will be an 8 digit number that is the DFR code Example LAST DFR X 00004000 over...

Page 39: ...In order to use these uploaders you must install software onto a computer which allows you to upload the treadmill software into each box Those boxes can be used to update the software in the E TR an...

Page 40: ...s and connecting the RS232 cable to the PC Installing the FISP software onto your PC FISP software is used to put the Pro Tread software into the uploader boxes Installing Pro Tread software into the...

Page 41: ...re 3 Click on the FISP Loader Program link 4 2 When you choose FISP Loader Program the following window will appear Click Save 3 The following window will appear Do not click Open yet 4 Move your mous...

Page 42: ...you are in the AVRISP folder Click Save End of procedure Extracting Unzipping the Zip Files 1 Open the AVRISP folder Right click on fisp_setup zip then left click on Open with Winzip 2 If using the f...

Page 43: ...the selection box across both files to select them both 2 Once both files are selected click and hold one of them and drag them to the white space in the AVRISP folder 3 7 The AVRISP folder should loo...

Page 44: ...appears click Run 2 Click Next to run the setup wizard 3 Make sure you are going to install into the AVRISP folder then click Next 4 Create the Start Menu folder as Fisp 5 This is your choice for a de...

Page 45: ...l display the FISP USB Ver X X as shown below 5 Under the Device drop down menu choose the Mega128 PROJECT CHANGE POINT You will need to upload one program at a time Primary or Secondary Follow the ne...

Page 46: ...ck on Load Fisp to send software to the uploader 11 You will see a Transferring Date status window Click Close when prompted 12 This will complete the programming of the Primary uploader Return to the...

Page 47: ...Service Manual E TR and E TRi 45 SOFTWARE MCB...

Page 48: ...iver CAUTION DO NOT TOUCH THE MOTOR CASE WITH THE POWER ON THE CASE OF THE MOTOR IS LIVE IN THE CIRCUIT AND CAN RESULT IN ELECTRICAL SHOCK Fig 1 Set Up Procedure for Programming mode 1 Turn the treadm...

Page 49: ...Fig 3 Jumpers in PROGRAM mode Fig 3 Fig 4 Fig 5 8 Plug the uploader cables to the uploader box Plug the power cable into the uploader inserting the small pin connector into the small hole Plug the RS...

Page 50: ...s then repeat the procedure If the GREEN led is on the upload was successful proceed to the next step Setting Back To Run Mode 1 Turn the power off at the on off switch 2 Move the jumpers back to thei...

Page 51: ...jumpers J1 and J2 should be blinking If they are lit solid 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...

Page 52: ...Service Manual E TR and E TRi 50 PART REPLACEMENT PROCEDURES Table Of Part Replacement Procedures Running Belt Tensioning Procedure Display Panel Keypad Electronics Replacement...

Page 53: ...h Whichever comes first Clean Deck with dry cloth and Retighten Belt using procedure below After 6 000 Miles 10 000 Km OR 6 Months 12 000 Miles 20 000 Km OR 12 Months 18 000 Miles 30 000 Km OR 18 Mont...

Page 54: ...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 55: ...e edge of the deck on each side See Fig 5 Fig 6 Step 6 Using the 1 4 Allen wrench begin tightening the tensioning screws see Fig 1 You will tighten or stretch the run belt until the forward lines on t...

Page 56: ...he LEFT side If the belt tracks to the RIGHT side Turn the LEFT bolt turn clockwise Turn the RIGHT bolt turn counter clockwise Turn the LEFT bolt turn counter clockwise Turn the RIGHT bolt turn clockw...

Page 57: ...ROUBLESHOOTING Table Of Troubleshooting Documents Check Speed System and Check Motor System Troubleshoot DFR Codes Code 1000000 100000 10000 Code 4000 Code 1000 Code 800 400 Code 200 Code 40 20 10 Rem...

Page 58: ...FR 4 register all zero Press 3 key No Yes Does the Last Code 3 read Check MO or Check SP No Press Speed or key until display reads Last DFR 3 xxxxxxxx Yes Does DFR 3 register any greater that zero Yes...

Page 59: ...Service Manual E TR and E TRi 57 DFR Code 1000000 100000 and 10000...

Page 60: ...Service Manual Treadmills E Series P Series 58 DFR Code 4000...

Page 61: ...Service Manual Treadmills E Series P Series 59 DFR Code 1000...

Page 62: ...pinched or damagd F3 F4 No Yes End End DFR Code 800 Phase Over Current 12 Blinks Possible Causes 1 Worn running belt 2 Dirty running belt 3 Faulty MCB DFR Code 400 Illegal Speed Command 11 Blinks Pos...

Page 63: ...ut AC voltage should be less than a 5 volt deferential from the original AC voltage that was taken with out a load G1 G3 No Yes End DFR Code 200 DC Link Bus Under Voltage 10 Blinks Possible Causes 1 L...

Page 64: ...e motor harness connector or for a damaged wire Yes Was there a damaged wire or bad connection on the phase wires to harness connector H2 No H3 H1 Yes No End DFR Code 40 Phase A Circuit Open 7 Blinks...

Page 65: ...Service Manual Treadmills E Series P Series 63 DFR Remaining Codes...

Page 66: ...ses 1 The running belt is worn Check the condition of the running belt Feel the underside of the belt If the belt feels glazed glossy in the center it is worn and should be replaced The underside of t...

Page 67: ...Service Manual AC Pro Tread 7600 7700 65 This page intentionally left blank...

Page 68: ...Star Trac Fitness 14410 Myford Road Irvine California 92606 800 503 1221 Tel 714 669 1660 Tel 714 669 0739 Fax X http support startrac com email support startrac com Doc 620 7734 Rev B SERVICE MANUAL...