Star Trac 8TR, Service Manual

Page 1: ...SERVICE MANUAL Startrac Treadmills Core Health Fitness ...

Page 2: ...en Elevation Calibration Procedure 36 8 Series E Series LED LCD Elevation Calibration Procedure 37 S Series Elevation Calibration Procedure 39 Embedded Screen Speed Calibration Procedure 41 All LED LCD Console Speed Calibration Procedure 41 Error Codes 42 TROUBLESHOOTING 50 Power Issues 50 Mechanical Issues 51 Electrical Issues 54 Console Issues 55 Console Procedures 57 Entertainment Issues 59 Par...

Page 3: ...al Number General Warranty Terms About Extended Warranties 8 SeriesTreadmills SKU 9 920X 9 925X 8 TRx 8 TRx Overall Weight Running Surface Width Length Height 477 lbs 216 kg 60 x 21 5 152 x 55 cm 36 91 cm 85 215 cm 63 160 cm 9 919X 8 TR Overall Weight Running Surface Width Length Height 576 lbs 261 kg 60 x 21 5 152 x 55 cm 32 81 cm 85 215 cm 60 152 cm PRODUCT SPOTLIGHT ...

Page 4: ...Weight Running Surface Width Length Height 490 lbs 270 kg 60 x 21 5 152 x 55 cm 36 91 cm 85 215 cm 79 200 cm 9 900X 9 915X 9 9002 E TR E TRi E TR Overall Weight Running Surface Width Length Height 575 5 lbs 261 04 kg 60 x 21 5 152 x 55 cm 32 81 3 cm 81 206 cm 59 77 151 81 cm E TRi Overall Weight Running Surface Width Length Height 595 lbs 270 kg 60 x 21 5 152 x 55 cm 32 81 3 cm 81 206 cm 75 190 cm...

Page 5: ...ight Running Surface Width Length Height 533 lbs 241 7 kg 60 x 20 152 x 51 cm 32 81 3 cm 81 206 cm 58 147 3 cm 9 355X 9 356X S TRx Overall Weight Running Surface Width Length Height 514 lbs 233 2 kg 60 x 20 152 x 51 cm 32 81 3 cm 81 206 cm 58 147 3 cm ...

Page 6: ...uct must be reconnected for use on a different type of electric circuit the reconnection should be made by qual ified service personnel in order to avoid a hazard 5 If the power supply cord is damaged it must be re placed by the manufacturer its service agent or similarly qualified persons in order to avoid hazard WARNING to reduce the risk of burns fire electrical shock or injury to person 1 This...

Page 7: ...ou feel pain or tightness in your chest become short of breath or feel faint If you feel pain or experience any abnormal symptoms stop exercising and consult your health care provider 9 Wear proper exercise clothing and athletic shoes during a workout Avoid wearing loose clothing Tie back long hair and keep towels away from the moving parts Face forward at all times and never attempt to turn aroun...

Page 8: ...pective owner s manuals Manuals Install Owner s 8 TRx 8 TRx 8 TR E TRx E TRxe E TRxi E TR E TRi S TRc S TRx Related Installation Manuals MYE PVS Brackets Installation Other Service Manuals For advanced troubleshooting regarding the OpenHub consoles or general TV signal issues for all touchscreens please refer to the OpenHub Service Manual OTHER MANUALS ...

Page 9: ...needed Drive System The MCB controls the power flow throughout the unit based on the commands from the display board On some models it also converts the incoming 110V into 220V nominal for the drive motor Danger High voltage in MCB Exercise extreme caution when working around live electrical components Pinouts and diagrams are provided for troubleshooting purposes only Pinout troubleshooting shoul...

Page 10: ...the elevation motor The power being sent will depend on the input voltage 110 VAC treadmills have a 110 volt elevation motor 220 VAC treadmills have a 220 VAC ele vation motor The MCB also sends 5 VDC to the elevation sensor potentiometer The MCB passes along the input VAC to the power supply The power supply then converts the input voltage to 12 VDC and sends it up to the display electronics to p...

Page 11: ... TRx E TR Part 715 3885 Note For E TRx units built prior to 2009 click here S TR S TRx S TRc 110V Version Part 740 6157 220V Version Part 740 6158 RPM Sensor Note On some older models not covered in this manual there is no external RPM sensor All Part 560 0069 Pinout RPM Disk Assembly 8 TRx 8 TR E TRx E TR Part 715 3574 S TR S TRx S TRc Part 740 6216 ...

Page 12: ...r and the LED s or in the case of embedded screens the display electronics refer col lectively to the Upper Board that has the processor and the Digitizer which displays the image and responds to touch Embedded Display Electronics 8TR TRx Part 701 0098 XX Others Part 715 3883 XX LCD LED Display Board 8TR TRx Part 701 0046 Others Part 715 3845 ...

Page 13: ...admill There are two parts of the power system external power and internal power All external components beyond the power cable are not covered by this manual and are assumed to be working in any trouble shooting step The internal components include the following parts Power Switch All Part 740 6116 ...

Page 14: ...Page 14 IEC Connector All Part 740 6083 Circuit Breaker All 110V Version Part 470 0417 220V Version Part 470 0415 EMI Filter All Part 440 0257 Basic Diagram ...

Page 15: ...plete list of alternate cords is below 220 0270 US ADAPTER CORD LINE NEMA 5 15 220 0271 US ADAPTER CORD LINE NEMA 6 15 220 0272 EU ADAPTER CORD LINE CEE 7 7 220 0273 UK ADAPTER CORD LINE BS1363 220 0274 AS NZS LINE CORD 220V IEC AS NZS3112 050 0235 China ADAPTER CORD LINE BBS 1363 220 0291 Brazil LINE CORD 220V NBR 14136 700 0136 Israel KIT LINE CORD DOCS ISRAEL S TR ...

Page 16: ...ning belt over a fresh deck surface will cause the running 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 damage will not be covered under warranty If replacing a deck due to wear it is advisable to replace the running belt as well because wear is commonly caused in conjunction with the running belt During a non...

Page 17: ... 8 TRx E TRx Part 715 3637 E TR 8 TR GEN 2 S TRc Part 740 8421 GEN 1 S TR S TRx S TRc Part 740 6055 GEN 2 S TR S TRx S TRc Part 715 3897 Running Belt All 8 TRx 8 TR E TRx E TR Part 130 1759 GEN 1 S TR S TRx S TRc Part 130 1708 Note Click Here for units prior to serial TRSC1307 L01095 110V or TRSC1306 L01000 220V GEN 2 S TR S TRx S TRc Part 740 6174 ...

Page 18: ...E TRx E TR Part 715 3689 KT GEN 1 S TR S TRx S TRc Part 800 3874 GEN 2 S TR S TRx S TRc Part 715 3689 KT Tail Roller All 8 TRx 8 TR E TRx E TR Part 715 3635 GEN1 S TR S TRx S TRc Part 740 6056 GEN 2 S TR S TRx S TRc Part 715 3695 ...

Page 19: ...Motor which includes the Elevation Sensor Potentiometer Elevation Motor All 8 TRx E TRx 110V Version Part 260 0941 220V Version Part 260 0942 8 TR E TR 110V Version Part 740 8415 220V Version Part 740 8440 S TR S TRx S TRc GEN 1 110V Version Part 740 6005 GEN 1 220V Version Part 740 6006 S TR S TRx S TRc GEN 2 110V Version Part 260 0950 GEN 2 220V Version Part 260 0951 ...

Page 20: ...Phase Drive Motor MCB EMI Filter Power Switch Central Control Board CCB Elevation Motor 8 Series Embedded Console Power Cord I O Data Cable Variable VDC FromPotentiometer 18 Amp Breaker Embedded Screen Treadmill Power Flow 110V Version Click on an icon to open the dia gram in a new window Click the button in the upper right to close the new view and return to the service manual Note these buttons ...

Page 21: ...work in a browser window Right click Save As or click the button in your browser to save this manual to your PC E Series Diagrams E TRx 110V Base 18A Standard E TRx 220V Base E TRx LED Display E TRx Embedded Display E TRx 110V Base 14A Variant E TRx Embedded Display Heartrate Detail Entertainment E TRx MyE E TRx MyE PVS E TRx PVS E TRx Updated MyE G1 E TRx Tatung PVS E TRx MyE G2 ...

Page 22: ...hese buttons will not work in a browser window Right click Save As or click the button in your browser to save this manual to your PC S Series Diagrams S TRx 110v Base S TRx 220v Base S TRx LED Display S TRc 110v Base S TRc 220v Base S TRc LED Display with C Safe S TRc LED Display no C Safe S TRci Israel 220v Base S TRci Display Entertainment S TRci MyE PVS ...

Page 23: ...nsole controls and commands most of the functions of the treadmill It is the user interface and the brain of the treadmill The console itself consists of the Display Electronics the Data Cable and one or more keypads 1 Console Boards Not all consoles have all boards please check the console diagrams for your specific unit Various boards within consoles perform the following functions Console Detai...

Page 24: ... Fit CPU software Link between converter board and Fit CPU All calculations determined from display software speed distance calories heart rate features incline percentage users program control scales functions etc Processes speed to MPH calibration and store the values Retrieves the speed sensor signal from the Translator board sensor feedback for speed calculation Input Heart Rate Signal for con...

Page 25: ...he metal contacts on the hot warm bar Polar is a wireless system that requires the user to wear the Polar chest strap Hot Bar Warm Bar The Hot Warm bar is the bar that is right in front of the user that has multiple functions and components A bar is a Hot Bar if it includes machine controls see below Hot Bar Example Warm Bar Example a Hot Bar Components 1 Stop Button 2 Emergency Stop lanyard 3 Con...

Page 26: ...Page 26 E Series S Series Consoles Embedded Console Both E S Series units use this console Part 715 3883 LED Console S Series Only Part 740 6041 LED Console E Series Only Part 715 3734 ...

Page 27: ...nit OpenHub or Navigate between different console settings E Series S Series These keys do not save the new value see OK Key below Note In older StarTrac documentation you will also see these keys represented by the following icons Increase and Decrease SPEED Keys E Series S Series Adjust the value of the displayed parameter up and down respectively in increments of 1 unit These keys do not save t...

Page 28: ...tor calibration function cal values Resets Console to default factory set tings error list List of last errors error stats N A N A Count of errors serial port tests N A N A Access to Serial Port Test function heartrate test N A N A Access to Heart Rate System Test func tion keypad test N A N A Access to Keypad Test function display test N A N A Access to LCD Test function program stats N A N A Acc...

Page 29: ...AN function ON or OFF Pause time 30 120 45 Pause duration in seconds during a program Mets OFF Enable Disable METS display Lang english Language is English ENGL German GERM Spanish SPAN Dutch DUCT Portuguess PORT French FREN Italian ITAL Swedish SWED Katakana KATA or Russian RUS Weight 50 500 226 155 70 Default user weight used in calorie cal culations if not entered by user lbs kg Max time 5 99 9...

Page 30: ...e The maximum number of minutes that a program can run The time my may changed by the facility The range is from 5 99 Weight The default weight of a user when the Quick Start program is used This value is used in the calorie count algorithm and can be changed Language The user interface language The options are Set A English Spanish French German Portuguese Set B English Dutch Swedish Italian Kata...

Page 31: ... stop The range can be set 20 60 Model Should be set to the model of the treadmill for which the display is on This will automati cally set some of the key settings to for the model to which it is set Date This should be set to the month and year that the treadmill was manufactured Example 12 10 would be December 2010 It is used for reference only and does not have any war ranty implications and i...

Page 32: ... has a sub menu of settings that are related specifically to elevation or speed calibration 10 Rev This the distance in inches that the running belt moves for ever ten rotations of the flywheel This number is critical for accurate speed calculations CNT RV This is the number of counts of the RPM sensor that equal one revolution of the flywheel which is 31 This number must never change Minimum PWM ...

Page 33: ...CCB When a PVS CCB is properly connected the version of software in the CCB will be display USB When a PVS CCB is properly connected the version of software for the USB is displayed Manager Mode E TR E TRx Only From the idle screen unit is powered on but not in a program press and hold the and keys together The word MANAGER will temporarily show in the marquee window and then go to the first setti...

Page 34: ... LCD displays as well as a few extra options related directly to touchscreens such as touchscreen calibration A limited Manager Mode is also available on the touchscreens Refer to the OpenHub Service Manual for more information and complete instructions on mainte nance and manager mode SERVICE MENU To access Service Menu options 1 While in Home Screen press VOL Up CH TRK Up and 3 simultaneously W ...

Page 35: ...me allowed for a single workout Weight The default user weight used for Quick Start programs Oper Hours The cumulative amount of usage hours Dist Logged The cumulative distance logged METs Display Allows the manager owner to select the METs Availability ON or OFF Pause Time Allows the manager owner to select the length of the pause 30 45 60 90 or 120 seconds Auto Fan Allows the manager owner to se...

Page 36: ...on Procedure Calibrates the incline of the treadmill 1 While in Home Screen press VOL Up CH TRK Up and 3 simultaneously 2 Service Menu will now be displayed 3 Select the Calibration and Setup sub menu from the list 4 Enter the password 218 on the pop up window requesting a Password 5 Select Incline Calibration on the Calibration and Setup screen 6 Press START to begin the calibration 7 After the I...

Page 37: ...ord MAINTENANCE will temporarily show in the marquee window then go to the first setting 3 Press the until the marquee window reads MODEL Verify that the model shown on the right side of the information window matches the base it is installed on i e 8TR vs 8TRx Note If the model is not correct use the to toggle between model types then press when the correct one is showing ...

Page 38: ...ion number reads 229 or 228 7 Press to save the minimum elevation 8 Press the key until the treadmill stops at its highest elevation 9 Press the raising the elevation count on the informa tion screen by 3 4 numbers which will slightly lower the tread mill Example if the elevation number stops at 8 then press the incline button until the elevation number reads 11 or 12 10 Press to save the maximum ...

Page 39: ...o raise the treadmill until it stops 4 Press the key to toggle between upper and lower elevation settings When adjusting the upper limit the line should be at the top 5 With the treadmill elevated at its highest point use the elevation down key to lower the treadmill 4 numbers from its high point reading This will increase the number displayed i e decreasing elevation will display from 30 to 34 6 ...

Page 40: ...he treadmill lowered at its lowest point use the eleva tion up key to raise the treadmill 4 numbers from its low point reading This will decrease the number displayed i e increasing elevation will display from 236 to 232 10 Press the Burn Calories button to save the lower limit the display will say UPDATING 11 Now the upper and lower limits have been set the elevation is calibrated Press the twice...

Page 41: ... is completed press EXIT The Calibration And Setup screen appears 8 Press Cancel to exit and go back to the Home Screen 9 The Speed Calibration has been completed All LED LCD Console Speed Calibration Procedure 1 From the idle screen unit is powered on but not in a program press and hold the and keys together 2 The word MAINTENANCE will temporarily show in the marquee window then go to the first s...

Page 42: ...not sufficient Bleeder wire is broken or missing CHK SPD SP Change Drive System RPM sensor gap is too big RPM sensor is not plugged in to the MCB RPM sensor is not completely plugged into the MCB MCB is not sending power to the RPM sensor Rail Stop Hot bar Emergency stop switch depressed Emergency stop switch failure or corrosion Emergency stop switch wire harness failure or corrosion ELV Stall Di...

Page 43: ...ard failure Console failure Related docs 637 4297 Treadle ERR Treadclimbers only Drive system Lower board failure Treadle optical sensors Treadle optical sensor wire harness Lower board This error can be triggered as a user walks and the range of motion is limited which prevents one of the optical sensors from triggering This is a soft error that will not interrupt user operation see 637 1534 Batt...

Page 44: ...he Display 3 If the problem still persists change the comms cable FIT_ERROR 5 ERR_ALL_QRYID_RESP_TIMEOUT No query id response received from display or XCB This is reported when the FitCPU does not receive a query id response from both the display and xCB during boot up 1 Re boot the unit and see if the prob lem goes away 2 If the problem persists check the comms cables between the FitCPU and the D...

Page 45: ...ISP_ERROR 15 ERR_CCB_READ_TIMEOUT Timeout during EEPROM read from CCB This is reported when the Display times out waiting for a read from the EEPROM on the CCB 1 Re boot the unit and see if the prob lem goes away 2 If the problem persists check the comms cable between the Display and the CCB 3 If the problem still persists change the comms cable DISP_ERROR 16 ERR_CCB_READ_FAILED CCB reports EEPROM...

Page 46: ...imeout This is reported when there is no com munication between the Display and the FitCPU for more than 2 seconds 1 Re boot the unit and see if the prob lem goes away 2 If the problem persists check the comms cable between the FitCPU and the Display 3 If the problem still persists change the comms cable DISP_ERROR 24 ERR_FIT_INVALID_PROG_PARAME TERS Fit reports invalid program parame ters This in...

Page 47: ...nd see if the prob lem goes away 2 If the problem persists replace the computer DISP_ERROR 32 ERR_CCB_FIFO_WRITE Error writing to CCB FIFO This is reported when the computer has an internal error 1 Re boot the unit and see if the prob lem goes away 2 If the problem persists replace the computer DISP_ERROR 33 ERR_INVALID_PROD_ID Invalid Product Id This is reported if the product id is invalid 1 Re ...

Page 48: ...nce Mode and ensure it is correct 3 Re calibrate the Speed FIT_ERROR 40 ERR_MCB_SPEED_LOST Fit CPU reports MCB error status Speed lost RPM Sensor 1 Re boot the unit and see if the prob lem goes away 2 If the problem persists check the Product Model in Maintenance Mode and ensure it is correct 3 Re calibrate the Speed 4 If the problem persists check the speed sensor Rotate the flywheel on the motor...

Page 49: ...ibration then the cable from the elevation motor to the MCB should be checked If the cable is OK then the elevation motor should be replaced FIT_ERROR 43 ERR_MCB_UNKNOWN_ERROR Fit CPU reports MCB error status Un known error status from MCB This error is a place holder for future error codes from the MCB FIT_ERROR 255 ERR_E_STOP Fit CPU detected emergency stop condition 1 Reset the E Stop switch an...

Page 50: ...rd or the power cord pulls itself out over time 637 4340 E Series Only Selecting the correct replacement power cord on an 8 Series 637 8485 8 Series Only The power cord is loose E TR S TRc only 637 1589 The power cord is loose Other E Series S Series 637 1308 Installing the IEC Power Cord Tension Relief kit on an E TRx 637 4240 The reset button on the warm bar is sticking 637 1347 A 220v S TRc man...

Page 51: ...e head roller or movement isn t smooth 637 1445 The running belt isn t centered on the rollers 637 1445 The running deck makes a squeaking noise when in use 637 1546 The running belt is lifting on the sides or ripping at the seam 637 1445 The physical speed of the running belt is noticeably higher or lower than the display shows 637 1343 Elevation Performing an Elevation Calibration LED LCD Consol...

Page 52: ...r or DFR Code 637 4467 Identifying MCB changes in 2010 MCB s 637 1338 Legacy prior MCB s are no longer produced Resolving Specific DFR Codes DFR Code 0 or 1 637 1441 DFR 80 or 800 637 1445 DFR Code 1000 637 1442 DFR Code 1 000 000 637 1364 E Series Only MCB Troubleshooting Setting up a FISP for use 635 4091 Downloading software for a FISP on a PC 635 4092 Loading software onto a FISP from a PC 635...

Page 53: ...Version 2 MCB Troubleshooting including Loose Components on 2011 MCBs MCB Transformers from 2010 Specific troubleshooting for errors Check Speed System Check Motor System DFR 100 000 DRF 1 000 000 Error Code 40 Treadmill won t calibrate MCB won t power up Speed Fluctuation Treadmill will reset 637 1394 ...

Page 54: ...37 1381 Testing without MCB Power 637 1380 No Power Flowchart Additional Troubleshooting 637 1383 A treadmill resets shortly after starting a program 637 1364 Testing a LED Keypad for working buttons 637 1373 MCB Will Not Power Up 637 1378 LED Fans won t turn on E Series with a Version 1 MCB Only 637 1379 E Series Only LED Lights are disabled only on the Fan Keypad 637 1357 Units prior to 2011 Hot...

Page 55: ... doesn t function or the fan button isn t blue 637 8481 OpenHub Only LED has a horizontal line across the display 637 4232 Console serial prior to EDEN1410 0000 only Step By Step for Specific Embedded Error Codes Error Code 6 637 1420 Error Code 14 637 4543 Error Code 17 637 4544 Error Code 21 637 4545 Error Code 23 637 4340 Error Code 38 637 1329 Error Code 42 637 1334 Choppy Video and Out of Syn...

Page 56: ...B loading screen or shuts down shortly after showing it 637 1408 An embedded console is missing the Coach 637 4211 Coach video or audio not working 637 1329 Coach audio works for a few minutes then stops working 637 1408 A heartrate appears on the console when not being used 637 4550 An E Series treadmill will not perform auto calibration 637 1364 No sound from the Headphone Jack 637 4535 E TRxe O...

Page 57: ...22 Identifying the correct keypad for a unit 637 4505 Accessing the Maintenance Mode 637 4540 Accessing the Diagnostic Mode 637 4533 Accessing the Manager Mode 637 4534 Accessing the Last Error List 637 1395 Accessing the Service Menu 637 4542 Accessing and reading the Usage Statistics 637 4541 Performing a Touchscreen Calibration 637 4532 Determining Made for iPod Compatibility 637 1330 Performin...

Page 58: ...3 Embedded 637 1370 E Series Updating the GUI to version 5 58 637 4475 Updating the CCB FitCPU Translator Board or for the GUI 637 1307 Step by Step Updating the GUI 637 4537 Updating the PVS controller software 637 4549 S Series Only Updating the PVS software on a Made For iPod PVS 637 4547 Updating S Series LCD with FISP 637 4548 S Series Only Step by Step Updating Software on S Series Treadmill...

Page 59: ... 1415 PVS will not turn on E Series Power Supply Testing 637 1379 Installing new PVS on Legacy Equipment 637 4356 Installing iPod Cable Port Plugs 637 1467 iPod Ready units only Understanding Nike and eFitness Requirements 637 1337 Only One Headphone Jack Working 637 1433 Parental Locks Stuck On 637 1388 Troubleshooting other PVS Errors including 637 1401 Poor Screen Connection with Poor Picture Q...

Page 60: ...l Only digital channels are available Only Analog channels are available Only 12 channels are available Some channels have a black screen Some channels state they are not available Some channels only get audio During a TV scan some channels are missing Poor Sound Quality TV Embedded Screen is entirely Green No Channels Found No TV Icon ...

Page 61: ...7 4553 Step by Step Replacing the Drive Motor 637 4241 Step by Step Replacing the Elevation Motor 637 4555 Replacing the Idler Arm on an S Series or E Series Treadmill 637 4273 Replacing the iPod Cable on a E TRxe Embedded Display 637 4529 Step by Step Replacing the RPM Sensor 637 4551 Step by Step Replacing the Rubber Deck Cushions 637 1473 ...

Page 62: ... 2018 CORE HEALTH FITNESS LLC PART NUMBER 620 8558 REV B ...