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Star Trac 7600 - page 1
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.com SERVICE MANUAL Pro Tread AC 7600 x 7700 ...
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Star Trac 7600 - page 2
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 recommends that you read the entire manual prior to perf ...
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Star Trac 7600 - page 3
Service Manual: E-TR and E-TRi 1 T ABLE OF CONTENTS INTRODUCTION ................................................................................................................... ............................... 1 TABLE OF CONTENTS .............................................................................................................. ...... ...
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Star Trac 7600 - page 4
Service Manual: E-TR and E-TRi 2 Running Belt “Do Not’s” ........................................................................................................ ....................................................... 15 Cleaning a Running Belt ................................................................................................... ...
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Star Trac 7600 - page 5
Service Manual: E-TR and E-TRi 3 DFR Code 1000 .............................................................................................................................................................................. 59 DFR Code 800 & 400 ...................................................................................................... ...
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Star Trac 7600 - page 6
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 connected to a dedicated power line having an outlet with ...
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Star Trac 7600 - page 7
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 measures: 85.5” l by 34.0” w (217 x 86.5cm). ...
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Star Trac 7600 - page 8
Service Manual: E-TR and E-TRi 6 POWER (ELECTRICITY) Objectives If you are not qualified/comfortable working with electricity you should consult a certified electrician. This section should provide you with the information necessary to properly service your Star Trac unit by giving you: x A basic understanding of electrical safety x A basic underst ...
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Star Trac 7600 - page 9
Service Manual: E-TR and E-TRi 7 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 ran ...
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Star Trac 7600 - 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: ...
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Star Trac 7600 - page 11
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 activities may include cleaning, vacuuming, visual insp ...
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Star Trac 7600 - page 12
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 MONTHLY AS NEEDED Wipe down all surfaces incl uding: Display, handrails shroud a nd heart rate grips. 9 Clean under the running be ...
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Star Trac 7600 - page 13
Service Manual: E-TR and E-TRi 11 DAILY Clean x Use a 5:1 dilution ratio (5 parts water to1 part Simple Green , Formula 409 , Fantastic ,or the like). + = (5 parts water) (1 part cleaner) Apply cleaning solution to a clean cloth then wipe the following areas (Do not spray directly onto surfaces): o Display (Keypad) o Heart Rate Grips o ...
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Star Trac 7600 - page 14
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 ...
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Star Trac 7600 - page 15
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 the drive belt for tension and wear. x Inspect the p ...
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Star Trac 7600 - page 16
Service Manual: E-TR and E-TRi 14 RUNNING BEL T 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 c ...
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Star Trac 7600 - page 17
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 at regular intervals, you can help to: x Increase ...
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Star Trac 7600 - page 18
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-purpose cleaner (409 , Simple Green , etc.) x Br ...
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Star Trac 7600 - page 19
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 REQUIRED x Masking tape and pen or pencil x Ruler or tape ...
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Star Trac 7600 - page 20
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 2: Apply a piece of masking tape on the edge of t ...
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Star Trac 7600 - page 21
Service Manual: E-TR and E-TRi 19 Fig 4 Step 4: Check to make sure tha t both lines are aligned with the edge of the deck at the same point. (See Fig 4) Fig 5 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) Step 6: You are now read ...
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Star Trac 7600 - page 22
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. To move belt back towards the center if it has tr ...
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Star Trac 7600 - page 23
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 debris build up from the roller using a plastic s ...
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Star Trac 7600 - page 24
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 grip between the belt and the rollers which will re ...
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Star Trac 7600 - page 25
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 loose clothing, long hair, loose and/or hanging jew ...
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Star Trac 7600 - page 26
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 “MAINTENANCE MODE” momentarily in the information wind ...
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Star Trac 7600 - page 27
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 utilize the number pad. ALPINE PASS : Sets parameter ...
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Star Trac 7600 - page 28
Service Manual: E-TR and E-TRi 26 DISPLA Y P ARAMETERS 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 set ...
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Star Trac 7600 - page 29
Service Manual: E-TR and E-TRi 27 Parameter 110V Setting 220V Setting Default Parameter Ranges NO RAIL STOP 0 0 – 65535 KEY DOWN 0 0 – 65535 SPEED CHG 0 0 – 65535 ELEV STALL 0 0 – 65535 ELEV RANGE 0 0 – 65535 ELEV LOST 0 0 – 65535 CHECK MOTOR SYS 0 0 – 65535 CHECK SPEED SYS 0 0 – 65535 ERROR CAPTURES FUSE BITS ERROR 0 0 – 65535 EL ...
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Star Trac 7600 - page 30
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: Sets the minimum start up speed for the unit. MAXI ...
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Star Trac 7600 - page 31
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 10_REV: Sets the speed and distance calculation val ...
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Star Trac 7600 - page 32
Service Manual: E-TR and E-TRi 30 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 ...
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Star Trac 7600 - page 33
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. DISPLAY TEST The Display Test can be used to test ...
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Star Trac 7600 - page 34
Service Manual: E-TR and E-TRi 32 CALIBRATE SCALE Press ‘Start’ key Display will enter CA LIBRATE 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 M AINTENANCE MODE Press ‘1’ key Unit will read REF W ...
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Star Trac 7600 - page 35
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 CONTACT 0 , , Grab the HR grips CONTACT X should ...
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Star Trac 7600 - page 36
Service Manual: E-TR and E-TRi 34 MAINTENANCE MODE – AUT O CALIBRA TION 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 ...
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Star Trac 7600 - page 37
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 OPHR Total unit OPER HOURS (Operating Hours) at time ...
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Star Trac 7600 - page 38
Service Manual: E-TR and E-TRi 36 DFR INFORMA TION DFR’s (Drive Fault Records) The AC MCB (Motor Control Board) monitors the drive system and reports a ny 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 ...
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Star Trac 7600 - page 39
Service Manual: E-TR and E-TRi 37 SOFTW ARE - DISPLA Y 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 ( ...
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Star Trac 7600 - page 40
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 at the top then click on the Latest Product Softwa ...
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Star Trac 7600 - page 41
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 the ‘Service Providers’ tab (*2). Click on ‘ ...
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Star Trac 7600 - page 42
Service Manual: E-TR and E-TRi 40 7. Open your web browser in the Latest Product Software section. Click on the latest Display Version of software for the 7000 (7k) treadmills. 8. When you choose Display Ver X.X / X.X, the following window will appear. Click ‘Save’. 9. The following window will appear. Make sure you are in the ‘AVRISP’ fold ...
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Star Trac 7600 - page 43
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 selection box across both files to sele ...
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Star Trac 7600 - page 44
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 install into the ‘AVRISP’ folde ...
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Star Trac 7600 - page 45
Service Manual: E-TR and E-TRi 43 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. 3. Open the ‘fisp.exe’ program. 4. The Fisp program will automatically d ...
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Star Trac 7600 - page 46
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 ‘OK’ to finish and ...
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Star Trac 7600 - page 47
Service Manual: E-TR and E-TRi 45 SOFTW ARE - MCB ...
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Star Trac 7600 - page 48
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 . Click on the Service Provider tab at the top then c ...
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Star Trac 7600 - page 49
Service Manual: E-TR and E-TRi 47 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 Fig 4 Fig 5 8. Plug the uploader cable ...
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Star Trac 7600 - page 50
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 led will remain lit. If the RED led is on, the u ...
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Star Trac 7600 - page 51
Service Manual: E-TR and E-TRi 49 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 th ...
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Star Trac 7600 - page 52
Service Manual: E-TR and E-TRi 50 P ART REPLACEMENT PROCEDURES Table Of Part Replacement Procedures x Running Belt Tensioning Procedure x Display Panel (Keypad)/Electronics Replacement ...
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Star Trac 7600 - page 53
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 tensioning and tracking procedure whenever the running ...
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Star Trac 7600 - page 54
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 to make sure that both lines are aligned with the ...
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Star Trac 7600 - page 55
Service Manual: E-TR and E-TRi 53 Fig 5 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 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 ...
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Star Trac 7600 - page 56
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 the LEFT side: If the belt tracks to the RIGHT side ...
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Star Trac 7600 - page 57
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 Running Belt ...
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Star Trac 7600 - page 58
Service Manual: E-TR and E-TRi 56 “Check Speed System” and “Check Motor System” Start Press 0, 2, and start keys sim ultaneou sly Screen will display “Maintenan ce Mode” Screen will display “Press list er ror to view last error list” Press “Incline – o r +“ key until display reads “Last Er ror List” Press “OK” key Pres ...
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Star Trac 7600 - page 59
Service Manual: E-TR and E-TRi 57 DFR Code 1000000, 100000 and 10000 ...
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Star Trac 7600 - page 60
Service Manual – Treadmills: E-Serie s x P-Series 58 DFR Code 4000 ...
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Star Trac 7600 - page 61
Service Manual – Treadmills: E-Serie s x P-Series 59 DFR Code 1000 ...
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Star Trac 7600 - page 62
Service Manual – Treadmills: E-Serie s x P-Series 60 DFR Code 800 & 400 Start Turn the po wer off then b ack on at the switch. Engage Motor Test Mode. Incline th e unit to max elevation. Stand at the high est point of the incline and pu sh body weight back. Does the ru nning belt slide smoothly acro ss deck? Yes No E1 Decline unit back to zer ...
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Star Trac 7600 - page 63
Service Manual – Treadmills: E-Serie s x P-Series 61 DFR Code 200 Start Turn the unit power off at the switch. Measure AC vo ltage at th e wall outlet. Was the AC vo ltage within the specs listed above? The AC voltage should be betwee n: 95 to 125vac for a 110 v unit 185 to 250vac for a 22 0v unit G1 No Check AC volta ge coming out of the EMI fil ...
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Star Trac 7600 - page 64
Service Manual – Treadmills: E-Serie s x P-Series 62 DFR Code 40, 20 & 10 Start Turn the powe r off then back on at the switch. There is a relay on t he MCB that will activate when turning th e AC power on when unit is i n operable conditio n. Did the display beep with out the relay switch activating? Check I/O cable (display cabl e) for pinc ...
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Star Trac 7600 - page 65
Service Manual – Treadmills: E-Serie s x P-Series 63 DFR Remaining Codes ...
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Star Trac 7600 - page 66
Service Manual – Treadmills: E-Serie s 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 running belt x Loose running belt To identify the ca ...
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Star Trac 7600 - page 67
Service Manual - AC Pro Tread 7600 x 7700 65 This page intentionally left blank ...
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Star Trac 7600 - page 68
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.com Doc: 620-7734 Rev: B SERVICE MANUAL ...
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