Star Trac 7600, 7700 User Manual

x

x

SERVICE MANUAL

Pro Tread AC

7600

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

7700

email: [e-mail]

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. This service manual is intended for use by a qualified technician as a
guide to diagnose and repair service issues on the referenced product.

If you have any questions or require additional assistance, contact 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 website for operating hours and holiday schedule

Toll Free: 800-503-1221

Tel: [phone]

Fax: [phone]

Website: http://support.startrac.com

Email: [e-mail]

Europe

Hours: Monday thru Friday

Tel: [phone]

Fax: [phone]

Website: http://support.startrac.com

Email: [e-mail]

(excluding U.K. holidays)

Español

Hours: Monday thru Friday

Website: http://support.startrac.com

Email: [e-mail]

Tel: [phone]

Fax: [phone]

(excluding U.S. holidays)

Asia/Middle East

Hours: Monday thru Friday

Tel: [phone]

Fax: [phone]

Website: http://support.startrac.com

Email: [e-mail]
Email: [e-mail]

(excluding Asia/M.E. holidays)

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Service Manual: E-TR and E-TRi

TABLE OF CONTENTS

INTRODUCTION.................................................................................................................................................. 1

TABLE OF CONTENTS ....................................................................................................................................... 1

PRECAUTIONS - SAFETY .................................................................................................................................. 4

ELECTRICAL SAFETY ................................................................................................................................................. 4

MECHANICAL SAFETY ...............................................................................................................................................4

EQUIPMENT PLACING ...................................................................................................................................... 5

POWER (ELECTRICITY) .................................................................................................................................... 6

Objectives .......................................................................................................................................................................... 6

Safety ................................................................................................................................... Error! Bookmark not defined.

Terminology ........................................................................................................................ Error! Bookmark not defined.

General Electricity............................................................................................................................................................ 7

Electrical Tools ................................................................................................................................................................. 7

Wiring................................................................................................................................................................................ 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................................................................................................................................. 10

*Running Belt & Deck Rewaxing..................................................................................................................................................10

DAILY ............................................................................................................................................................................. 11

Clean ..............................................................................................................................................................................................11

Inspect ............................................................................................................................................................................................ 11

WEEKLY ........................................................................................................................................................................ 12

Clean ..............................................................................................................................................................................................12

Inspect ............................................................................................................................................................................................ 12

MONTHLY ..................................................................................................................................................................... 13

Clean ..............................................................................................................................................................................................13

Inspect ............................................................................................................................................................................................ 13

Lubricate.........................................................................................................................................................................................13

BI-MONTHLY.................................................................................................................... Error! Bookmark not defined.

Calibration and System Check ........................................................................................................Error! Bookmark not defined.

AS NEEDED ...................................................................................................................................................................13

Belt Service .................................................................................................................................................................................... 13

RUNNING BELT................................................................................................................................................. 14

Importance of Running Belt Maintenance ................................................................................................................... 15

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Service Manual: E-TR and E-TRi

Running Belt “Do Not’s” ...............................................................................................................................................................15

Cleaning a Running Belt ................................................................................................................................................ 16

Running Belt Tension..................................................................................................................................................... 17

Running Belt Alignment ................................................................................................................................................ 20

Roller Care & Maintenance........................................................................................................................................... 21

Applying Wax to a Waxless Running Belt ................................................................................................................... 22

MAINTENANCE MODE .................................................................................................................................... 24

Engaging Maintenance Mode ........................................................................................................................................ 24

Maintenance Mode Keys................................................................................................................................................ 25

DISPLAY PARAMETERS .................................................................................................................................. 26

Parameter Defaults.........................................................................................................................................................26

Parameter Setting Definitions ....................................................................................................................................... 28

MAINTENANCE MODE – TEST MODES ....................................................................................................... 31

DISPLAY TEST ............................................................................................................................................................................31

MOTOR TEST...............................................................................................................................................................................31

BELT/DECK TEST .......................................................................................................................................................................31

CALIBRATE SCALE....................................................................................................................................................................32

CSAFE TEST.................................................................................................................................................................................33

HEART RATE TEST.....................................................................................................................................................................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 Meanings................................................................................................................................................... 36

How Do You Know What or If a DFR Code Has Been Captured?................................................................................................ 36

SOFTWARE - DISPLAY..................................................................................................................................... 37

Uploaders......................................................................................................................................................................... 37

Uploading Software into the Uploaders........................................................................................................................ 38

SOFTWARE - MCB ............................................................................................................................................ 45

Uploading Software into the AC MCB with MCB Uploader .....................................................................................46

PART REPLACEMENT PROCEDURES.......................................................................................................... 50

Table Of Part Replacement Procedures ....................................................................................................................... 50

Running Belt Tensioning Procedure............................................................................................................................. 51

TROUBLESHOOTING ....................................................................................................................................... 55

Table Of Troubleshooting Documents..........................................................................................................................55

“Check Speed System” and “Check Motor System”...................................................................................................................... 56

DFR Code 1000000, 100000 and 10000 ........................................................................................................................................57

DFR Code 4000.............................................................................................................................................................................. 58

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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

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Service Manual: E-TR and E-TRi

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. If the product
must be reconnected for use on a different type of electric circuit, the reconnection should be made
by qualified service personnel.

Your safety and the safety of those around you must come first

when working on any piece of Star Trac equipment!

ELECTRICAL SAFETY

x Always make 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.

x When replacing fuses, be sure the fuses are of the correct amperage rating. DO NOT exceed the fuse

amp rating. If necessary use a fuse of lower rating until the proper fuse may be obtained.

x When checking continuity at the wire connector, insert the test probe carefully to prevent the terminals

from bending.

x To pull apart electrical connectors, pull on the connector itself, not the wires.

MECHANICAL SAFETY

x When working on any mechanical equipment, be sure they are not moving when placing your body

parts anywhere near them.

x Avoid wearing loose clothing and jewelry while performing work on any unit with moving parts, whether

they are moving or not.

The 7600 and 7700 treadmills weight approximately 323 lbs (146.5 kg). Use caution when lifting,
moving or servicing.

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Service Manual: E-TR and E-TRi

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). See the following graph for
proper equipment spacing requirements:

inches

(0.5 m)

m 20.0 o

m 20.0 o

inches

(0.5 m)

inches

(1.25 m)

m 48.0 o

m 20.0 o

inches

(0.5 m)

m 20.0 o

m 48.0 o

inches

(0.5 m)

inches

(1.25 m)

m 20.0 o

inches

(0.5 m)

m 20.0 o

m 48.0 o

inches

(0.5 m)

inches

(1.25 m)

m 20.0 o

inches

(0.5 m)

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Service Manual: E-TR and E-TRi

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 understanding of electrical terminology
x A basic understanding of electricity in general
x A basic understanding of electrical tools
x An overview of your Star Trac unit

Safety

See the “PRECAUTIONS – SAFETY” section of this manual.

Terminology

CURRENT – The number of electrically charged particles that flow past a given point on a
circuit in a given time

AMPERE (AMP) – A measure of current
VOLT – Measures the current pressure of a circuit

x Star Trac refers to the 2 most common global voltages as:

o 110V (or 110VAC)
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 = current, V = voltage, R = resistance

I = V / R

V

I =



R

Depending on what you are trying to solve, other variations can be made:

Voltage:

Resistance:

V = I x R
R = V / I

All variations of Ohm’s Law are mathematically equal to one another.

RESISTANCE – Used to dissipate passing current into heat to lower a voltage. Resistance
is measured in Ohm’s.

POTENTIOMETER (POT) – An electronic component which has an adjustable resistance
HOT wire – Delivers power to the unit. Typically has black, brown, or red insulation
NEUTRAL wire – Once electricity has done its work, it goes back through the neutral wire

to complete the circuit. Typically has white or blue insulation
GROUND wire – In addition to the neutral wire, the ground wire offers current another path
should an electrical short happen. Also help to dissipate static build-up from the running
belt and other components. Typically has green insulation (may be bare copper in some
cases)

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Service Manual: E-TR and E-TRi

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. For this service
manual we will refer to the digital style for diagnostics.

Wiring

The 7600 or 7700 series treadmill is intended for commercial usage. Depending on the location type
and country a unit is manufactured for, it will come equipped with a special power cord and plug.

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 normal 110V position, while the
NEUTRAL line has been turned 90q.

In this configuration, both the HOT and
NEUTRAL 220V lines are horizontal
(both opposite from the 110V config.)

This is the US standard 15 amp
configuration. Both HOT and
NEUTRAL lines are vertical.

THIS CONFIGURATION SHOULD

ONLY

BE USED ON TREADMILL

MODELS INTENDED FOR HOME

USE WITH A 15 AMP CIRCUIT

BREAKER!

Wire Configurations

HOT NEUTRAL GROUND
USA Wire
European Wire

Black White Green
Brown Blue Green/White

Green/Yellow

US Plugs

Small Flat prong Large Flat prong Round prong

Note: Some US units may have European wiring colors.

Star Trac treadmills require a “Dedicated” power line for proper operation and safety. Units should
never share a neutral or ground line. One 20 amp (or 15 amp) breaker per panel per treadmill only.

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Service Manual: E-TR and E-TRi

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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Service Manual: E-TR and E-TRi

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.

Value of Preventive Maintenance

Long-term benefits of proper regular preventive maintenance include:

x Decreased product downtime
x Decreased cost of repair
x Improved product reliability
x Continuous user satisfaction

Long-term effects and cost comparisons usually favor preventive maintenance

over performing maintenance actions only when the system fails.

Determining When to Perform Maintenance

Some 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 performed at pre-determined intervals (as
outlined in the “Preventive Maintenance Schedule” section). It is imperative to understand that this is
a baseline and PM schedules should be adapted to the environment and usage that the unit receives.

Preventive Maintenance Cautions

x While maintaining equipment you will want to avoid spraying any liquids directly onto any

surface of the unit. Always spray cleaning solutions onto a clean towel first then wipe the unit.

x While vacuuming the floor area using an upright vacuum, avoid getting the power cord caught

in the beater-brush of the vacuum.

x Disconnect the power cord from the wall before vacuuming under the shroud.
x Use extreme caution while vacuuming around wires and/or electrical components under the

shroud.

x Do not attempt to clean the running belt with a mop
x Do not apply any cleaners, protectants or solutions onto the running belt (i.e. Armor All,

SlickStuff, belt dressing, etc.)

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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 including:

Display, handrails shroud and heart rate grips.

Clean under the running belt (soft cloth only)

Visually inspect running belt for alignment and tension

Ensure the power cord is not under the treadmill

Vacuum floor under and around treadmill

Inspect inside surface of running belt and top of deck

Correct any display or handrail squeaks and rattles

Visually inspect display panel (keypad) for wear

Vacuum inside shroud

Visually inspect the drive belt

Visually inspect the power cord for pinches or breaks

Wipe clean and lubricate elevation screws

Change belt and flip/new deck

Running belt & deck rewaxing*

* *

*Running Belt & Deck Rewaxing

The Pro Tread models 7600 and 7700 are equipped 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.
Wax may be applied to alleviate running belt noise (see waxing instructions).

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Service Manual: E-TR and E-TRi

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 Handrails
o Shroud
o Side Bed Covers
o Under Belt Edge

Inspect

x Inspect running belt for proper alignment

(see Running Belt section for adjustment)

x Inspect for wear and tear on exterior parts

to include:

o Side stop switch for function
o Shroud, housing and other

plastics for damage

o Running belt seam for tears or

splits

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Service Manual: E-TR and E-TRi

WEEKLY

Clean

Inspect

x Inspect display panel (keypad) for wear
x Inspect inside of running belt and top of

x Inspect all mounting hardware and

Elevate the treadmill and vacuum the floor
around and underneath.

deck

correct any squeaks or rattles

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Service Manual: E-TR and E-TRi

MONTHLY

Clean

x Unplug the treadmill and remove the

Inspect

x Inspect the drive belt for tension and wear.
x Inspect the power cord for pinches and/or

broken prongs

Lubricate

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

x 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. TriFlow, WD-40, or the like).

AS NEEDED

Belt Service

x In high use locations, it may be advisable to replace the running belt with a new one to

prevent undetected wear. It is advisable to replace a running belt in a high use location in a
preventive manner, to prevent potential wear related issues. A worn or wearing belt can
cause undetectable issues.

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Service Manual: E-TR and E-TRi

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.

The Pro Tread models 7600 and 7700 are equipped 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 belt noise (see waxing instructions).

During a non-belt and/or deck related service, if a running belt and/or deck are removed, it may be
acceptable to re-install the belt and deck as long as no visible signs of wear are present or the
situation does not require replacement.

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.

If you have questions on whether or not to replace a running belt and/or deck, contact Star Trac
Customer Support.

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Service Manual: E-TR and E-TRi

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 the life of a running belt
x Reduce unnecessary down-time
x Prevent electrical component failures

Dirt is an abrasive. When it builds up under a running belt, it can act like sandpaper, wearing off the
slick coating of the deck and reducing the life of both the running belt and deck surface.

Additionally, lack of proper PM can cause a running belt to over heat and can delaminate (separate
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 too loose. If a
running belt is too loose, it has the potential of tracking to the side and becoming damaged.

A worn running belt will cause other components (i.e. MCB, Drive Motor, etc.) to develop enough heat
that over time will cause failure to those components.

Taking care of a running belt at regular intervals can greatly reduce maintenance costs and
unnecessary downtime.

Running Belt “Do Not’s”

x Do not use Armor All, Slick Stuff, WD-40 or the like, on the running surface of a belt
x Do not use cleaners with ammonia or alcohol on the belt
x Do not use any lubricants under the running belt
x Do not over-tension a running belt
x Do not wash a running belt then reinstall it
x Do not reuse a deck surface when installing a new running belt

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Service Manual: E-TR and E-TRi

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. 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 entire underside of the belt.

TIP: Fold the dirty towel and shake into trash.

2. CLEAN BELT SURFACE

Spray the diluted cleaning solution onto a towel then wipe the running belt surface. For
heavier soiled areas, spray a tiny bit of solution onto the spot and use the bristle brush to
gently agitate the spot then wipe with the towel.

3. CLEAN SIDEBED COVERS
Spray the towel with cleaning solution to give a final wipe of the sidebed covers to help ensure
cleanliness.

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Service Manual: E-TR and E-TRi

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.

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 Months
24,000 Miles (40,000 Km) OR 24 Months
30,000 Miles (50,000 Km) OR 30 Months

OR whichever comes first.

x Clean deck with dry cloth. Clean between the belt and deck using the “Cleaning A

Running Belt” section. Clean the head and tail rollers using the “Roller Care &
Maintenance” section. Retighten belt using the following procedure “Running Belt
Retensioning Procedure”.

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Service Manual: E-TR and E-TRi

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 finger­guards.)

Step 2: Apply a piece of masking tape on the
edge of the running belt on both sides.

Fig 2

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.)

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Service Manual: E-TR and E-TRi

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)

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.
(See Fig 5)

Fig 5

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 the tape are aligned with the
edge of the deck.

Be careful to ensure the Tail Roller does not
turn while you are stretching the belt. If the
Tail Roller turns while you are stretching the
belt, start the procedure over. If the Tail

Fig 6

Roller turns while stretching the belt you will
not obtain proper tension.

When finished, remove the tape from the running
belt.

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Service Manual: E-TR and E-TRi