Star Trac 4-TR Service Manual
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Star Trac 4-TR Service Manual

Core health & fitness
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Core Health & Fitness
4-TR Treadmills
SERVICE
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Summary of Contents for Star Trac 4-TR

  • Page 1 Core Health & Fitness 4-TR Treadmills SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS OPERATION - CONSOLES ............................. 2 ..................6 CALIBRATION MENU MAP ............................. 7 ACTIVE VIEWS ..................14 MAINTENANCE MODE ............................17 WIRING DIAGRAMS ............................20 PART LIST ............................22 SERVICE PROCEDURES ............................25 Removing the Shrouds ..................25 Replace the Elevation Motor or Frame ..................28 Lubricate the Running Belt ..................30 Replace the Running Belt/Deck...

  • Page 3: Safety First

    OPERATION - CONSOLES SAFETY FIRST Your 4-TR treadmill is equipped with an easy to reach HOT BAR® that provides you with an addi- tional PAUSE/STOP button and a Stop Switch. The Stop Lanyard Clip attached to the HOT BAR® is provided for your protection to stop the machine.
  • Page 4 Use the keypad controls on the console to select through the screens. After selecting options or immediately after selecting quick start, the active screen will display. Use the buttons to switch between active views. Page 3...
  • Page 5 Quick Keys DISPLAY MEASUREMENTS Time Current total workout time Speed Current speed Pace Current pace Distance Distance run Incline Current degree incline Calories Accumulated calories burned Cal/Hour Current rate of calorie burn WATTS Current user Watts METS Current user METS Heart Rate Current HR in beats per minute, if available...
  • Page 6 WORKOUT SELECTION KEYS AND PROGRAM DEFINITIONS On the main screen are several choices: Select a Workout User selects from a variety of pre-loaded workout options: Warm Up Burn Fat Improve Cardio Capacity (HR Control Programs) Train (Speed, Strength, Endurance, 5K Time Trial) Evaluate Fitness Level (Fitness Test, Firefighter Test) Create a Workout...

  • Page 7: Calibration

    CALIBRATION Speed & Elevation Calibration Procedure On the numeric keypad, press and hold the keys together. The Service Menu will display. Use direction buttons to navigate. Press the button to enter Calibration & Setup mode. Use the arrow keys to select “Calibration”, then press the button.
  • Page 8 MENU MAP Enhanced Images: Pictures can be zoomed in to any level for detail. Use the standard zoom tools for your platform to zoom in. Use the keypad controls on the console to select through the screens. After selecting options or imme- diately after selecting quick start, the active screen will - Main Selection Screen display.
  • Page 9 Page 8...
  • Page 10 Page 9...
  • Page 11 Page 10...
  • Page 12 Page 11...
  • Page 13 Page 12...
  • Page 14 Page 13...

  • Page 15: Active Views

    ACTIVE VIEWS - Progress View . 10 - Pause View Page 14...
  • Page 16 . 11 - Simple View . 12 - Track View Page 15...
  • Page 17 . 13 - Heart View Page 16...

  • Page 18: Maintenance Mode

    MAINTENANCE MODE Maintenance Mode allows access to service and diagnostic information, as well as provides the ability to adjust certain program default parameters. To enter Maintenance Mode: 1. On the numeric keypad, press and hold the keys together. Service Menu will display. 2.
  • Page 19 MAINTENANCE MODE While in Maintenance Mode, the following information can be accessed and/or modified: SW version - The latest software version loaded in the system. • MCU SW version - Software version for the MCU • • MCB SW version - Software version for the MCB Model - The product type (treadmill, bike, etc.).
  • Page 20 MANAGER MODE While in Manager Mode, the following information can be accessed and/or modified: • SW version - The latest software version loaded in the system. MCU SW version - Software version for the MCU • • MCB SW version - Software version for the MCB Page 19...
  • Page 21 WIRING DIAGRAMS Wiring Diagram 9-3613 - 110V, 15AMP, UL/CSA Page 20...
  • Page 22 Wiring Diagram 9-3614 220V, UL/CSA/CE Page 21...

  • Page 23: Part List

    SCREW, #10-24, 1/2”, PHTC, PH, CS, ZP 120-3448 WASHER, FLAT, M10, 10.5mm ID x 20mm OD, 2mm THK 110-3092 SCREW, 5/16 X .875, BHSCS 120-3454 SPACER, 10.2MM ID, 36MM OD, MOTOR, 4-TR 110-3093 SCREW, 1/4-20 X .25, SET, SELF-LOCKING 120-3455 WASHER, RUBBER, 14.1MMX36MMX5MM 110-3126 SCREW, 5/16-18x3.0, FULL THD, SHC, HE, CS, ZI, G2...
  • Page 24 Description Description 731-0119 NUT,M12X1.75, NYLOC 740-9464 ASSY, DECK, 25.75 X 53.75, 4-TR 731-0355 WASHER,PLAIN,M8,NARROW 740-9465 ASSY,90V DC MOTOR, 4-TR 731-0357 WASHER,PLAIN,M12 740-9467 KIT, HARDWARE, 4-TR 731-0358 SCREW, M12 X 1.75, 75mm, BHC, HK 740-9469 ASSY, CABLE, LINE WIRE, 4-TR 731-0359 SCREW,M8 X 1.25,25mm,BHC,HK...
  • Page 25 Enhanced Images: Pictures can be zoomed in to any level for detail. Use the standard zoom tools for your platform to zoom in. 4-TR (All): Deck & Belts 4-TR (110V): Electrical Deck & Belts Electrical (110V) 4-TR (All): Handrails 4-TR (All): Shrouds Handrails Shrouds 4-TR (All): HW Card & Wiring Wiring & Hardware Card Page 24...

  • Page 26: Removing The Shrouds

    SERVICE PROCEDURES Removing the Shrouds The 4-TR has 12 shrouds (highlighted in blue). For most procedures you will not need to remove all the shrouds. This procedure walks through complete removal of all shrouds and should be done in order to remove all screws.
  • Page 27 Remove the crossmember cap #101 by removing the (3) screws #19 at the bottom of the unit. 4-TR: Remove Endcaps & Crossmember Remove sidecovers #116 by removing the (5) screws #19 at the bottom of the unit and (5) screws #19 on the side with (5) washers #49.
  • Page 28 Remove remaining (3) screws #37 with (3) washers #50 from the top of shroud #122 to remove it. Once all shrouds are removed, check #50 (yellow) for damage or wear and replace as needed. 4-TR: Remove Nose Covers All shrouds are removed. Page 27...

  • Page 29: Replace The Elevation Motor Or Frame

    Rotate unit to the floor. Caution: Unit is heavy. Two persons may be required to safely tilt the unit. Disconnect bolt #4 from elevation motor by removing pin #58. Remove pin #58 and (4) washers #48. Page 28 4-TR: Disconnect Elevation Frame...
  • Page 30 Install (2) bushings #99 in the new frame #126. Check (2) elevation frame cushions #103 and replace if worn. 4-TR: Replace Elevation Frame Optional: Replace Motor To replace elevation motor, remove bolt #95 from nut #96 with (2) washers #42.

  • Page 31: Lubricate The Running Belt

    (blue) on both sides of the applicator (included in the kit) Insert the applicator under the belt so that it can be grasped from both sides. 4-TR: Apply Lube to Applicator Move the applicator towards the motor compartment then back towards the rear roller.

  • Page 32: Replace The Running Belt/Deck

    Remove all shrouds. Walk the drive belt #54 off the motor pulley. Remove retaining bolt #16 and washers #43 & #44 4-TR: Release Head Roller Remove (2) bolts #22 to release rear roller #73. 4-TR: Loosen Running Belt Page 31...
  • Page 33 Thoroughly clean area under cushions (yellow) with a putty knife to clear any remaining rubber debris then use 180 grit sandpaper to clean and roughen the frame surface. 4-TR: Replace Deck Cushions Page 32...
  • Page 34 After sanding, use a towel with rubbing alcohol and wipe the frame to clear any debris. Use the towel and alcohol to wipe down the surface of the deck rubber that will make contact with the frame. Apply epoxy 140-3115-KT on the frame in a zigzag motion across the entire frame.
  • Page 35 Slide deck and new belt #55 into frame around rollers. Arrows on Startrac logo point in direction of belt movement. 4-TR: Install Running Belt Install the drive belt #54 on the motor pulley. Secure head roller with bolt #16 and washers #43 &...
  • Page 36 (blue) on both sides of the applicator (included in the kit) Insert the applicator under the belt so that it can be grasped from both sides. 4-TR: Apply Lube to Applicator Move the applicator towards the motor compartment then back towards the rear roller.
  • Page 37 #43 & #44. Reconnect rear roller to bolt #22 and tighten equally on both sides until roller is secure on frame. 4-TR: Secure Running Belt Align the tension adjustment lines on the running belt to the tops of stops #107 &#108.
  • Page 38 Turn the left bolt #22 ¼ turn clockwise b. Turn the right bolt #22 ¼ turn counter-clockwise 4-TR: Belt Tracks Left If the belt tracks to the RIGHT side: a. Turn the left bolt #22 ¼ turn counter-clockwise b. Turn the right bolt #22 ¼...

  • Page 39: Replace Drive Motor

    Remove sidewall covers and motor shroud. Walk the drive belt #54 off the motor pulley. 4-TR: Walk Off Drive Belt Unplug motor from MCB Release motor tension bolt #32. Release (2) motor tension bolts #33. 4-TR: Release Motor Tension...
  • Page 40 Install speed sensor bracket on new motor with (2) washers #47 under #5 bracket and (2) washers #46 above as shown. 4-TR: Install Motor Components Install new motor onto frame. Use (8) rubber washers #53 above and below frame. Tighten (4) bolts #77 finger-tight only.
  • Page 41 #32 to tighten drive belt. Tighten (4) bolts #77 fully. Plug motor and RPM sensor back into MCB. 4-TR: Tension Motor Prior to replacing shrouds, perform a calibration on the console . (See page 6) Warning: This step requires the power to be on.

  • Page 42: Checking The Rpm Gap

    Checking the RPM Gap Unplug the RPM sensor #70 from the MCB #124 4-TR: Unplug RPM Sensor Use a phillips screwdriver and a 6mm socket to remove the RPM sensor and bracket from the drive motor. Use a small crescent wrench to remove...
  • Page 43 2.00 mm Gap 2.00 mm Gap When installing the new sensor, ensure a 2 mm gap between the new sensor #70 and the RPM disk #93. 4-TR: RPM Sensor Gap Page 42...

  • Page 44: Replacing The Motor Brush

    Replacing the Motor Brush Use a #2 phillips screwdriver to remove the screws securing the motor shroud to the frame. Use a flathead screwdriver to gently pry the brush cover off of the motor. Disconnect the connector tab within the motor, push down on the small metal spring tab to release the brush from the brush housing, then remove the brush.
  • Page 45 SUPPORT AND SERVICE The Support website provides a wealth of resources to help you get the best experience from your unit. It is important to check the website periodically for Owner’s Manual and Installation Instruc- tions, Service Bulletins, and other information. The resources include: •...
  • Page 46 © 2019 CORE HEALTH & FITNESS, LLC PART NUMBER 637-8656, REV A...

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