Star Trac E-TR User manual

2 600-7919 Rev A
STAR TRAC
14410 Myford Road
Irvine, CA 926060 USA
WORK INSTRUCTIONS,
E-TR / E-TRe INSTALLATION

3 600-7919 Rev A
GENERAL
Before using this product, it is essential to read ALL installation Instructions and this
ENTIRE operations manual; the manual describes equipment setup and instructs
members on how to use it correctly and safely.
1. Hex (Allen) key, 1/4” (Included)
2. Hex (Allen) key, 5/32” (Included)
3. Screwdriver (blade-tip), 3/32” (Included)
4. Screwdriver, Philips, #2 (Included)
5. Torque wrench (not included)
TOOLS REQUIRED
FACTORY CERTIFIED INSTALLER
Copyright 2008. Star Trac by Unisen, Inc. Star Trac Fitness, Star Trac®, and the Star Trac Logo are registered trademarks of Unisen Inc. All rights
reserved, including those to reproduce this book or parts thereof in any form without first obtaining written permission from Star Trac.
iPod
®
is a registered trademark of Apple, Inc.
MYE
®
is a registered trademark of MYE Entertainment LLC.
Every effort has been made to keep this information current; however, periodically, changes are made to the information herein, and these changes
will be incorporated into new editions of this publication. All product names and logos are trademarks of their respective owners. Printed in the USA.
If you are a Factory Certified Installer you must:
• Adhere to all torque and assembly specifications.
• Use a CALIBRATED TORQUE WRENCH with the necessary hex key sockets
• NOT USE a powered drill, powered driver or powered impact tool for any part of the assembly.
• Complete the assembly checklist is completed on each Star Trac product.
• Complete the final programming, functional and cosmetic checklists for each Star Trac product.

4 600-7919 Rev A
Step 3.
Remove the side box.
Step 4.
Lay all boxes on the floor and verify that all
components are included (see next page for
details).
Step 2.
Remove the top cover.
Step 1.
Lay the unit in the area where it is going to be
assembled and remove the straps.
UNPACKING INSTRUCTIONS

5 600-7919 Rev A
Step 7.
Verify components in box two (continued):
1.Neck cover.
2.Display console’s top back cover (p/n 020-7074).
3.Neck grommet.
4.Power cable.
5.Owner’s manual with warranty registration card.
6.Hardware kit.
Step 8.
Verify components in box two (continued):
• Display console’s upper back cover (p/n 020-7069).
• Display console’s lower back cover (p/n 020-7070).
Step 6.
Verify components included in box two:
Top rail with electronic display assembly.
Step 5.
Verify components included in box One:
• Left handrail (p/n 020-7179).
• Right handrail (p/n 020-7181).
• Front neck assembly.
1 2 3
4 5 6

6 600-7919 Rev A
Step 9.
Verify tools included in the hardware kit :
Step 10.
Verify hardware included in the hardware kit:
Step 12.
With a helper, lift the treadmill frame assembly
from the shipping crate platform and place it in
the location where it will be used. Make sure the
unit is placed near a power outlet.
Caution: The motor shroud end of the frame assem-
bly is very heavy. It may require two people to lift this
end when moving the frame assembly.
Step 11.
Remove the packaging materials from the
frame assembly with motor shroud.
Item Description QTY
1 Hex (Allen) key, 1/4” 1
2 Hex (Allen) key, 5/32” 1
3 Screwdriver (blade-tip), 3/32” 1
4 Screwdriver, Phillips, #2 1
Item Description QTY
1 Screw 5/16”-18x3.0”, Socket Head Cap 2
2 Screw 5/16”-18x1.0”, Socket Head Cap 12
3 Screw 1/4”-28 3/8”, Button Head Socket Cap 4
4 Screw #10-24 x 3/4, Truss Head, 4
5 Screw M4x.7, 19mm, Pan Head, 14
6 Washer, Flat, 5/16” I.D. x 1.2” O.D. 14
7 Washer, Split Lock, 5/16” 14
1 2 3 4 5
6
7
1
3
2
4

7 600-7919 Rev A
Step 3.
Position neck close to the service opening in
the front of treadmill so the cables go into the
opening first.
Step 4.
Route all cables from neck into motor compart-
ment through lower neck service opening.
Caution: Make sure not to pinch any cables.
Step 2.
Verify the cables are properly fed through at-
tached protective tube in the base of the neck.
Note: The tube will protect cables from getting
pinched during installation and will make it easier to
route them through service opening.
Step 1.
Remove the screws securing the motor shroud
to the frame assembly, and lift the shroud off of
the frame assembly. Retain the screws for later
use when re-installing the motor shroud.
Note: Make sure the shroud is properly stored to
prevent damage.
INSTALLATION INSTRUCTIONS

8 600-7919 Rev A
Step 7.
Now install the top display rail. Align the rail’s
mounting holes with the neck holes.
Note: If the electronic display console was assembled
to the rail; remove the screws holding it to the rail and
store the display for later use.
Hint: If one person is assembling the unit, insert two
5/16 screws into top rail holes and use them to align
and temporary hold the rail while you secure it from the
back.
Step 6.
Align the front holes and fasten with (2) 5/16-18
x 3.0”, (2) 5/16 washers and (2) lock washers.
DO NOT fully tighten yet.
Step 5.
Once the neck is in place, align the top holes.
Using the 1/4” Hex key, fasten the neck to the
frame with (2) 5/16-18 x 1.0” socket head
screws, (2) 5/16 washers and (2) lock washers.
DO NOT fully tighten yet.
Step 8.
Once the display frame is in place, fasten it to
the neck using the 1/4” Hex key with (2) 5/16-18
x 1.0” socket head screws, (2) 5/16 washers
and (2) lock washers. DO NOT fully tighten yet.

9 600-7919 Rev A
Step 9.
Identify left and right handrails by the part num-
ber affixed on the bottom of rails. (left hand-
rail’s part number is 020-7179, and right hand-
rail’s part number is 020-7181).
Assemble left handrail joint as shown above.
DO NOT fasten the (2) #10 button head socket
screws in the upper handrail joints until both
handrails are in place.
Step 10.
Install left handrail to the frame as shown using
(3) 5/16-18 x 1.0” socket head screws and (3)
5/16 washers. Partially lift up the side bed cov-
ers, if necessary. Note the orientation of the
mounting plate. DO NOT tighten screws fully
yet. Repeat install for right handrail.
Step 12.
Now tighten the 2 front neck screws (5/16-18 x
3.0” socket head) to a torque value of 240in-lbs
(27 Nm).
Step 11.
Make sure the gap between the rails is closed
and, using the 5/32” Hex key, fasten the (2)
#10 button head socket screws. The screws
should be torqued to a value of 35in-lbs (4.0
Nm).

10 600-7919 Rev A
Step 13.
Tighten the 2 upper neck screws (5/16-18 x 3.0”
socket head) to a torque value of 240in-lbs (27
Nm).
Step 14.
Now tighten the 4 display rail fasteners (where
neck is joined with display rail) to a torque
value of 240in-lbs (27 Nm).
Step 15.
Tighten handrail fasteners where handrails are
joined with treadmill frame. Use the following
torque specifications:
5/16-18 x 1.0” socket head screws- 240in-lbs
(27Nm).
Step 16.
Make sure the side bed covers joins properly
to the end caps and that there is no gap be-
tween the two parts.

11 600-7919 Rev A
Step 17.
Fasten the side bed covers (left and right) with
#10-24 x 3/4 Truss head screws.
Step 19.
Route the fan power cable (p/n 715-3678)
through the pre-installed cable tie saddles.
Note: Make sure the fan power cable is routed away
from all moving parts, including the RPM disk.
Step 18.
Route the main I/O cable (p/n 715-3781) under
the elevation cable and connect it to I/O inter-
face J2 Connector on the Motor Control Board.
Note: Make sure the main I/O cable is routed away
from all moving parts, including the flywheel.
Step 20.
Now connect fan power cable to fan power sup-
ply board.

12 600-7919 Rev A
Step 21.
Insert the power cord through the tie wrap loop
below motor compartment and connect it to the
power receptacle.
Step 22.
Secure the power cable to the frame with the tie
-strap and cut excess strap.
Caution: Make sure not to damage the power cord.
Step 24.
Re-Install the (2) #10 Truss head screws that
were saved earlier.
Step 23.
Re-install the shroud over motor compartment.
Slide the back end of shroud in place (where
shroud meets rails) then align the screw holes
on the front of shroud with the holes on the
frame.

13 600-7919 Rev A
Step 25.
Fasten motor shroud with (6) #10 Truss head
screws.
Step 27.
Install left and right handrail grommets. Slide
the grommet down the rail and snap it in place
over the bed rails covers. Push down and ro-
tate the grommet slightly to seat the tabs into
the plastic covers.
Note: Make sure the grommet is tightly secured in
place.
Step 28.
Position the treadmill in its place. If leveling the
treadmill is necessary, loosen the lock nuts of
the leveling feet, rotate the feet until the tread-
mill is stabilized, then re-tighten the lock nuts.
Step 26.
Snap the front motor shroud cap in place, then
slide and install the neck grommet over the cap.
1
2

14 600-7919 Rev A
Step 4.
Identify the 7 cables coming our of the neck:
a. DC power cable.
b. Fan power cable.
c. Contact heart rate cable.
d. Coax cable.
e. Main I/O cable.
f. Rail stop cable.
g. E-Stop cable.
Note: If the unit is not equipped with a PVS kit or iPod®
kit, then the PVS power cable and coax cable should be
tucked down the neck for possible future use.
a
b c d
e f
g
Step 1.
Remove electronic display console from pack-
aging materials.
Note: If you are installing an iPod® Kit, a MYE Entertain-
ment kit or a Personal Viewing Screen kit along with this
display, it is recommended that you install the kit’s center
console before you mount the display onto the frame.
Step 2.
If the back display covers are attached to dis-
play console then remove and save them for
later use, otherwise proceed to the next step.
Step 3.
Position the display assembly while a helper
makes necessary connections.
LED DISPLAY CONSOLE INSTALLATION INSTRUCTIONS

15 600-7919 Rev A
Step 5.
Connect the E-Stop cable “g” into J25 connec-
tor on the display board.
Step 6.
Connect the rail stop cable “f” into J5 connector
on the display board.
Step 7.
Connect the fan power cable “b” into J20 con-
nector on the display board.
Step 8.
Connect the contact heart rate cable “c” into
heart rate board connector on the display
board.

16 600-7919 Rev A
Step 9.
Connect the main I/O cable “e” into J1 connec-
tor on the display board.
Step 10.
Mount the assembly to the frame and note the
screw locations (see picture above). Secure
top assembly with (4) M4 screws and (4) flat
5/16 washers.
Step 11.
Attach ground strap of the display assembly to
the frame with a screw and washer.
Step 12.
Secure the lower left and lower right of the as-
sembly with (1) M4 screw and (1) flat 5/16
washer each.
Screw Locations

17 600-7919 Rev A
Step 13.
Install the top back cover piece (p/n 020-7074)
onto the upper display back cover (p/n 020-
7069).
Step 14.
Install the lower display back cover onto display
using (6) M4 x0.7 x 19mm long Phillips head
screws. Next install upper display back cover onto
display with (8) of the same screws, tighten all
screws.
Caution: Do use power tools or over torque the
screws.
Step 16.
Turn power on. Perform a visual inspection,
and test the features and functions of the unit
prior to use.
Note: Refer to the User’s Manual for calibration in-
structions and other settings.
Step 15.
If not performed previously, position the tread-
mill where you plan to use it. If necessary, level
the treadmill using the two adjustable feet under
the tail roller. Loosen the lock nuts, rotate the
feet until the treadmill is stabilized, and re-
tighten the lock nuts.
YOU HAVE NOW COMPLETED THE E-SERIES TREADMILL INSTALLATION

18 600-7919 Rev A
ATTENTION
• Star Trac recommends that the treadmill be spaced a minimum of 20.0 inches (0.5 m) apart to
allow safe and easy ingress and egress. Even more importantly, there must be at least 48
inches (1.25 m) of free space behind the treadmill.
• As with any motorized equipment, the area where treadmills are located must be free of obstruc-
tions and fixtures with sharp edges to prevent injury in the event that a user trips or loses bal-
ance and falls.
Use the checklist below to ensure the proper installation of the E-Series Treadmill:
1. All parts and hardware in the package are accounted for.
2. All screws are tightened and torqued down to their specified values.
3. Neck is properly mounted and secured to the base frame.
4. Left and right handrails are properly mounted and secured to the based frame.
5. Display frame is properly mounted and secured to the neck and handrails.
6. Electronic display console is properly mounted and secured to the display frame.
7. All cables and harnesses are properly plugged to their respective connectors.
8. All cables inside the motor compartment are routed away from all moving parts.
9. Motor shroud and side bed covers are properly installed and secured.
10. Unit is leveled to the floor.
11. Using a chest strap or wireless heart rate simulator, verify heart rate is recording properly.
12. Once powered up, all features of the unit function properly.

19 600-7919 Rev A
Step 1.
Remove the embedded display console from
the box & all packing material. Verify no visual
damage on the assembly.
Step 2.
Verify the following items are included in the
package:
1. Hardware kit.
2. Headphone jack kit
3. Owner’s manual with warranty registration
card.
Verify all items in the Display Console package:
• 1 bag of screws & washers.
• 1 bag of headphone jack/plug kit.
• 1 Operation Manual.
• 1 complete Display Console assembly.
EMBEDDED DISPLAY CONSOLE INSTALLATION INSTRUCTIONS
1
2
3

20 600-7919 Rev A
Step 4.
Using a Phillips head screw driver, remove the
screw that holds in the headphone jack cap at
the lower front of the display. Retain the
screw.
Note: You will no longer need the cap, if desired,
you can store it away for any possible future use.
Step 3.
Peel off yellow tape that holds the back covers to the embedded display assembly, then remove the
back covers to expose the display assembly. Save the covers for later use.
Step 5.
Attach the new headphone jack to the available
cut-out at the lower front of the display, then
secure with previously retained screw.

21 600-7919 Rev A
Step 7.
Connect right angle end of the headphone cord
plug to the board.
Step 8.
Connect straight end of the headphone cord
plug to the cut-out piece (noted 2).
Note: be sure to feed the cord under the plastics to
prevent possible pinch.
1
Headphone cord
connections
1
2
Step 6.
Use provided alcohol wipe to clean the surface
area, then apply the headphone decal as
shown.
Step 9.
Position the display assembly while a helper
makes necessary connections.