Star Trac E-TRx User manual

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STAR TRAC
14410 Myford Road
Irvine, CA 926060 USA
WORK INSTRUCTIONS,
E-TRx / E-TRxe INSTALLATION

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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.

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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

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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 the following components are included in
box two:
Top rail with electronic display assembly.
Step 5.
Verify the following components are included in
box one:
• Left handrail (p/n 020-7179).
• Right handrail (p/n 020-7181).
• Front neck assembly.
1 3
2
54 6

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Step 9.
Verify the following tools are 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 5
4 Screw #10-24 x 3/4, Truss Head, 7
5 Screw M4x.7, 19mm, Pan Head, 16
6 Washer, Flat, 5/16” I.D. x 1.2” O.D. 16
7 Washer, Split Lock, 5/16” 16
1 2 3 4 5
7
6
1
3
2
4

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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.
Remove the neck form shipping box and verify
the cables are properly fed through attached
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.
Lift the front motor shroud off of the frame as-
sembly.
Note: Make sure the shroud is properly stored to
prevent damage.
INSTALLATION INSTRUCTIONS

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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.
Insert neck into place, then 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.
Route the fan power cable (p/n 715-3678) be-
hind the elevation motor and connect it to fan
power supply board.
Note: Make sure the fan power cable is routed away
from all moving parts, including the RPM disk.
Step 7.
Route the main I/O cable (p/n 715-3781) behind
the elevation motor 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.

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Step 10.
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 11.
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.
Step 12.
Identify left and right handrails by the part number
affixed on the bottom of rails. (left rail’s part number
is 020-7179, and right rail’s part number is 020-
7181).
Assemble handrail joint as shown. DO NOT fasten
the (2) #10 button head socket screws in the upper
handrail joints until both handrails are in place.
Step 9. (for E-TRxe model only)
Route the user detect cable behind the eleva-
tion motor and plug it into the user detect con-
nector on the left side of frame.
Note: This user-detect cable is only available on the
E-TRxe model. If your unit is not equipped with an
embedded display; then skip this step.

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Step 15.
Now tighten the 2 front neck screws (5/16-18 x
3.0” socket head) to a torque value of 200 in-
lbs (22.5 Nm).
Step 14.
Make sure the gap between the rails is closed
and, using the 5/32” Hex key, fasten the (2)
#10 button head socket screws. Tighten the
screws to a a torque value of 45 in-lbs (5.0
Nm). Repeat for the other side.
Step 16.
Tighten the 2 upper neck screws (5/16-18 x 3.0”
socket head) to a torque value of 200 in-lbs
(22.5 Nm).
Step 13.
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.

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Step 17.
Now tighten the 4 display rail fasteners (where
neck is joined with display rail) to a torque
value of 200 in-lbs (22.5 Nm).
Step 18.
Tighten handrail fasteners where handrails are
joined with treadmill frame. Tighten the screws
to a torque value of 200 in-lbs (22.5 Nm). Re-
peat for the other side.
Step 19.
Verify that the side bed covers join properly to
the end caps and that there is no gap between
the two parts.
Step 20.
Fasten the side bed covers (left and right) with
(1) #10-24 x 3/4 Truss head screw on each
side.

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Step 22.
Secure the front of the motor shroud with (2)
#10 Truss head screws.
Step 23.
Now secure the sides of the motor shroud and
the bed covers to the frame with (4) #10 Truss
head screws.
Step 24.
Snap the front motor shroud cap in place, then
slide and install the neck grommet over the cap.
1
2
Step 21.
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.

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Step 27.
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 25.
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.
Insert the power cord through the tie wrap loop
below motor compartment and connect it to the
power receptacle.
Note: Don’t turn on the power switch yet.

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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 display
console then remove and save them for later
use, otherwise proceed to the next step.
Step 3.
Position the display assembly near the top rail
while a helper makes the necessary connec-
tions.
LED DISPLAY CONSOLE INSTALLATION INSTRUCTIONS
Step 4.
Identify the cables coming from neck and rails:
Note 1: If the unit is not equipped with a PVS or iPod® kit,
then the PVS power cable and coax cable should be
tucked down the neck.
Note 2: The User-Detect cable is only available on the E-
TRxe model.
a. DC power cable f. Rail stop cable
b. Fan power cable g. E-Stop cable
c. Contact heart rate cable h. Coax cable
d. Headphone jack cable i. hot Bar keypad cable
e. Main I/O cable j. User-Detect (E-TRxe only)
a c
b
e
d
g
f i
h
j

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Step 5.
Connect the E-Stop cable (g) to J25 connector
on the display board, then connect the rail stop
cable (f) to J5 connector on the display board.
.
Step 6.
Connect the Hot Bar cable (i) to J15 connector
on the display board.
Step 7.
Connect the fan power cable (b) to J20 connec-
tor on the display board.
Step 8.
Connect the contact heart rate cable (c) to heart
rate board connector on the display board.

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Step 9.
Connect the main I/O cable (e) to J1 connector
on the display board.
Step 10.
Mount the display assembly to the frame and
note the screw locations (see figure 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 dis-
play assembly with (1) M4 screw and (1) flat
5/16 washer on each side.
Screw Locations

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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 dis-
play using (6) M4 screws. Next install upper
display back cover onto display with (8) of the
same screws, tighten all screws.
Caution: Do not use power tools or over torque the
screws.
Step 16.
Turn the power switch on. Perform a visual in-
spection, 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-TRx TREADMILL INSTALLATION

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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 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.

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THIS PAGE INTENTIONALLY LEFT BLANK

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Step 2.
Take out the embedded display console out of
the box and remove all packing material. Verify
no visual damage is present on the assembly.
Step 1.
Remove all contents from the packaging and
verify that you have the following parts:
1. Embedded display console.
2. E-TRe tool kit
3. E-TRxe tool kit
4. Owner’s manual
5. Warranty registration card
EMBEDDED DISPLAY CONSOLE INSTALLATION INSTRUCTIONS
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.
1
3
2 54

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Step 8.
Position the display assembly near the top rail
while a helper makes the necessary connec-
tions.
Step 11.
Connect the rail stop cable (f) to JP9 connector
on the center console board.
Rail Stop
Step 10.
Connect headphone cable (d) coming from Hot
Bar rail to audio jack on the center console
board.
a c
b
e
d
g
f i
h
j
Step 9.
Identify the cables coming from neck and rails:
Note: The fan power cable (b) in not needed on the em-
bedded display; it can be tucked down the neck for possi-
ble future use.
a. DC power cable f. Rail stop cable
b. Fan power cable g. E-Stop cable
c. Contact heart rate cable h. Coax cable
d. Headphone jack cable i. hot Bar keypad cable
e. Main I/O cable j. User-Detect (E-TRxe only)