CYBEX Pro+, Service Manual

Page 1: ...Cybex Pro Treadmill Service Manual Cardiovascular Systems Part Number LT 21649 4 A www cybexinternational com ...

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Page 3: ...serve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes 2008 Cybex International Inc All rights reserved Printed in United States of America 10 Trotter Drive Medway MA 02053 888 462 9239 508 533 4300 FAX 508 533 5183 www cybexinternational com techhelp cybexintl com LT 2...

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Page 5: ...e limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If t...

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Page 7: ...tage 3 1 Return Material Authorization RMA 3 2 Damaged Parts 3 3 Ordering Parts 3 4 Table of Contents 4 Service Warnings Cautions 4 1 Test Mode 4 2 LED Functions 4 3 Key Functions 4 3 Error Codes 4 4 Motor Current and Voltage 4 5 Speed Sensor Adjustment 4 6 IR Compensation 4 8 Speed Calibration 4 9 Running Belt and Deck 4 10 Rear Roller 4 11 Front Roller 4 13 Drive Belt 4 13 Drive Motor 4 15 Motor...

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Page 9: ...electric current to reduce the risk of electric shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Che...

Page 10: ...any malfunctions damage or repairs to the facility Place your feet on the two top steps when starting or stopping the treadmill Stop and place the treadmill at 0 degrees incline level after each use Keep children away from the treadmill Teenagers and disabled persons must be supervised while using Obtain instruction before using Keep all body parts hair towels water bottles and the like free and c...

Page 11: ...from a qualified technician DO NOT place the cord near heated surfaces or sharp edges DO NOT use the treadmill outdoors DO NOT operate the treadmill around or where aerosol spray or where oxygen products are being used Read and understand the Owner s Manual completely before using the treadmill Ensure all users wear proper footwear on or around all Cybex equipment Set up and operate the treadmill ...

Page 12: ...n or damaged decals do one of the following Fax orders to 508 533 5183 or contact Cybex Customer Service at 888 462 9239 If you live outside of the USA call 508 533 4300 For location or part number of labels see the parts list and exploded view diagram Warning Decals Warning decals indicate a potentially hazardous situation which if not avoided could result in death or serious injury The warning d...

Page 13: ... serious injury dist Date Mileage Service Initials DE 16609 4 Enter Test Mode by holding down any key while turning the treadmill to the on I position Press except on all Cybex Sport models DIST appears on the display Check Running Belt Tension Tracking Move Treadmill Vacuum Underneath Remove Motor Cover to Clean Underneath with a Dry Cloth Vacuum Replace Belt Flip Deck Check Motor Brushes Replace...

Page 14: ...Safety Page 1 6 Cybex Pro Treadmill Service Manual ...

Page 15: ...on decals indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury There are no caution decals used on the Cybex Pro treadmill However there is a caution in the installation instructions for initial installation only See below ...

Page 16: ...top key in place 2 Without falling off the treadmill carefully step backward until the e stop falls off the treadmill NOTE If the e stop clip falls off your clothing then the test has failed Reclip the e stop clip to your clothing and repeat this step 3 Replace e stop after successfully testing the e stop key See the illustration shown below 4 The treadmill is now ready to be used 5 After use remo...

Page 17: ...belt Over tightening the belt can cause the belt to stretch and require replacement Regular Maintenance Activities WARNING All maintenance activities shall be performed by qualified personnel Failure to do so could result in serious injury Preventive maintenance activities must be performed to maintain normal operation of your treadmill Keeping a log sheet of all maintenance actions will assist yo...

Page 18: ...ide parts of the treadmill Electrical shock could occur even if the treadmill is unplugged Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the treadmill To clean the motor components you must loosen the six Phillips screws that hold the motor cover in place Lift the cover straight up the screws and side covers will stay in place Use a ...

Page 19: ...t is slipping under each step perform this procedure Tools Required 3 4 Socket wrench 1 Tension the belt Use a 3 4 socket wrench to turn each bolt 1 2 turn clockwise See Figure 1 A NOTE Be sure to adjust each bolt equally on each side Turn the power on and press the B Quick Start key Press the C Speed keys to bring the speed up to 3 5 4 mph 5 6 6 4 kph Allow the treadmill to run for a minute Obser...

Page 20: ...ion again Make sure the running belt tension B is tight enough so that the belt does not slip or hesitate when stepped on Refer to step 1E Checking the Belt and Deck Surfaces The running belt and deck should be checked periodically for any excessive wear In an effort to make sure that the running belt operates properly visually inspect the belt often to make sure that there are no tears or fraying...

Page 21: ...ooved yet highly polished the deck should be flipped to an unused surface or replaced In time a worn belt and deck can cause high current draw and ultimately motor failure NOTE When replacing the deck replace the belt at the same time For instructions on replacing the belt and deck see Running Belt and Deck in the Service chapter 7 Clean under the belt To minimize the effect of friction between th...

Page 22: ...brushes and replace worn motor brushes Rotate and replace the running deck Replace the running belt Check the current draw Measure motor voltage at maximum speed with no load NOTE See the Service chapter of this manual for detailed procedures for the maintenance activities listed above Elevation Motor Lubrication In time the elevation motor pivot points may develop a squeak Lubricate the upper and...

Page 23: ...kilometers will be displayed Record Mileage C NOTE To exit Test Mode press the Stop key First 500 miles 800 km Check running belt tension and tracking Every 5 000 miles 8 000 km Check running belt tension and tracking Move treadmill and vacuum underneath Remove motor cover to clean underneath with a dry cloth and vacuum Every 10 000 miles 16 090 km Replace running belt and flip deck Check motor br...

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Page 25: ...ex customers living outside the USA contact Cybex Customer Service at 508 533 4300 or fax 508 533 5183 Find information on the web at www cybexinternational com or by e mail at techhelp cybexintl com Serial Number and Voltage Your serial number and voltage can be found on the front of your treadmill See Figure 1 For your convenience record your serial number and voltage below so that you will have...

Page 26: ...or the defect in the item you wish to return 3 Provide the model and serial number of your treadmill The serial number is located on the front panel of your treadmill The serial number begins with a letter for example R09 101331100 4 At Cybex s discretion the technician may request that you return the problem part s to Cybex for evaluation and repair or replacement The technician will assign you a...

Page 27: ...amage claim The carrier will provide you with the required forms for filing such claims Concealed Damage Damage not seen with a visual check upon receipt of a shipment but noticed later must be reported to the carrier as soon as possible Upon discovery of the damage a written or phone request to the carrier asking them to perform an inspection of the materials must be made within ten days of the d...

Page 28: ...ak with a customer service representative call 888 462 9239 for customers living within the USA or 508 533 4300 for customers outside the USA Use only Cybex replacement parts when servicing Failure to do so could result in personal injury Cybex will void warranty if non Cybex replacement parts are used CAUTION ...

Page 29: ...h your feet on the two steps WARNING Disconnect the power cord before beginning this procedure Keep wet items away from inside parts of the treadmill Electrical shock could occur even if the treadmill is unplugged Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the treadmill CAUTION If the drive motor is warm wait until it is cool to t...

Page 30: ...he display while turning the power switch to the on I position When all keys are released PRO and the software revision rx x are shown on the display To exit Test Mode press Stop Stuck Key List If Test Mode occurs without holding any keys a key may be stuck closed or Error 7 may have occurred You may need to replace the upper and or lower display overlay See Figure 1 If KEY is displayed you can de...

Page 31: ...he numbers indicate actual belt speed The right most decimal point indicates the pulses from the speed sensor on the motor Key Functions While in Test Mode press the following keys for desired information Quick Start Starts the belt at 1 0 mph 1 0 kph Also will run calibration if held for 3 seconds Heart Rate Program key Lights all of the LEDs for a short period of time Weight Loss key Lights only...

Page 32: ...um See H then G bAd2 Internal RAM error See H then G bAd3 Watchdog timeout See H then G Err1 Belt didn t start or no speed sense See I E D B then A Err2 Underspeed 2 mph for 2 seconds without correction in process See I E C then B Err3 Speed sense lost See I E A B and C Err5 No 0 switch sense within timed limits This is declared when the timed elevation reaches 2 without tripping the index See F a...

Page 33: ...treadmill up to 3 mph 4 8 kph Press the C METs key and take note of the load value in the top center display Have a second person walk on the belt at 3 mph 4 8 kph and take note of the load value in the D top center display and the weight of the person NOTE Call Cybex Customer Service to confirm that the load is within acceptable range Loads over 200 are generally unacceptable Press E Stop to exit...

Page 34: ...ver 1 4 Socket wrench 7 16 Open end wrench WARNING Disconnect the power cord before beginning this procedure 1 Disconnect the external power source Turn the main power switch on the left side to the off O position A Unplug the treadmill from the power outlet B 2 Remove the motor cover Using a Phillips screwdriver loosen three screws on each motor cover side left and right A Lift the motor cover ce...

Page 35: ...ates in over 0 5 mph increments then your speed sensor gap needs to be inspected Slowly adjust the speed down to 1 0 MPH 1 0 KPH E Press F Stop and turn the power switch to the off O position Enter G Test Mode again and check the error log for Error 3 If Error 3 occurred readjust the speed sensor and test again NOTE If you are unsure whether an error is new you can clear the error log by pressing ...

Page 36: ... 0 mph 1 0 kph WARNING Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the treadmill CAUTION The belt will be jerky during the next step Hold the handrail to support yourself Hold on to the handrails as you step on the running belt begin walking and notice how the belt C feels the belt may surge vibrate or slack NOTE If the belt doesn ...

Page 37: ... display board the lower control board or the drive motor If you ve replaced the lower board perform the IR Compensation procedure first then the Speed Calibration procedure 1 Calibrate the speed Stay off the running belt during this procedure A CAUTION During this procedure STAY OFF THE RUNNING BELT Stand with your feet on the two steps In B Test Mode press and hold the Quick Start key for three ...

Page 38: ...et wrench 9 16 Socket wrench with a 3 extension WARNING Disconnect the power cord before beginning this procedure 1 Disconnect the external power source Turn the main power switch on the left side to the off O position A Unplug the treadmill from the power outlet B 2 Remove the motor cover Using a Phillips screwdriver loosen the three screws on each motor cover side A left and right See Figure 2 L...

Page 39: ...in place Repeat this step for the other side See Figure 5 Grasp each top step and slide it out and off the treadmill See Figure 5 B Rear Roller 6 Remove the rear roller Using a 3 4 open end or socket wrench loosen A the two rear roller bolts one roller bolt on each side NOTE Loosen each bolt evenly making sure not to loosen either bolt too many turns before moving to the other bolt See Figure 6 Wh...

Page 40: ...e deck stiffeners Using a 1 2 Socket wrench remove the two whiz lock screws that secure the deck pivot shaft to A the frame See Figure 8 Figure 7 Screws 5 on Each Side Washers 5 on Each Side Running Deck Deck Support 1 on Each Side Running Belt Figure 8 Flat Head Screw Bolt Washer Deck Bushing Propeller Nut Deck Pivot Shaft Retaining Ring Whiz lock Screw Deck Stiffener Left Deck Stiffener Right Fr...

Page 41: ...h with a 3 extension in B the right front roller access hole Remove the right front roller screw Slide the drive belt off of the front roller and remove C the front roller 11 Remove the running deck and running belt Lift one side of the deck and slide it out of the A running belt Drive Belt NOTE If you are replacing the drive belt follow steps 12 13 and 15 If not skip to step 14 See the Drive Moto...

Page 42: ...ule under the motor cover Using a 7 16 open end or socket wrench attach the ten B washers and screws that hold the deck to the treadmill frame See Figure 7 17 Secure the rear roller Slide the rear roller into the running belt See Figure 6 A Slide the hardware for each side into position B NOTE Place the end of the bolt in first and then hold the rear roller up while you pivot the group of hardware...

Page 43: ...se pliers WARNING Disconnect the power cord before beginning this procedure Keep wet items away from inside parts of the treadmill Electrical shock could occur even if the treadmill is unplugged Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the treadmill 1 Disconnect the external power source Turn the main power switch on the left si...

Page 44: ...te from the drive motor cables International units only E Carefully remove the drive motor F NOTE If you are replacing the drive belt with a new one follow step 6B 8A If not skip to step 8 6 Remove the drive belt optional Using a 3 4 socket wrench loosen each rear roller bolt 10 12 revolutions to release tension on A the running belt Using a 9 16 socket wrench with a 3 extension remove the two fro...

Page 45: ...brushes must be replaced as a pair This will ensure even commutator contact and brush wear Therefore always measure both brush lengths to determine whether you should replace the pair Check both brushes for cracks or chips NOTE When Err9 appears on screen it indicates excessive motor brush wear The treadmill will run 100 miles 161 kilometers longer and then be inoperable until brushes are replaced...

Page 46: ...tting burning or uneven wear Commutator bars that are dirty penny brownish copper are in great condition However some commutator bars may be pitted or blackened on one edge Too many of these indicate a worn commutator and the motor should be replaced The commutator may be cleaned with narrow commutator stone if carbon build up is present NOTE File down the stone if it won t fit in the brush holder...

Page 47: ...il it is flush with the motor B 15 Align the drive motor Carefully lower the drive motor in position on the motor saddle A Turn the motor so the exit cable is positioned at a 3 o clock angle toward the front roller See B Figure 16 Using a straight edge such as the lower board shield line up the face of the flywheel pulley with C the face of the front roller pulley until they are flush See Figure 1...

Page 48: ...sing wire ties tie the motor C cable to the base so that no wires get pinched See Figure 17 NOTE Be sure that the wires are tied away from the fan and running belt For internationally installed treadmills only place the ferrite shown in Figure 17 in between the wire ties Refer to the lower board shield D to confirm the locations for the connectors and check to see that all of the cables are connec...

Page 49: ... cord before beginning this procedure Keep wet items away from inside parts of the treadmill Electrical shock could occur even if the treadmill is unplugged 1 Disconnect the external power source Turn the main power switch on the left side to the off O position A Unplug the treadmill from the power outlet B 2 Remove the motor cover Using a Phillips screwdriver loosen three screws on each motor cov...

Page 50: ...a 9 16 open end wrench and a 9 16 C socket wrench securely tighten the top mounting bolt and nut Connect the elevation motor cable to the D lower board NOTE The board is labeled P3 at the elevation port The connector can only fit in one direction Connect the main power cord into the E power outlet and turn the power switch on I NOTE Wait for the elevation tube to turn and find the zero switch Once...

Page 51: ...readmill is unplugged Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the treadmill 1 Disconnect the external power source Turn the main power switch on the left side to the off O position A Unplug the treadmill from the power outlet B 2 Remove the motor cover Using a Phillips screwdriver loosen three screws on each motor cover side le...

Page 52: ...e the lower control board and bracket NOTE Wear an ESD strap for the rest of this procedure Position the lower control board bracket in place on the base A NOTE The elevation motor connector and ground stud will be positioned toward the back left corner Using a Phillips screwdriver secure the four screws that hold the bracket to the base B 7 Connect the cables to the lower control board Connect th...

Page 53: ...2 Secure the motor cover Lower the motor cover center into position See Figure 2 A Using a Phillips screwdriver tighten the three screws on each side Be sure the screws are B catching the center motor cover s holes See Figure 2 Power Cord NOTE This procedure will cover the power cable line filter and power switch Tools Required Phillips screwdriver 3 8 Nutdriver or socket wrench ESD Electro Static...

Page 54: ...5 Remove the power switch Observe the armature LED on the lower board labeled ILT4 A After the armature LED goes off proceed to step 3C B Using a Phillips screwdriver remove the two screws that hold the switch and its plate C to the treadmill Disconnect the four fast on connectors that go into the power switch D Using a 3 8 nutdriver remove the one nut and one washer from the ground wire on the E ...

Page 55: ...er cables if applicable Connect the white cable to the front right fast on on the line filter and route it through the A access hole Connect the black cable to the front left fast on on the line filter and route it through the B access hole Connect the ends of these two cables to the lower board The white connects to the fast on C labeled AC Line 1 The black connects to the fast on labeled AC Line...

Page 56: ...driver secure the switch plate to the treadmill with the I on F toward the top Upper Display Board Tools Required Phillips screwdriver ESD Electro Static Discharge grounding strap 1 Disconnect the external power source Turn the main power switch on the left side to the off O position A Unplug the treadmill from the power outlet B NOTE The display board is susceptible to damage from a discharge of ...

Page 57: ...onsole A Using a Phillips screwdriver secure the six screws that hold the display board to the console B 5 Connect the cables Connect these cables into the display board the display cable 2 connectors the two upper A switch membranes the lower switch membrane the contact heart rate cable the CSAFE board to display board jumper and the upper to lower board jumper See Figure 23 6 Check the connectio...

Page 58: ...Using a Phillips screwdriver remove the nine screws that hold the console back to the console A front Gently pull off the console back B 3 Remove the heart rate board Using a Phillips screwdriver remove the three screws from the heart rate board A If you re not replacing the cable disconnect the two cables and one molex placeholder from the B heart rate board You will re attach the molex connector...

Page 59: ...he handrail E 6 Route the new heart rate cable Connect the double connector into the right side of the A heart rate board See Figure 24 Locate the short and long side of the heart rate cable B Route the short cable end to the left from treadmill C user s viewpoint and the long end to the right Place the cable behind the handrail and tie with four D wire ties in the locations they were removed in s...

Page 60: ...ables use a Phillips screwdriver to secure the nine screws A that hold the console back to the console front 11 Connect the external power source Plug the treadmill into the power outlet A 12 Calibrate speed if you replaced the display board Follow the A Speed Calibration procedure located in this chapter CSAFE Board Tools Required Phillips screwdriver 1 Disconnect the external power source Turn t...

Page 61: ... power switch on the left side to the off O position A Unplug the treadmill from the power outlet B NOTE The display board is susceptible to damage from a discharge of static electricity While handling parts underneath the console cover use an ESD grounding strap This eliminates the potential voltage static difference between you and the equipment you are working on Wear an ESD strap for the rest ...

Page 62: ...ng a Phillips screwdriver loosen the wire retaining screw that holds the display D cable in place near the display board Remove the cable from the wire ties at the junction and near the bottom of the upright E Figure 27 Shield Display Cable Screws 4 Screws 9 Screws 3 Left Junction Covers P3 and P8 Connectors on Upper Display Board Console Back Cover P1 and P2 on Lower Board Left Side Cover NOTE Ri...

Page 63: ...e out Route the cable into the access hole F Connect the display cable to the lower control board at P1 and P2 G 7 Secure the cable Using a Phillips screwdriver open the clip described in step 5D and secure the cable in A the clip Locate the line on the display cable described in step 6D and tie the cable with the wire tie B near the bottom of the upright Open the wire holder at the junction put t...

Page 64: ...NOTE The display board is susceptible to damage from a discharge of static electricity While handling parts underneath the console cover use an ESD grounding strap This eliminates the potential voltage static difference between you and the equipment you are working on Wear an ESD strap for the rest of this procedure 3 Remove the display overlay While wearing an ESD strap disconnect the switch memb...

Page 65: ...s that hold the console front to the frame A While being sure not to pinch any cables secure the console back to the console with the five B Phillips screws 6 Test the new display overlay Turn the main power switch to the on I position A Plug the treadmill into the power outlet B Try each key to be sure that it functions properly C ...

Page 66: ...0 HXHD CAP G8 YEL ZN 47 1 HS 17937 Bolt 3 8 24 X 2 75 HXHD CAP G8 YEL ZN ITEM QTY PART NO DESCRIPTION 48 1 MR 16412 Motor Elevation 115 VAC 48 1 MR 16541 Motor Elevation 230 VAC 49 1 SK 17079 Tube Nut Motor Elevation Kit 50 1 FT 16825 Sleeve Elevation Mounting Top 51 1 FT 16826 Sleeve Elevation Mounting Bottom 53 6 HS 15732 Screw SEM 8 32 unc x 62 PNHD phil pl 54 1 HW 10856 Washer for ground 55 1 ...

Page 67: ...1 HS 20036 Screw 5 16 18 x 1 50 ScHd Stl Zn 206 2 HS 41107 Bolt 5 16 18 x 1 50 Bh SS Bl 207 2 HX 20782 Bushing T Type Rubber Ring Mount Vibration Isolator 208 8 HW 20779 Washer Flat 1 44 x 325 SS 209 6 HX 20778 Bushing Rubber Ring Mount Vibration Isolator 210 1 HW 53018 Washer 5 16 Split ITEM QTY PART NO DESCRIPTION 211 4 HS 20731 Screw M4x10 ScHd Stl Blk 212 4 HW 21285 Washer Lock M4 Zn 213 4 HW ...

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Page 70: ...DTR DATA TERMINAL READY 5 GND 6 DSR DATA SET READY 7 RTS REQUEST TO SEND 8 CTS CLEAR TO SEND 9 RI RING DETECT ADAPTER SERVICE PROGRAMMING P1 P2 P1 P2 CN 16924 20A 250V SB 115V 15A 250V SB 220 240V 3A ELV MOTOR DWN COM UP GND 1 7 4 2 3 5 6 8 N C 0 GND REF ZERO SWITCH CHASSIS GROUND ELEV UP ELEV DWN ELEV NEUTRAL THERMAL INTERNAL ZERO SWITCH SWITCH MAX ELEV INTERNAL N C 16 AW 17706 CABLE CHR GRIP AW ...