Cybex LCX-425T Treadmill Service Manual Cardiovascular Systems Part Number LT-19638 Rev C www.cybexinternational.
Cybex LCX-425T Treadmill Service Manual Cardiovascular Systems Part Number LT-19638 Rev C Cybex® and the Cybex logo are registered trademarks of Cybex International, Inc. Polar® is a registered trademark of Polar Electro Inc. DISCLAIMER: Cybex International, Inc. makes no representations or warranties regarding the contents of this manual.
Cybex 425T Treadmill Service Manual About This Manual An Owner’s Manual is shipped with each unit. To purchase additional copies of this manual or any other Cybex manual, please do one of the following: • • • • order online at www.cybexinternational.com fax your order to 508-533-5183 contact Cybex Customer Service at 888-462-9239 or contact Cybex Customer Service at 508-533-4300 NOTE: Refer to www.cybexinternational.com for changes and updates to this manual.
Cybex 425T Treadmill Service Manual DECLARATION OF CONFORMITY August 24, 2006 This Declaration of Conformity is suitable to the European Standard EN 45014, “General criteria for supplier’s declaration of conformity.” We, Manufacturer: Cybex International, Inc.
Cybex 425T Treadmill Service Manual As a result of test reports and their evaluation by accredited laboratories, we are in possession of the following certificates for products which carry this marking: Canada, USA CAN/CSA-C22.2 No.68-92/99, UL Std. No.
Cybex 425T Treadmill Service Manual EN 61000-3-2 Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions (equipment input current <= 16A per phase) EN 61000-3-3 Electromagnetic compatibility (EMC) - Part 3-3: Limits - Limitation of voltage changes, voltage fluctuations and flicker in public low-voltage supply systems, for equipment with rated current <= 16 A per phase and not subject to conditional connection EN 60335-1:2002 +A11:2004 +A1:2004 “Safety of Household and
Cybex 425T Treadmill Service Manual Table of Contents Front Pages About this Manual . . . . . . . . . . . . . . . . . . FCC Compliance Information. . . . . . . . . . Declaration of Conformity . . . . . . . . . . . . Table of Contents . . . . . . . . . . . . . . . . . . . 4 Service i i ii v 1 Safety Important Voltage Information . . . . . . . Grounding Instructions. . . . . . . . . . . . . Important Safety Instructions . . . . . . . . Warning Decals . . . . . . . . . . . . . . . . . . Caution Decals . . .
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Cybex 425T Treadmill Service Manual 1 - Safety IMPORTANT: Read all instructions and warnings before using the treadmill. Important Voltage Information Before plugging the power cord into an electrical outlet, verify that the voltage requirements for your area match the voltage of the treadmill that you have received.
Cybex 425T Treadmill Service Manual Important Safety Instructions (Save These Instructions) ! DANGER: To reduce the risk of electric shock, always unplug this treadmill from the electrical outlet immediately after using it and before cleaning it. ! WARNING: Serious injury could occur if these precautions are not observed. To reduce the risk of burns, fires, electric shock, or injury: User Safety Precautions • DO NOT wear loose or dangling clothing while using.
Cybex 425T Treadmill Service Manual • Use a dedicated line when operating the treadmill. NOTE: A dedicated line requires one circuit breaker per unit. • Connect the treadmill to a properly grounded outlet only. • DO NOT operate electrically powered treadmills in damp or wet locations. • Keep the running belt clean and dry at all times. • DO NOT leave the treadmill unattended when plugged in and running.
Cybex 425T Treadmill Service Manual • Carefully read and understand the following before using the 425T treadmill: • Warning Decals • Caution Decals To replace any worn or damaged decals do one of the following: Visit www. cybexinternational.com to shop for parts online, fax your order 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.
DE-19238 Cybex 425T Treadmill Service Manual DE-19238 Warning Motor Cover Safety Page 1-5
Cybex 425T Treadmill Service Manual DE-16928 Warning Motor Cover Safety Page 1-6
Cybex 425T Treadmill Service Manual Caution Decals Caution decals indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. There are no caution decals used on this unit. However, there are caution statements listed in Chapters 5 and 6 of this manual. See Chapters 5 and 6. Emergency Stop Key (e-stop) The e-stop key functions as the emergency stop. In an emergency situation, remove the e-stop key and the treadmill will come to a stop.
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Cybex 425T Treadmill Service Manual 2 - Preventive Maintenance Warnings/Cautions All warnings and cautions listed in this chapter are as follows: ! WARNING: All maintenance activities shall be performed by qualified personnel. Failure to do so could result in serious injury. ! WARNING: To prevent electrical shock, be sure that the treadmill is unplugged from the electrical outlet before performing any cleaning or maintenance procedures. ! WARNING: Keep wet items away from inside parts of the treadmill.
Cybex 425T Treadmill Service Manual NOTE: Do not spray cleaning solution directly on the treadmill. Direct spraying could cause damage to the electronics and may void the warranty. ! WARNING: To prevent electrical shock, be sure that the treadmill is unplugged from the electrical outlet before performing any cleaning or maintenance procedures. After Each Use — Wipe up any liquid spills immediately.
Cybex 425T Treadmill Service Manual Running Belt Maintenance Belt and Deck — Wipe the belt surface and the deck area with a clean dry towel to minimize the effect of friction between the deck and the running belt. This should be done often to prevent premature wear of the deck, running belt, and the drive motor system. See the Service Schedule at the end of this chapter. The running belt may become loose and slip on the drive roller with each foot plant.
Cybex 425T Treadmill Service Manual 2. Center the belt. NOTE: While centering the belt choose one bolt to adjust. Do not adjust both bolts. A. With the treadmill running at 5 mph (8 kph) observe the running belt. If the belt tracks off center to the right or left the deck will become exposed. Use a 3/4” socket wrench to tighten the rear roller bolt on the side of the treadmill toward which the belt is moving.
Cybex 425T Treadmill Service Manual Other Preventive Maintenance Other preventive maintenance activities must be completed by a qualified service technician at the recommended intervals listed in the Service Schedule at the end of this chapter. These activities include: • Measure the motor brushes and replace worn motor brushes • Replace the running deck and bushings • Replace the running belt Elevation Motor Lubrication — In time the elevation motor pivot points may develop a squeak.
Cybex 425T Treadmill Service Manual Service Schedule All maintenance activities shall be performed by qualified personnel. Failure to do so could result in serious injury. NOTE: This is the minimum recommended service. 1. Determine mileage. A. While in Dormant Mode enter Test Mode by pressing and holding the Heart Rate and Level keys simultaneously for five seconds. B. Press the Dist key. DIST appears on the display. Record Mileage.
Cybex 425T Treadmill Service Manual 2. Resetting the service odometer. A. While in Dormant Mode enter Test Mode by pressing and holding the Heart Rate and Level keys simultaneously for five seconds. B. Press the Cool Down key to display “SVC” and miles or kilometers on service odometer. C. Press the or key to display “RST”. D. Press the Enter key to reset the service odometer to zero. NOTE: Service may be performed before the 9,000 miles (14,500 km) service prompt appears.
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Cybex 425T Treadmill Service Manual 3 - Customer Service Contacting Service Hours of phone service are Monday through Friday from 8:30 a.m. to 6:00 p.m. Eastern Standard Time. For Cybex customers living in the USA, contact Cybex Customer Service at 888-462-9239. For Cybex customers living outside the USA, contact Cybex Customer Service at 508-533-4300 or fax 508-533-5183. Order parts and find information on the web at www.cybexinternational.com or by e-mail at techhelp@ cybexintl.com.
Cybex 425T Treadmill Service Manual Return Material Authorization (RMA) The Return Material Authorization (RMA) system outlines the procedures to follow when returning material for replacement, repair, or credit. The system assures that returned materials are properly handled and analyzed. Follow the following procedures carefully. Contact your authorized Cybex dealer on all warranty-related matters. Your local Cybex dealer will request an RMA from Cybex, if applicable.
Cybex 425T Treadmill Service Manual 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 date of delivery. Keep all shipping containers and packing materials: they will be needed as part of the inspection process.
Cybex 425T Treadmill Service Manual Customer Service Page 3-4
Cybex 425T Treadmill Service Manual 4 - Service Warnings/Cautions All warnings and cautions listed in this chapter are as follows: ! WARNING: All maintenance activities shall be performed by qualified personnel. Failure to do so could result in serious injury. ! CAUTION: Use only Cybex replacement parts when servicing. Failure to do so could result in personal injury. ! WARNING: Disconnect the power cord before beginning this procedure.
Cybex 425T Treadmill Service Manual ! WARNING: All maintenance activities shall be performed by qualified personnel. Failure to do so could result in serious injury. For any service related concerns, call Cybex Customer Service at 800-766-3211 (for Cybex customers living within the USA). For customers living outside the USA, call 508-533-4300 or fax 508-533-5183. NOTE: Read and understand each procedure thoroughly before servicing.
Cybex 425T Treadmill Service Manual LED Functions LEDs are used to indicate the status of many of the treadmill inputs. After entering Test Mode refer to the following list to check that these LEDs are functioning properly. See Figure 2. Elevation sensor LED: On when 0% elevation sensor is active above 0% and off below 0%. E-stop key sensor LED: Off when e-stop key is removed. Speed sensor LED: Blinks on once per speed sensor pulse.
Cybex 425T Treadmill Service Manual Pause/Stop Press once to exit Test Mode. Time Displays the setup constants, each of which may be modified by pressing the Up and Down arrows. Each depression of Time cycles to the next parameter. The Enter key must be pressed to save a changed value. See Setting Operation Options in chapter 5 of the Owner’s Manual for details. Up Arrow Increases display constants, see Time. Down Arrow Decreases display constants, see Time. Enter Required to save setup values.
Cybex 425T Treadmill Service Manual Speed Sensor Adjustment Tools Required • Phillips head screwdriver • 1/2” open end wrench (2) ! WARNING: Disconnect the power cord before beginning this procedure. 1. Disconnect the external power source. A. Unplug the treadmill from the power outlet. 2. Remove the motor cover. A. Using a Phillips head screwdriver, loosen two screws on each motor cover side (left and right). See Figure 3. Motor Cover B.
Cybex 425T Treadmill Service Manual C. After reaching maximum speed reduce the speed to 1.0 mph (1.6 kph). If a speed error occurs then your speed sensor gap needs to be readjusted. D. Press Pause/Stop. E. Enter Test Mode again and check the error log for Error 3. If any new errors 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 the scan key twice and then repeat steps 3A through 4E. F.
Cybex 425T Treadmill Service Manual Running Belt and Deck NOTE: During this procedure you will have the option to remove the running deck, running belt, end caps, rear roller, front roller, rubber mounts and drive belt. Follow this procedure from step 1 even though the heading for some of these procedures will appear before the step where you remove that part. Tools Required • Phillips head screwdriver • 7/16” socket wrench 1. Elevate the treadmill. A.
Cybex 425T Treadmill Service Manual C. Grasp each top platform and slide it up and off the treadmill. End Caps Tools Required • Phillips head screwdriver Bottom Caps 5. Remove the end caps. A. Using a Phillips head screwdriver, remove the two screws securing each of the bottom caps to the frame See Figure 6. B. Using a Phillips head screwdriver, remove the three screws securing each of the lower top caps to the upper top caps See Figure 7. Screws (2) Figure 6 C.
Cybex 425T Treadmill Service Manual Rear Roller Tools Required Bolt Rear Roller Bronze Bushing Running Belt • 3/4” socket wrench • 7/16” socket wrench • 3/16” allen wrench 7. Remove the rear roller. Nut A. Using a 3/4” socket wrench, remove the two rear roller bolts, bronze bushing and nut (one roller bolt on each side). NOTE: Loosen each bolt evenly, making sure not Figure 8 to loosen either bolt too many turns before moving to the other bolt. See Figure 8. B.
Cybex 425T Treadmill Service Manual Front Roller 9. Remove the front roller. ! WARNING: Drive belt is under tension. Do not pinch fingers while releasing tension. Idler Arm Tools Required • 3/4” socket wrench • 7/16” socket wrench A. Release drive belt tension by placing a Phillips head screwdriver into the square hole located in the bottom of the idler pulley assembly. See Figure 10. B. While pushing down on the Phillips head screwdriver carefully slide the drive belt off of the drive motor pulley.
Cybex 425T Treadmill Service Manual 14. Secure the front roller. A. Slide the front roller into the running belt. B. Slide the new drive belt around the front roller before attaching the front roller. C. Using a 9/16” socket wrench attach the two bolts that fasten the front roller to the frame. NOTE: Tighten each of the two bolts evenly, making sure not to tighten one bolt too many turns before moving to the other bolt. 15. Secure the drive belt. A.
Cybex 425T Treadmill Service Manual A. Carefully lower the treadmill to the ground. B. Lower the motor cover center into position. See Figure 2. C. Using a Phillips head screwdriver, tighten the two screws on each side and the two screws in the front of the unit. 20. Adjust the running belt tension and tracking. A. Follow the Tension and Center the Belt procedure located in the Preventive Maintenance chapter of this manual.
Cybex 425T Treadmill Service Manual A. Using a Phillips head screwdriver loosen but do not remove the two screws securing the left motor cover in place. Loosen the two screws securing the right motor cover. B. Lift the top motor cover up and off of the treadmill. 4. Elevate the treadmill. A. Without standing on the belt, press the Start key and begin running the treadmill. B. Press the up arrow and elevate the treadmill fully. 5. Disconnect the power. A.
Cybex 425T Treadmill Service Manual 8. Remove the black brush assembly. A. Using a large flat head screwdriver pry out the brush retainer on the drive motor that secures the black wire. The brush and spring will pop out. 9. Examine the brush and commutator. A. Inspect the commutator by looking through the top brush holder into the motor. Slowly spin the motor by turning the flywheel. Look for noticeable damage and for signs of wear such as arcing, pitting, burning, or uneven wear.
Cybex 425T Treadmill Service Manual C. Secure the drive motor cables to the drive motor housing with a wire tie. D. Attach the ferrite removed in step 7D around the two drive motor cables. E. Connect the drive motor cables to the lower board. The black wire connects to A2, The red wire connects to A1 ! WARNING: Avoid touching lower board components such as resistors and capacitors. F. Secure the drive motor cables to the other cables in the lower control board with two wire ties. 12.
Cybex 425T Treadmill Service Manual Motor Brushes 220 VAC Product Numbers SK-18554 NOTES: This procedure describes the replacement of motor brushes on the 425T model treadmill. Motor brushes are wear items that will periodically need to be replaced. Both drive motor brushes must be replaced as a pair. This will ensure even commutator contact and brush wear. However, the negative brush will wear 20% faster than the positive brush.
Cybex 425T Treadmill Service Manual 5. Remove the brush access covers. A. Using a flat head screwdriver pry off both brush access covers on the drive motor. 6. Remove the brushes. A. Using the needle nose pliers pry the brush wire connector off of the terminal in the drive motor. B. Using your fingers press in the spring clip until the locking tab disengages and the spring can be removed from the brush holder. C. Repeat steps 6A and 6B for other brush. 7. Examine the brush and commutator. A.
Cybex 425T Treadmill Service Manual 9. Lower treadmill. A. Carefully lower the rear of the treadmill until the back feet are resting on the ground. 10.Test the unit for proper operation. A. Connect the treadmill to the power outlet. B. The treadmill will lower itself. Wait until the treadmill resets its elevation to 0%. C. Operate the unit at all levels to verify proper operation.
Cybex 425T Treadmill Service Manual A. Using a 1/2” open end wrench remove the two motor plate bolts. See Figure 15. B. Slowly and carefully lower the drive motor plate. Motor Plate Bolts and Washers 5. Disconnect the motor cables. A. Locate the red and black drive motor cables exiting the drive motor and connected to A1 and A2 on the lower control board. B. Disconnect the two motor cables from the lower board. ! WARNING: Avoid touching lower board components such as resistors and capacitors. C.
Cybex 425T Treadmill Service Manual 7. Install Drive motor. ! WARNING: Drive Motor is heavy, use care when lifting. A. Lift the drive motor up and into the motor base plate. B. Using a 1/2” socket with a 6” extension secure the drive motor to the motor base plate using four mounting nuts. 8. Connect the motor cables. A. Locate the red and black drive motor cables exiting the drive motor. B. Connect the two motor cables from the lower board.
Cybex 425T Treadmill Service Manual Elevation COM Elevation UP Black Motor -A2 Elevation DOWN Red Motor + A1 Elevation Ground AC Line Neutral White AC2 Ground Cable Elevation Switch P1 Display Cable P3 Speed Sensor P2 Display Cable P4 AC Line Neutral Black AC1 Mounting Screw (2) Figure 17 2. Remove the lower control board. A. Raise the motor base plate. B. Using a Phillips head screwdriver, remove the two screws that hold the lower control board to the motor base plate. C.
Cybex 425T Treadmill Service Manual 4. Connect the cables to the lower control board. A. Connect the cables from the lower control board. This includes: the elevation motor cables (COM, UP, DOWN and GND); Ground cable; elevation switch (P1); display cable (P3); speed sensor (P2); display cable (P4); AC line hot, black (AC1); AC line neutral, white (AC2); drive motor cable red (A1) and drive motor cable black (A2). See Figure 17. 5. Secure the wires. A.
D. Connect the white fast-on connectors from the power cord to the circuit breaker with the white wire. See Figure 18. Line Filter Circuit Breakers Ground Wire Stud AC Line 2 (AC2) Lower Board Power Cord AC Line 1 (AC1) Strain Relief Figure 18 Circuit Breakers Tools Required • Flat head screwdriver 9. Remove the circuit breakers. A. Disconnect the four fast-on connectors that connect to the circuit breakers. B.
Cybex 425T Treadmill Service Manual Line Filter Tools Required • Phillips head screwdriver 11. Replace the line filter. NOTE: Take notice of which cables are connected to the line filter. A. Disconnect the two fast-ons connectors that go from the line filter to the lower board (cables labeled AC1 and AC2 on the lower board). See Figure 18. B. Disconnect the two fast-ons connectors that go from the line filter to the circuit breakers. See Figure 18. C.
Cybex 425T Treadmill Service Manual 14. Secure the drive belt. A. Place the Phillips head screwdriver into the square hole located in the bottom of the idler pulley assembly. ! WARNING: Do not pinch fingers while tensioning belt. B. While pushing down on the Phillips head screwdriver carefully slide the drive belt into the grooves on the flywheel pulley and front roller. Slowly release tension on the idler pulley assembly. C.
Cybex 425T Treadmill Service Manual Elevation Motor Tools Required • Phillips head screwdriver • 9/16” Open end wrench • 9/16” Socket wrench ! 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. 1. Disconnect the external power source. A. Unplug the treadmill from the power outlet. 2. Remove the motor cover. A.
Cybex 425T Treadmill Service Manual 6. Secure the elevation motor. A. Carefully place the elevation motor in position on the treadmill. See Figure 19. B. Slide both bolts into the slots and attached the hex nuts as shown in Figure 19. C. Using a 9/16” open end wrench and a 9/16” socket wrench, securely tighten the nuts and two bolts installed in step 7B. D. Connect the elevation motor cable to the cable connector plate. E. Tie the elevation cable with a wire tie to the frame. 7. Secure the motor cover. A.
Cybex 425T Treadmill Service Manual Upper Display Board NOTE: This procedure will cover the upper display board, display overlays, contact heart rate grips, e-stop switch and display cable. Tools Required • Phillips head screwdriver • ESD (Electro Static Discharge) grounding strap 1. Disconnect the external power source. A. Unplug the treadmill from the power outlet. NOTE: The display board is susceptible to damage from a discharge of static electricity.
Cybex 425T Treadmill Service Manual Mounting Screws (5) Polar Heart Rate Cable Display Cable (2 Connectors) Ground Wire Contact Heart Rate Cable Figure 22 E. Remove the console assembly. 3. Remove the display board. A. Using a Phillips head screwdriver, remove the five screws that hold the display board to the console. See Figure 22. B. Gently flip the display board over and disconnect the upper switch membrane and the lower switch membrane.
Cybex 425T Treadmill Service Manual C. Carefully place the display overlay in position within the indentation on the console front and firmly rub the display overlay so that it adheres to the console. D. Connect the upper switch membrane and the lower switch membrane to the display board. 6. Attach the display board. A. Place the display board in position on the front console. B. Using a Phillips head screwdriver, secure the five screws that hold the display board to the console.
Cybex 425T Treadmill Service Manual E-Stop switch Console Back Tools Required • Phillips head screwdriver • Wire cutters 8. Remove the console back plate. A. Using a Philips head screwdriver remove the ten screws securing the console back from the upright assembly. See Figure 24. Upright Assembly Screws Figure 24 B. Using a Philips head screwdriver remove the two screws that secure the console backin place. See Figure 25.
Cybex 425T Treadmill Service Manual 10. Remove the lower handle cover. A. Using a Philips head screwdriver remove the two screws securing the lower handle cover to the upper handle cover. See Figure 27. Lower Handle Cover Upper Handle Cover E-Stop Switch Screws Screws Figure 27 Figure 28 11. Remove the e-stop switch. A. Using a Philips head screwdriver remove the two screws securing the e-stop switch. See Figure 28. 12. Install the e-stop switch. A.
Cybex 425T Treadmill Service Manual 14. Attach the new display cable. A. Push the new display cable down through the handrail and out the handrail’s bottom hole. B. Plug the display cable into the connector plate in the base. See Figure 29. C. Secure the display cable with wire ties to the handrail. 15. Install the lower handle cover. A. Using a Philips head screwdriver install the two screws securing the lower handle cover to the upper handle cover. See Figure 27. 16. Install the accesory tray. A.
Cybex 425T Treadmill Service Manual 21. Route the new contact heart rate cable. A. Connect the contact heart rate connector into the bottom of the heart rate board. See Figure 22. Black Wire (Back) B. Locate the short and long side of the heart rate cable. C. Route the short cable end to the left (from treadmill user’s viewpoint) and the long end to the right. Red Wire (Front) D. Fold the each cable and place it into the hole that leads to the grip. See Figure 30. E.
Cybex 425T Treadmill Service Manual 23. Secure the new metal contacts. A. Remove the protective paper from the four metal contacts and from the eight strips of tape on the plastic housing. B. Locate the small bump on the metal contact prong and on the connectors. See Figure 34. Line Up Bumps Prong on Metal Plate C. Connect the each cable to a metal prong with the bumps lined up. See Figure 34. Figure 34 D. Push the excess wire into its rectangular hole. E.
Cybex 425T Treadmill Service Manual Parts List ITEM QTY. PART NO. NO.
Cybex 425T Treadmill Service Manual ITEM QTY. PART NO. NO.
Cybex 425T Treadmill Service Manual ITEM NO. 406 407 NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NOTE: Service Page 4-38 QTY. PART NO. DESCRIPTION 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 4 2 1 1 1 1 1 1 1 2 NS = Screw, 10-24 x 1/2”, RECESS, PAN HD, TT, SS Screw, SEMS, 8-32 x .
Console Assembly Optional Monitor Bracket 315 304 Console Assembly 300 316 402 312 317 312 1 404 310 405 314 313 9 403 309 311 70 305 407 308 306 406 211 70 64 70 11 40 41 44 31 Idler Pulley Assembly Upright Assembly Upright Assembly 97 33 95 42 42 56 33 66 47 65 35 35 10 61 17 34 34 62 34 96 35 39 23 48 49 35 205 63 50 29 200 34 35 31 68 18 98 34 2 94 301 31 208 35 39 318 97 204 46 46 12 210 43 203 6 45 45 27 27 204 205 8 51 21
GND 3 3 RED AW-19235 WIRE, CONTROLLER GROUND UP THERMAL ELV-MOTOR ZERO POSITION SWITCH NORMALLY CLOSED OPEN <=10.