Cybex Sport Treadmill Owner’s & Service Manual Cardiovascular Systems Part Number LT-16602-4 Rev J Cybex and the Cybex logo are registered trademarks of Cybex International, Inc. Stableflex and the Stableflex logo are registered trademarks of Cybex International, Inc. Safety Sentry™ is a registered trademark of Cybex international, Inc. DISCLAIMER: Cybex International, Inc. makes no representations or warranties regarding the contents of this manual.
IMPORTANT WARRANTY INFORMATION To validate this warranty, complete the following information and return this card to Cybex within ten days of equipment installation.
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Cybex Sport Treadmill Owner’s & Service Manual About This Manual An Owner’s & Service Manual is shipped with each Cybex Sport treadmill. To purchase additional copies of this manual or any other Cybex manual, please do one of the following: • • • • order online at www.eCybex.
Cybex Sport Treadmill Owner’s & Service Manual NOTE: For European customers only.
Cybex Sport Treadmill Owner’s & Service Manual Table of Contents Front Pages About this Manual . . . . . . . . . . . . . . . . . . i FCC Compliance Information . . . . . . . . . . i Declaration of Conformity . . . . . . . . . . . . ii Table of Contents . . . . . . . . . . . . . . . . . . iii 1 Safety Important Voltage Information Grounding Instructions . . . . . Important Safety Instructions Warning Decals . . . . . . . . . . . Caution Decals . . . . . . . . . . . Emergency Stop Key (e-stop) . . . . . .
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Cybex Sport Treadmill Owner’s & 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 Sport Treadmill Owner’s & 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 • Place your feet on the two top steps when starting or stopping the treadmill.
Cybex Sport Treadmill Owner’s & Service Manual • Use a dedicated line when operating the treadmill. • 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. • Use this treadmill for commercial use only. • DO NOT leave the treadmill unattended when plugged in and running.
Cybex Sport Treadmill Owner’s & Service Manual • Ensure all User and Facility safety precautions are observed. • Carefully read and understand the following before using the Pro+ treadmill: • Warning Decals • Caution Decals To replace any worn or damaged decals do one of the following: Visit eCybex.com to shop for parts online, fax your order to 508-533-5183 or contact Cybex Customer Service at 800-766-3211. If you live outside of the USA, call 508-533-4300.
Cybex Sport Treadmill Owner’s & Service Manual Underneath Motor Cover Safety Page 1-5
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Cybex Sport Treadmill Owner’s & 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 the Cybex Sport treadmill. However, there is a caution in the installation instructions for initial installation only. See below.
Cybex Sport Treadmill Owner’s & Service Manual 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. Before using the treadmill, clip the e-stop key as described below. 1. Clip the e-stop key to your clothing. NOTE: Be sure the string is free of knots and has enough slack for you to run comfortably with the e-stop key in place. 2.
Cybex Sport Treadmill Owner’s & Service Manual 2 - Technical Specifications Specifications Length: 79” (200 cm) Width: 32” (82 cm) Running Area: 20” x 58” (51 cm x 147 cm) Weight of Product: 385 lbs. (173 kg) Shipping Weight 415 lbs. (187 kg) Speed Range: 0.5 to 10 mph (0.8 to 16 kph) in 0.1 mph or 0.
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Cybex Sport Treadmill Owner’s & Service Manual 3 - Operation Read and understand all instructions and warnings prior to using the treadmill. See all of the safety related information located in chapter 1. Terms & Symbols Used This section lists some of the common terms and symbols used in this chapter. Other terms and symbols are listed in this chapter as appropriate. Dormant Mode — This occurs when the treadmill is plugged in, turned to the on (I) position and not in use.
Cybex Sport Treadmill Owner’s & Service Manual Quick Operation Guide NOTE: Maximum user weight is 400 lbs. (181 kg). The following is a quick overview of the operation of the treadmill. For more information read Detailed Operation Guide in this chapter. 1. Place your feet on the two top steps located on each side of the running belt. ! CAUTION: Do not stand on the running belt when starting the treadmill. Always place your feet on the two top steps when beginning a workout. 2.
Cybex Sport Treadmill Owner’s & Service Manual ! CAUTION: Do not stand on the running belt when starting the treadmill. Always place your feet on the two top steps when beginning a workout. 3. Place your feet on the two top steps located on each side of the running belt. 4. Clip the e-stop clip onto your clothing and carefully test the e-stop key to ensure it will fall off properly in case of an emergency. See Emergency Stop Key (e-stop) in Chapter 1 for properly testing the e-stop key.
Cybex Sport Treadmill Owner’s & Service Manual the contact heart rate grips. The left window will display the time elapsed. NOTE: During your workout the time will show in the format of minutes:seconds. The right window will display the current speed. See Figure 1. 1. select program 2. adjust manual + - incline speed weight weight weight loss level 30 minute walking workout enter level scan cardio dist cal mets min mi / km 20 minute aerobic exercise Cybex International, Inc.
Cybex Sport Treadmill Owner’s & Service Manual your workout and add to the time you already accumulated. If the Quick Start key has not been pressed during the 20 second pause, workout data will be cleared and the display will change to Dormant Mode. Press Stop a second time to interrupt workout data from cycling and to change the display to Dormant Mode. The function of the immobilization method: The purpose of immobilizing the treadmill is to prevent unauthorized use.
Cybex Sport Treadmill Owner’s & Service Manual Changing Speed — Press the Speed + — keys to change the speed in increments of 0.1 mph or 0.10 kph. Minimum to maximum speed is from 0.5 - 10 mph (0.8 - 16 kph). Changing Incline — Press the Incline keys to change the elevation in increments of 1%. Elevation ranges from -2 to 15%. NOTE: Elevation is defined as the ratio of rise or fall over run of the treadmill deck. Workout Time — You can workout up to 60 minutes in by pressing Quick Start.
Cybex Sport Treadmill Owner’s & Service Manual Data displayed during a program: The top center display will continually review each set of data. Each set of data is displayed for 3 seconds before the next set is displayed. The corresponding LED lights as the data is displayed. To review accumulated data after a program: The display automatically cycles through your accumulated workout data during the Workout Review for up to 20 seconds.
Cybex Sport Treadmill Owner’s & Service Manual Heart Rate Zone Heart Rate is described by the number of times your heart beats in a minute. At rest, the average adult will have a heart rate of about 72 beats per minute (bpm). As one begins to exercise, heart rate increases and continues to increase as exercise intensity or difficulty increases. Monitoring your heart rate is an effective way to control the intensity of your workout and subsequently the results it will have.
Cybex Sport Treadmill Owner’s & Service Manual The degree of incline can be related to % grade by taking the Tangent of the grade. For instance, 15% grade is equal to 8.53 Degrees (Tan(.15)=8.53º). The opposite is true to determine % Grade from Degree of incline (ArcTan (8.53º)=.15). Visit our website at www.ecybex.com/education to use the body mass calculator, calorie calculator and to get performance training tips. Use of Programs ! WARNING: Obtain a medical exam before beginning any exercise program.
Cybex Sport Treadmill Owner’s & Service Manual When you workout in Manual Mode, be sure to include a three-to-five minute warm-up and cool-down period. You can warm-up by setting a slow speed for walking/jogging on the treadmill at zero incline and then gradually increase the speed to the target for your workout. Reverse this process for your cool-down period, slowing down the speed gradually and returning the incline to zero.
Cybex Sport Treadmill Owner’s & Service Manual Weight Loss Custom 2 Profiles Show Level 10 at 20 Minutes MPH 12.4 12.0 11.0 KPH 20.0 19.0 18.0 17.0 10.0 16.0 15.0 9.0 14.0 8.0 13.0 12.0 7.0 Speed 6.0 11.0 10.0 9.0 5.0 8.0 7.0 4.0 6.0 3.0 5.0 4.0 2.0 1.0 3.0 2.0 1.
Cybex Sport Treadmill Owner’s & Service Manual Cardio Program Overview This program was designed for the exercise participant who wants to improve the overall efficiency of their cardio-respiratory system. Unlike some of the other treadmill programs that incorporate low and moderate intensity segments, the Cardio program contains overall higher intensity levels with more moderate recovery segments.
Cybex Sport Treadmill Owner’s & Service Manual Cardio Custom 1 Profiles Show Level 10 at 20 Minutes MPH 12.4 12.0 11.0 KPH 20.0 19.0 18.0 17.0 10.0 16.0 15.0 9.0 14.0 8.0 13.0 12.0 7.0 Speed 6.0 11.0 10.0 9.0 5.0 8.0 7.0 4.0 6.0 3.0 5.0 4.0 2.0 1.0 3.0 2.0 1.
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Cybex Sport Treadmill Owner’s & Service Manual 4 - 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 power is shut off and the treadmill is unplugged from the electrical outlet before performing any cleaning or maintenance procedures.
Cybex Sport Treadmill Owner’s & 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 power is shut off and 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 Sport Treadmill Owner’s & Service Manual often to prevent premature wear of the deck, running belt, and the drive motor system. See the Service Schedule in this chapter to determine the minimum recommended cleaning. The running belt may become loose and slip on the drive roller with each foot plant. If it does, follow the Tensioning and Centering the Belt in this chapter. See the Service Schedule in this chapter for a minimum schedule for checking the belt tension.
Cybex Sport Treadmill Owner’s & Service Manual 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 Sport Treadmill Owner’s & Service Manual Side Panel Top Steps End Caps Screws Side Panel Figure 3 4. Remove the side panels. A. Pull each side panel out and off the treadmill. See Figure 3. 5. Remove the top steps. Screws (3 Under Each Top Step) A. Using a Phillips head screwdriver, remove the three screws that hold each top step in place. See Figure 4. B. Grasp each top step and lift it out and off the treadmill. See Figures 3 and 4. Figure 4 6. Check the belt and deck condition. A.
Cybex Sport Treadmill Owner’s & Service Manual 8. Secure the top steps. A. Place each top step in position. See Figure 4. B. Using a Phillips head screwdriver, tighten the three screws that hold each top step in place. See Figure 4. 9. Secure the end caps. A. Using a Phillips head screwdriver, tighten the screw securing each end cap in place. See Figure 3. 10. Secure the side panels. A.
Cybex Sport Treadmill Owner’s & Service Manual Service Schedule Preventive Maintenance Page 4-7
Cybex Sport Treadmill Owner’s & Service Manual Log Sheet Serial Number Date of Data Collection Total Miles/Kilometers Total Hours Motor Current @ 3 mph (4.8 kph) Motor Voltage @ 10 mph (16.1 kph) - without load - with 160 lbs. load (72 kg) Notes: Total Miles/Kilometers Total Hours Motor Current @ 3 mph (4.8 kph) Motor Voltage @ 10 mph (16.1 kph) - without load - with 160 lbs. load (72 kg) Notes: Total Miles Total Hours Motor Current @ 3 mph (4.8 kph) Motor Voltage @ 10 mph (16.
Cybex Sport Treadmill Owner’s & Service Manual 5 - Setup & Assembly Warnings/Cautions All warnings and cautions listed in this chapter are as follows: ! WARNING: Use extreme caution when assembling the treadmill. Failure to do so could result in injury. ! CAUTION: A minimum of two people are required to lift, move and assemble this treadmill. Always use proper lifting methods when moving heavy items. ! CAUTION: Do not pinch your hands or other body parts while pivoting the treadmill. See Figure 3.
Cybex Sport Treadmill Owner’s & Service Manual Electrical Power Requirements The power requirements for this treadmill are a grounded, dedicated circuit, rated for one of the following: 115 VAC ±5%, 60 Hz and 20 amps; 208/220 VAC, 60 Hz, 15 amps or 230 VAC ±5%, 50 Hz and 15 amps. Contact your electrician to ensure the power supply complies with local building codes. Do not use a ground plug adapter to adapt the 3-prong power cord plug to a non-grounded electrical outlet. Do not use an extension cord.
Cybex Sport Treadmill Owner’s & Service Manual Item Qty Part Number Description 1 1 Varies Base with uprights and console attached 5 1 AX-16724 Motor cover, center, with decals 6 1 PL-16465 Motor cover, right (in box) 7 1 PL-16464 Motor cover, left (in box) NA 1 AX-16956 Hardware pack (in box) NA 1 LT-16602 Sport Manual (in box) NA 1 LT-16314 Assembly Poster NOTE: NA means not applicable.
Cybex Sport Treadmill Owner’s & Service Manual C. Check off ( ✔) each item in the hardware pack as you find it. See Figure 2. Item Qty 2 8 3 2 4 8 8 1 Part Number HS-16929 HS-16950 HS-16939 HX-00438 Description Screw, hex head whiz-lock 3-8-16 x 5-8 Screw, button head 5-16-18 x 7-8 Screw, Phillips head sems 10-32 x .
Cybex Sport Treadmill Owner’s & Service Manual ! CAUTION: A minimum of two people are required to lift, move and assemble this treadmill. Always use proper lifting methods when moving heavy items. 4. Lift and move the treadmill. A. At least two people should lift and move the treadmill to a level location where you intend to leave it. Use proper lifting methods. ! CAUTION: Do not pinch your hands or other body parts while pivoting the treadmill. See Figure 3. 5.
Cybex Sport Treadmill Owner’s & Service Manual 6. Verify the model and voltage. A. Verify that you have the correct model by looking at the console and reading the model name. B. Verify that you have the correct voltage by looking at the lower board and reading the voltage sticker. 7. Secure the uprights. A. Using a 9/16” socket wrench, loosely attach the uprights with two of the 3-8-16 x 5-8 hex head whiz-lock screws. NOTE: Do not securely tighten the screws until step 7C. See Figure 4. B.
Cybex Sport Treadmill Owner’s & Service Manual 3 Figure 7 B. Using the hex key provided, tighten the two pivot screws on the handrail. See Figure 8. Pivot Screws Figure 8 9. Remove the left side panel. A. Pull the left side panel away from the base. See Figure 9. Left Side Panel Figure 9 10. Arrange power cord. A. Decide whether you will plug the power cord into an outlet near the front of the treadmill or the back of the treadmill. Follow the corresponding routing procedure below.
Cybex Sport Treadmill Owner’s & Service Manual Front routing: a. Unwind the power cord and route it under the upright. b. Slide the grommet into the front exit hole with the curved end first. See Figure 10. Grommet Wire Ties Arms Figure 10 Back routing: a. Using a Phillips head screwdriver, remove the left end cap. b. Remove the grommet from the back exit hole and slide it into the front exit hole. c. Slide the grommet on the power cord into the back exit hole with the curved end first. d.
Cybex Sport Treadmill Owner’s & Service Manual 11. Attach the motor cover (three pieces). A. Using a Phillips head screwdriver, partially tighten each motor cover side (left and right) with four 10-32 x .75 Phillips head screws. See Figure 12. B. Place the motor cover center into position. See Figure 12. C. Using a Phillips head screwdriver, finish tightening all eight screws. Be sure the screws are catching the motor cover’s holes. 5 6 4 4 7 Figure 12 12. Level your treadmill. A.
Cybex Sport Treadmill Owner’s & Service Manual Emergency Stop Button Emergency Stop Key Figure 13 Setup & Assembly Page 5-10
Cybex Sport Treadmill Owner’s & Service Manual ! WARNING: Be sure that all electrical requirements are met as indicated in the specifications at the front of the manual and at the beginning of this chapter prior to proceeding. Testing the Treadmill Operation Use the following instructions to test the full speed and incline range of the treadmill and to check the belt for proper operation. ! CAUTION: During this procedure STAY OFF THE RUNNING BELT! Stand with your feet on the two steps. 1.
Cybex Sport Treadmill Owner’s & Service Manual 11. Run the treadmill through its full % grade range. Press the Incline key until the treadmill reaches its highest grade (15%). Next press the Incline key until the treadmill is down to -2% grade. Then press the Incline key until the treadmill is back to 0% grade. 12. Press Stop twice to stop the running belt, end the workout review, and return the display to Dormant Mode. Setting Operation Options 1.
Cybex Sport Treadmill Owner’s & Service Manual 6 - Customer Service Contacting Service Hours of phone service are Monday - Friday from 8:00 a.m. - 6:00 p.m. Eastern Time. For Cybex customers living in the USA, contact Cybex Customer Service at 800-766-3211. Your options at this number include: • Press 63 to place a parts order or to check parts order status. • Press 64 to speak to a technical support representative regarding trouble shooting or to schedule a field service call.
Cybex Sport Treadmill Owner’s & Service Manual 1. Call the Customer Service Hotline listed above for the return of any item that is defective. 2. Provide the technician with a detailed description of the problem you are having 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.
Cybex Sport Treadmill Owner’s & Service Manual Damaged Parts Materials damaged in shipment should not be returned for credit. Shipping damages are the responsibility of the carrier (UPS, Federal Express, trucking companies, etc.) Apparent Damage — Upon receipt of your shipment, check all boxes carefully. Any damage seen with a visual check must be noted on the freight bill and signed by the carrier's agent. Failure to do so will result in the carrier's refusal to honor your damage claim.
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Cybex Sport Treadmill Owner’s & Service Manual 7 - 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. ! WARNING: Do not touch components on the lower board.
Cybex Sport Treadmill Owner’s & 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 508533-4300 or fax 508-533-5183. NOTE: Read and understand each procedure thoroughly before servicing.
Cybex Sport Treadmill Owner’s & Service Manual LED Functions LEDs are used to indicate the status of many of the treadmill inputs.
Cybex Sport Treadmill Owner’s & Service Manual Error Codes Error codes notify you of a problem condition and are displayed on the console. These codes can also help to indicate the part of the treadmill most likely to be causing the problem. Errors that present a hazard to the user provide a measure of safety by causing a one second beep, stopping the treadmill and locking out operation of the treadmill. A log of errors can be viewed and cleared.
Cybex Sport Treadmill Owner’s & Service Manual motor cover of each Cybex Sport treadmill. By performing these procedures you can evaluate the performance of your drive motor and help prevent premature failure. Tools Required • Phillips head screwdriver • Voltage meter 1. Measure current draw. A. Enter Test Mode by holding down any key on the display while turning the power switch to the on (I) position. B. Press the Quick Start key. The belt will move at 1 mph (1.6 kph). C.
Cybex Sport Treadmill Owner’s & Service Manual 5. Check the motor voltage. A. Plug the treadmill back in and turn it to the on (I) position. B. Without standing on the belt, press the Quick Start key. C. Press the + key to adjust the speed of the treadmill up to its highest speed 10 mph (16 kph). NOTE: Safety Sentry will turn off the treadmill if no activity is detected within 20 seconds. Therefore, do this test quickly or press a key as needed. D.
Cybex Sport Treadmill Owner’s & Service Manual 4. Adjust the speed sensor gap (if needed). A. Using a Phillips head screwdriver, loosen the screw that attaches the speed sensor to the motor saddle. See Figure 3 (speed sensor screw). B. Adjust the gap between the speed sensor and the flywheel to 3/16” (.48 cm) and tighten the screw. See Figure 3. Flywheel Gap Speed Sensor Screw Figure 3 5. Test for speed errors. A. Connect the power cord to a power outlet. B. Enter Test Mode. C.
Cybex Sport Treadmill Owner’s & Service Manual IR Compensation NOTE: This procedure is required after replacing the lower control board or the drive motor. Tools Required • Phillips head screwdriver • Plastic (or non-conductive), flat head screwdriver 1. Please read instructions thoroughly before performing this procedure. 2. Remove the motor cover. A. Using a Phillips head screwdriver, loosen three screws on each motor cover side (left and right). See Figure 2. B.
Cybex Sport Treadmill Owner’s & Service Manual F. Using a plastic small flat head screwdriver, turn the IR control slightly in one direction as follows: • Turn clockwise to remove the slack from the belt • Turn counter-clockwise to remove the vibration or surging from the belt G. Retest by walking on the belt and adjusting the IR COMP control until the running belt does not surge, vibrate or feel too slack. NOTE: You should not be able to stop the belt with your feet easily. H. Press Stop. I.
Cybex Sport Treadmill Owner’s & Service Manual Running Belt & Deck NOTE: During this procedure you will have the option to remove the running deck, running belt, rubber mounts, rear roller, front roller 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.
Cybex Sport Treadmill Owner’s & Service Manual 4. Remove the side panels. A. Pull each side panel out and off the treadmill. See Figure 5. 5. Remove the top steps. A. Using a Phillips head screwdriver, remove the three screws that hold one of the top steps in place. Repeat this step for the other side. See Figure 5. B. Grasp each top step and slide it out and off the treadmill. See Figure 5. Side Panel Screws (3 Under Each Top Step) Top Steps Side Panel Figure 5 Rear Roller 6. Remove the rear roller.
Cybex Sport Treadmill Owner’s & Service Manual 7. Loosen the deck. A. Using a 7/16” open-end or socket wrench, remove the ten screws and ten washers that hold the deck in place. See Figure 7. NOTE: Leave the deck in place until step 9B. Screws (5 on Each Side) Deck Washers (5 on Each Side) Screw Securing Deck Stiffener (1 on Each Side) Rubber Mount (1 on Each Side) Deck Stiffener (1 on Each Side) Figure 7 Front Roller 8. Loosen the front roller. A.
Cybex Sport Treadmill Owner’s & Service Manual B. Lift one side of the deck and slide it out of the running belt. C. Tilt up the left side of the front roller and slip the running belt off. 10. Inspect the rubber mounts. A. Using a Phillips head screwdriver, remove the screw securing each deck stiffener. See Figure 7. B. Inspect the rubber mounts under the deck stiffeners for cracks or wear. NOTE: Unscrew and replace the rubber mounts if the rubber is cracked or worn. C.
Cybex Sport Treadmill Owner’s & Service Manual D. Confirm that the drive belt is positioned three grooves over from the face of the flywheel and three grooves over from the face of the pulley. See Figure 10. NOTE: Failure to align the drive belt could cause squeaking. 14. Secure the drive belt tension. 3 Grooves NOTE: Follow this step only if you replaced the drive belt. A. Using a 1/2” socket wrench, tighten the two screws on the motor saddle. See Figure 9.
Cybex Sport Treadmill Owner’s & Service Manual 20. Secure the motor cover. A. Lower the motor cover center into position. See Figure 2. B. Using a Phillips head screwdriver, tighten the three screws on each side. NOTE: Be sure the screws are catching the center motor cover’s holes. 21. 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 Sport Treadmill Owner’s & Service Manual 4. Remove the motor straps and drive belt from the motor. A. Using 7/16” open end wrench, remove the nut on each motor strap and remove the motor straps from the motor saddle. See Figure 12. B. Slip the drive belt around the flywheel pulley and off the motor. See Figure 13. Drive Belt Drive Motor Cable Green Yellow Red Black Flywheel Pulley Motor Ground Wire Lower Board Line Filter Figure 13 5. Disconnect the motor cables.
Cybex Sport Treadmill Owner’s & Service Manual D. If you are replacing the drive belt, slip the drive belt off the front roller pulley and discard it. 7. Attach the front roller. A. Slide the new drive belt around the front roller. B. Using a 9/16” socket wrench with a 3” extension, insert the two screws that fasten the front roller to the frame. NOTE: Tighten each of the two screws evenly, making sure not to tighten one screw too many turns before moving to the other screw. See Figure 8. 8.
Cybex Sport Treadmill Owner’s & Service Manual ! CAUTION: If the drive motor is warm wait until it is cool to the touch before proceeding. The inside components may be hot. ! WARNING: Keep the motor dry. Do not get the inside of the motor wet. NOTE: If you are checking and/or replacing the motor brushes follow steps 10-15. If not, skip to step 16. ! WARNING: Wait until the armature LED is off before removing the motor brush covers. 10. Check the armature LED. A.
Cybex Sport Treadmill Owner’s & Service Manual wear such as arcing, pitting, 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 hole.
Cybex Sport Treadmill Owner’s & Service Manual C. Using a straight-edge (such as the lower board shield), line up the face of the flywheel pulley with the face of the front roller pulley until they are flush. See Figure 10. NOTE: Do not put the drive belt on until step 18A. Motor Strap Screws (Position Vertically) Nuts Motor Exit Wire (Position at 3 O’clock) 17. Secure the motor straps. NOTE: Tighten motor strap to 80 in-lbs. A.
Cybex Sport Treadmill Owner’s & Service Manual Tie Cables Away from Fan Wire Ties Fan NOTE: The ferrite is for internationally installed motors. Ferrite Figure 18 E. Refer to the lower board shield to confirm the locations for the connectors and check to see that all of the cables are connected firmly. See Figure 19. F. Place the lower board shield in position and push the clips down. NOTE: The clips will snap in. See Figure 19. Clips (3) Lower Board Shield 20. Secure the motor cover. A.
Cybex Sport Treadmill Owner’s & Service Manual Elevation Motor Tools Required • • • • Phillips head screwdriver Wooden block 4” (10 cm) tall (2) 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. Turn the main power switch on the left side to the off (O) position. B.
Cybex Sport Treadmill Owner’s & Service Manual 6. Calibrate the elevation motor. A. The switch should be at zero elevation before adjusting the tube nut. If necessary connect the elevation motor, bring the elevation up to 1% incline and then back down to 0%. B. Turn the tube with your fingers until it measures 12.517” (31.8 cm) from the center of the top hole to the center of the bottom hole. See Figure 20. Elevation Motor 12.517” (31.8 cm) Frame Bolts Nuts 7. Secure the elevation motor. Tube A.
Cybex Sport Treadmill Owner’s & Service Manual Lower Control Board NOTE: You will remove and replace the entire lower bracket in this procedure. Tools Required • Phillips head screwdriver • 3/8” Nutdriver or socket wrench • ESD (Electro Static Discharge) grounding strap ! 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.
Cybex Sport Treadmill Owner’s & Service Manual B. Remove the entire bracket with its lower board. NOTE: Cybex may want this part back for evaluation. Contact Cybex Customer Service at 800-766-3211 and press 64 when prompted. 6. Replace the lower control board and bracket. NOTE: Wear an ESD strap for the rest of this procedure. A. Position the lower control board bracket in place on the base. NOTE: The elevation motor connector and ground stud will be orientated toward the back left corner. B.
Cybex Sport Treadmill Owner’s & Service Manual 8. Secure the line filter. A. Using a Phillips head screwdriver, secure the two screws that hold the line filter to the lower control board bracket. 9. Secure the wires. A. Check to see that all of the cables are connected firmly in their proper place. B. Tie the wires back with the wire ties on the base and be sure no wires get pinched. C. Place the lower board shield in position and push the clips down. NOTE: The clips will snap in. 10.
Cybex Sport Treadmill Owner’s & Service Manual 2. Remove the motor cover. A. Using a Phillips head screwdriver, loosen three screws on each motor cover side (left and right). See Figure 2. B. Lift the motor cover center up and off the treadmill. The screws will stay in place. C. Remove the left plastic side cover. 3. Remove the left end cap. A. Using a Phillips head screwdriver, remove the screw that holds the left end cap in place. See Figure 4. 4. Remove the left side panel. A.
Cybex Sport Treadmill Owner’s & Service Manual Line Filter NOTE: If you are replacing the line filter follow steps 7 and 8. If not skip to step 9. 7. Replace the line filter (optional). A. Disconnect the fast-on that goes from the line filter to the drive motor (green cable). B. Disconnect the two fast-ons that go from the line filter to the lower board (cables labeled AC Line 1 and AC Line 2 on the lower board). C.
Cybex Sport Treadmill Owner’s & Service Manual Blue Brown Black White Shown From Front of Switch with “I” Toward the Top Access Hole Power Cord Behind Base Brackets Figure 23 D. With the ground wire through the access hole to the lower control bracket, put the ground wire terminal on the stud on the lower board bracket. E. Using a 3/8” nutdriver, secure the one nut over the ground wire terminal. F.
Cybex Sport Treadmill Owner’s & Service Manual B. Using a Phillips head screwdriver, remove the three screws that hold the bottom back cover to the console front. C. Gently pull off the console backs. NOTE: The bottom back will have delicate wires attached to it. Do not apply pressure to it. 3. Remove the display board. A.
Cybex Sport Treadmill Owner’s & Service Manual 5. Connect the cables. A. Connect these cables into the display board: the display cable (2 connectors), the two upper switch membranes, the lower switch membrane, the contact heart rate cable and the upper to lower board jumper. See Figure 19. 6. Check the connections. A. Check to see that all of the cables are connected firmly in their proper place. 7. Secure the console back. A.
Cybex Sport Treadmill Owner’s & Service Manual 4. Remove the heart rate bracket. Screw A. Using a Phillips head screwdriver, remove the three screws that hold the lower back of the console in place and gently pull the back off. NOTE: Gently suspend the back by the wires, being careful not to damage any of the wires. B. Using a Phillips head screwdriver, remove the nine black screws that hold the console front to the handrail. NOTE: Do not loose the starwasher that is under the CSAFE jumper terminal.
Cybex Sport Treadmill Owner’s & Service Manual CSAFE Board 6. Remove the CSAFE board. A. Using a Phillips head screwdriver, remove the two screws that hold the CSAFE board and jumper to the console. B. Gently pull the CSAFE board down and out of the display board. See Figure 27. 7. Attach the new CSAFE board. A. Gently push the CSAFE board into its connector on the display board. See Figure 27. CSAFE Board Connects to Display Board B. Place the jumper terminal over a hole on the CSAFE board. C.
Cybex Sport Treadmill Owner’s & Service Manual Display Cable Tools Required • Phillips head screwdriver • ESD (Electro Static Discharge) grounding strap • Wire cutters ! 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.
Cybex Sport Treadmill Owner’s & Service Manual B. Disconnect the display cable (P1 and P2) from the lower board. See Figure 21. C. Disconnect the display cable (P3 and P8) from the upper display board. See Figure 24. D. Using a Phillips head screwdriver, loosen the wire retaining screw that holds the display cable in place near the display board. E. Remove the cable from the wire ties at the junction and near the bottom of the upright. F.
Cybex Sport Treadmill Owner’s & Service Manual NOTE: “Right” and “left” denote user orientation. Top Console Back Cover P3 and P8 Connectors on Upper Display Board Bottom Hole Screws (3) Screws (5) Wire Holder Left Junction Covers Display Cable Upright Shield P1 and P2 on Lower Board Access Hole Screws (4) Left Side Cover Figure 29 8. Secure the left junction covers. A. Using a Phillips screwdriver, tighten the three screws that hold the junction covers in place. 9. Secure the motor cover. A.
Cybex Sport Treadmill Owner’s & Service Manual 10. Secure the console back. A. While being sure not to pinch any cables, attach the top console back to the console front with the five Phillips head screws. Display Overlays NOTE: This procedure will cover the upper and/or lower display overlay. Early versions of the upper display overlay had no switch membranes on the Cybex Sport treadmill. Tools Required • Phillips head screwdriver • ESD (Electro Static Discharge) grounding strap • Razor blade 1.
Cybex Sport Treadmill Owner’s & Service Manual 5. Attach the console back. A. While being sure not to pinch any cables, secure the console back to the console with the five Phillips head screws. 6. Test the new display overlay. A. Turn the main power switch to the on (I) position. B. Plug the treadmill into the power outlet. C. Try each key to be sure that it functions properly. Parts List ITEM NO.
Cybex Sport Treadmill Owner’s & Service Manual ITEM NO. 41 42 43 44 46 47 48 48 49 50 51 52 52 53 54 55 56 57 58 58 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 PART NO.
Cybex Sport Treadmill Owner’s & Service Manual ITEM NO. 100 100 101 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 120 121 122 123 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 PART NO.
Cybex Sport Treadmill Owner’s & Service Manual Page 7-41
20A DOMESTIC 115V - EC-15783 (20EP1) 20A DOMESTIC 220V - EC-16948 (20EQ1) 15A INTERNATIONAL - EC-16576 (15VT1) 109 - 125V 60 Hz (AW-16640 POWER CORD) 208 - 240V 60 Hz (AW-16639 POWER CORD) 208 - 240V 50 Hz (AW-16638 POWER CORD) LINE FILTER AW-16572 (DOM) AW-16938 (DOM) BLK WHT INTERNAL MAX ELEV.
