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CYBEX Pro+ Service Manual

Cardiovascular systems
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See also: Owner's Service Manual
Cybex Pro+ Treadmill
Service Manual
Cardiovascular Systems
Part Number LT-21649-4 A
www.cybexinternational.com

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Summary of Contents for CYBEX Pro+

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

  • Page 3: Service Manual

    Service Manual Cardiovascular Systems Part Number LT-21649-4 A Cybex ® and the Cybex logo are registered trademarks of Cybex International, Inc. Safety Sentry™ is a registered trademark of ® Cybex international, Inc. Polar is a registered trademark of Polar. DISCLAIMER: Cybex International, Inc.

  • Page 5: About This Manual

    • Contact Cybex Customer Service at 888-462-9239 or 508-533-4300 To contact Cybex with comments about this manual send an email to techhelp@cybexintl.com. FCC Compliance Information ! WARNING: Changes or modifi cations to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate...
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  • Page 7: Table Of Contents

    Table of Contents Front Pages 4 Service About this Manual ....i Warnings/Cautions....4-1 FCC Compliance Information .
  • Page 8 Cybex Pro+ Treadmill Service Manual This page intentionally left blank. Page iv...

  • Page 9: Safety

    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. The power requirements for the Cybex Pro+ treadmill include a grounded, dedicated circuit, rated for one of the following: 115 VAC ±5%, 60 Hz and 20 amps;...

  • Page 10: Important Safety Instructions

    Cybex Pro+ 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, fi...
  • Page 11 • DO NOT attempt repairs, electrical or mechanical. Seek qualifi ed repair personnel when servicing. If you live in the USA, contact Cybex Customer Service at 888-462-9239. If you live outside the USA, contact Cybex Customer Service at 508-533-4300. •...

  • Page 12: Warning Decals

    To replace any worn 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.

  • Page 13: Service Schedule

    Cybex Pro+ Treadmill Service Manual All maintenance activities shall be performed by qualified personnel. Failure to do so could result in serious injury. Service Schedule NOTE: This is the minimum recommended service. Date Mileage Service Initials 1. Determine mileage. Enter Test Mode by holding...
  • Page 14 Cybex Pro+ Treadmill Service Manual Safety Page 1-6...

  • Page 15: 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 Pro+ treadmill. However, there is a caution in the installation instructions for initial installation only. See below.

  • Page 16: Emergency Stop Key (E-Stop)

    Cybex Pro+ Treadmill 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.

  • Page 17: Preventive Maintenance

    NOTE: Worn or damaged components shall be replaced immediately or the treadmill removed from service until the repair is made. NOTE: Cybex is not responsible for performing regular inspection and maintenance actions for your treadmill. Instruct all personnel in equipment inspection and maintenance actions and also in accident reporting/recording.

  • Page 18: Cleaning Your Treadmill

    Cybex Pro+ Treadmill Service Manual Cleaning Your Treadmill When cleaning your treadmill spray a mild cleaning agent, such as a water and dishsoap solution, on a clean cloth fi rst and then wipe the treadmill with the damp cloth. NOTE: Do not spray cleaning solution directly on the treadmill. Direct spraying could cause damage to the electronics and may void the warranty.

  • Page 19: Running Belt Maintenance

    Cybex Pro+ Treadmill Service Manual Running Belt Maintenance Belt and Deck – Clean the belt and the deck surfaces to minimize the effect of friction between the wood deck and the running belt. Clean the underside of the running belt and the top of the running deck surface by wiping them with a clean dry towel.
  • Page 20 Cybex Pro+ Treadmill Service Manual 2. Center the belt. NOTE: While centering the belt choose one bolt to adjust. Do not adjust both bolts. 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.
  • Page 21 Running Belt and Deck in the Service chapter. 7. Clean under the belt. To minimize the effect of friction between the deck and the running belt, Cybex recommends cleaning the underside of the running belt and the top of the running deck surface by wiping them with a clean, dry towel.

  • Page 22: Other Preventive Maintenance

    Cybex Pro+ Treadmill Service Manual 8. Secure the top steps. Place each top step in position. See Figure 4. Using a Phillips screwdriver, tighten the three screws that hold each top step in place. See Figure 4. 9. Secure the end caps.

  • Page 23: Service Schedule

    Cybex Pro+ Treadmill Service Manual Service Schedule All maintenance activities shall be performed by qualifi ed personnel. Failure to do so could result in serious injury. NOTE: This is the minimum recommended service. 1. Determine mileage. While in Dormant Mode enter Test Mode by holding down any key while turning the treadmill to the on (I) position.
  • Page 24 Cybex Pro+ Treadmill Service Manual This page intentionally left blank Preventive Maintenance Page 2-8...

  • Page 25: Customer Service

    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 it ready if you call Cybex Customer Service.

  • Page 26: Return Material Authorization (Rma)

    Contact your authorized Cybex dealer on all warranty-related matters. Your local Cybex dealer will request an RMA from Cybex, if applicable. Under no circumstances will defective parts or equipment be accepted by Cybex without proper RMA and an Automated Return Service (ARS) label.

  • Page 27: Damaged Parts

    Cybex Pro+ Treadmill 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.

  • Page 28: Ordering Parts

    Cybex Pro+ Treadmill Service Manual Ordering Parts Fax orders to 508-533-5183. To speak with a customer service representative, call 888-462-9239 (for customers living within the USA) or 508-533-4300 (for customers outside the USA). CAUTION Use only Cybex replacement parts when servicing.

  • Page 29: Service

    ! WARNING: All maintenance activities shall be performed by qualifi ed 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.

  • Page 30: Test Mode

    ! WARNING: All maintenance activities shall be performed by qualifi ed personnel. Failure to do so could result in serious injury. For any service related concerns, call Cybex Customer Service at 888-462-9239 (for Cybex customers living within the USA). For customers living outside the USA, call 508-533-4300 or fax 508-533-5183.

  • Page 31: Led Functions

    Cybex Pro+ 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: Heart LED – Blinks on with every signal from the contact heart rate receiver.

  • Page 32: Error Codes

    Cybex Pro+ Treadmill Service Manual Error Codes Error codes notify you of a problem condition and are displayed on the center of 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.

  • Page 33: Motor Current And Voltage

    Service Schedule in the Preventive Maintenance chapter of this manual. For your convenience a service schedule decal is provided under the motor cover of each Cybex Pro+ treadmill. By performing these procedures you can evaluate the performance of your drive motor and help prevent premature failure.

  • Page 34: Speed Sensor Adjustment

    Note the reading on the voltage meter then carefully remove both leads. Call Cybex Customer Service to fi nd out if the reading is within an acceptable range.
  • Page 35 Cybex Pro+ Treadmill Service Manual Using a 7/16” Open end wrench, tighten the mounting nut that attaches the speed sensor bracket to the drive motor. See Figure 3. Ensure that the gap between the speed sensor and drive motor fan is even on both sides. See Figure 3.

  • Page 36: Ir Compensation

    Cybex Pro+ Treadmill Service Manual IR Compensation NOTE: This procedure is required after replacing the lower control board or the drive motor. Tools Required • Phillips screwdriver • Plastic (or non-conductive), fl at head screwdriver 1. Please read instructions thoroughly before performing this procedure.

  • Page 37: Speed Calibration

    Cybex Pro+ Treadmill Service Manual 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.

  • Page 38: Running Belt And Deck

    Cybex Pro+ Treadmill Service Manual Running Belt and 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.

  • Page 39: Rear Roller

    Cybex Pro+ Treadmill Service Manual 4. Remove the side panels. Pull each side panel out and off the treadmill. See Figure 5. 5. Remove the top steps. Using a Phillips screwdriver, remove the three screws that hold one of the top steps in place.
  • Page 40 Cybex Pro+ Treadmill Service Manual 7. Remove the deck. 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. Screws (5 on Each Side) Running Deck Running...

  • Page 41: Front Roller

    Cybex Pro+ Treadmill Service Manual Using a Phillips screwdriver, remove the fl at head screw securing each deck stiffener to the deck bushing. See fi gure 8. 9. Inspect the deck bushings. Inspect the deck bushings under the deck stiffeners for cracks or wear.
  • Page 42 Cybex Pro+ Treadmill Service Manual 14. Secure the front roller. Open grooves Slide the front roller into the running belt. NOTE: It doesn’t matter on Front Roller which way the running belt goes. Be sure the drive belt is around the fl ywheel pulley and the front roller before attaching the front roller.

  • Page 43: Drive Motor

    Cybex Pro+ Treadmill Service Manual 20. Secure the end caps. Using a Phillips screwdriver, tighten the screw that holds each end cap in place. See Figure 4. 21. Secure the motor cover. Lower the motor cover center into position. See Figure 2.
  • Page 44 Cybex Pro+ Treadmill Service Manual Slip the drive belt around the fl ywheel pulley and off the motor. See Figure 14. 5. Disconnect the motor cables. Screws (Loosen) ! WARNING: Do not touch components on the lower board. A charge can remain after unplugging the power cord and turning off the treadmill.

  • Page 45: Motor Brushes

    Cybex Pro+ Treadmill Service Manual 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.
  • Page 46 Cybex Pro+ Treadmill Service Manual 10. Remove the drive motor brush access covers. Squeeze each of the two rectangular brush covers to remove it from the motor. See Figure 15. Drive Motor Brush Access Cover Round Brush Cover Figure 15 Lift off the round brush cover.
  • Page 47 Cybex Pro+ Treadmill Service Manual Locate the brush with the two wires and slide it into the motor brush holder (located nearest the round access hole). Locate the brush with the one wire and slide it into the motor brush holder on the opposite side.
  • Page 48 Cybex Pro+ Treadmill Service Manual 17. Align the drive belt. Confi rm that the drive belt fi lls all grooves in the drive motor fl ywheel pulley and there are open grooves on the inside of the front roller. See Figure 11. NOTE: Failure to align the drive belt could cause squeaking.

  • Page 49: Elevation Motor

    Cybex Pro+ Treadmill Service Manual 19. Secure the motor cover. Lower the motor cover center into position. See Figure 2. Using a Phillips screwdriver, tighten the three screws on each side. NOTE: Be sure the screws are catching the center motor cover's holes.
  • Page 50 Cybex Pro+ Treadmill Service Manual 4. Disconnect the elevation motor cable. ! WARNING: Do not touch components on the lower board. A charge can remain after unplugging the power cord and turning off the treadmill. Pull up on the lower board shield. It will snap out.

  • Page 51: Lower Control Board

    Cybex Pro+ Treadmill Service Manual Carefully remove the wooden blocks from under the front end assembly. This will load the elevation assembly. Lower the elevation to zero percent. Stop the treadmill and turn the main power switch in the front panel to the off (O) position.
  • Page 52 Using a Phillips screwdriver, remove the four screws that hold the lower control bracket to the base. Remove the entire bracket with its lower board. NOTE: Cybex may want this part back for evaluation. Contact Cybex Customer Service at 888-462-9239. 6. Replace the lower control board and bracket.

  • Page 53: Power Cord

    Cybex Pro+ Treadmill Service Manual Put the ground wire terminal on the stud on the lower board bracket. Using a 3/8” nutdriver, secure the one nut and one washer over the ground wire terminal. 8. Secure the line fi lter.

  • Page 54: Power Switch

    Cybex Pro+ Treadmill Service Manual Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. Remove the left plastic side cover. 3. Remove the left end cap. Using a Phillips screwdriver, remove the screw that holds the left end cap in place.

  • Page 55: Line Filter

    Cybex Pro+ Treadmill Service Manual Line Filter NOTE: If you are replacing the line fi lter follow steps 7 and 8. If not skip to step 9. 7. Replace the line fi lter (optional). Disconnect the two fast-ons that go from the line fi lter to the lower board (cables labeled AC Line 1 and AC Line 2 on the lower board).

  • Page 56: Upper Display Board

    Cybex Pro+ Treadmill Service Manual Connect these two power cord cables to the power switch: • The blue cable connects to the top left switch fast-on. • The brown cable connects to the top right switch fast-on NOTE: You will connect the ground in step 10D.
  • Page 57 Cybex Pro+ Treadmill Service Manual 3. Remove the display board. Disconnect these cables from the display board: the display cable (2 connectors), the two upper 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.

  • Page 58: Contact Heart Rate Board

    Cybex Pro+ Treadmill Service Manual 7. Secure the console back. While being sure not to pinch any cables, use a Phillips screwdriver to secure the nine screws that hold the back cover to the console front. 8. Calibrate speed. Follow the Speed Calibration procedure located in this chapter.

  • Page 59: Contact Heart Rate Grips

    Cybex Pro+ Treadmill Service Manual Contact Heart Rate Grips Tools Required • Phillips screwdriver • Needle nose pliers • Wire cutters 5. Remove the old heart rate grips and cable. Using a Phillips screwdriver, remove the two screws from each lower grip.

  • Page 60: Csafe Board

    Cybex Pro+ Treadmill Service Manual 7. Install the new heart rate grips. Using the needle nose pliers, carefully connect the heart rate wire to each grip. NOTE: Ensure that the red heart rate wire is connected to the top grip and the black heart rate wire is connected to the bottom grip.

  • Page 61: Display Cable

    Cybex Pro+ Treadmill Service Manual Gently push the CSAFE connector into its port on the display board. See Figure 23. Using a Phillips screwdriver, secure the CSAFE board with the three screws removed during step 3B. NOTE: Do not overtighten.
  • Page 62 Cybex Pro+ Treadmill Service Manual Pull up on the lower board shield until the shield snaps out. Disconnect the display cable (P1 and P2) from the lower board. See Figure 27 . NOTE: “Right” and “left” denote user orientation. Console...
  • Page 63 Cybex Pro+ Treadmill Service Manual Using wire cutters, cut the cable at its center near the junction and pull both ends out of the treadmill. NOTE: Pull the upper end up and out and the lower end down and out.

  • Page 64: Display Overlays

    Cybex Pro+ Treadmill Service Manual Display Overlays NOTE: This procedure will cover the upper and/or lower display overlay. They are removed and replaced the same on the Cybex Pro+ treadmill. Tools Required • Phillips screwdriver • ESD (Electro Static Discharge) grounding strap •...
  • Page 65 Cybex Pro+ Treadmill Service Manual 5. Secure the console covers. Using a Phillips screwdriver, tighten the six screws that hold the console front to the frame. While being sure not to pinch any cables, secure the console back to the console with the fi ve Phillips screws.

  • Page 66: Parts List

    Wheel, Rubber, 3” Dia PL-17659 Console, Back, Plastic HN-17935 Nut, Lock, 3/8 - 24, GRD C, STL, ZN DE-17712 Decal, Logo, Cybex Intl, 9 x 7” DE-17144-X Decal, International only* PL-17658 Front Console, Plastic HS-17936 Bolt, 3/8 - 24 X 2.0”, HXHD CAP,...
  • Page 67 Cybex Pro+ Treadmill Service Manual ITEM QTY. PART NO. DESCRIPTION ITEM QTY. PART NO. DESCRIPTION HS-20731 Screw, M4x10 ScHd Stl, Blk PL-17686 Tab, Bookholder HW-21285 Washer, Lock, M4 Zn HX-16931 Clamp, Cable, 5-16 dia Standard HW-20214 Washer, Flat, M4 AD-16559...
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  • Page 69 AV Option 110 125 133 131 Cybex Pro+ Treadmill Service Manual Page 4-41...

  • Page 70: Schematic

    ROW 2 SWITCH SIG (GREEN) ROW 3 SWITCH AW-17707 COL 1 SWITCH E-STOP MAGNET COL 2 SWITCH CABLE, CHR TO DISPLAY PCA, SALUTRON SERIAL OUTPUT BOTTOM SWITCH MEMBRANE EC-17763 E-STOP KEY SW-18305 Page 4-42 Cybex Pro+ Treadmill Service Manual Cybex Pro+ Schematic...

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