CYBEX TROTTER Owner's Service Manual
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CYBEX TROTTER Owner's Service Manual

CYBEX TROTTER Owner's Service Manual

Cardiovascular systems
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Cybex TROTTER Elite Treadmill
Owner's & Service Manual
Cardiovascular Systems
Part Number LT-16601-4 Rev J
Cybex and the Cybex logo are registered trademarks of Cybex International, Inc. TROTTER and the TROTTER 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. Polar is a registered trademark of Polar.
DISCLAIMER:
Cybex International, Inc. makes no representations or warranties regarding the contents of this manual. We
reserve 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.
© 2003, Cybex International, Inc. All rights reserved. Printed in United States of America.
10 Trotter Drive Medway, MA 02053 • 800-766-3211 • 508-533-4300 • FAX 508-533-5183
www.eCybex.com • techhelp@cybexintl.com • techpubs@cybexintl.com • LT-16601-4 Rev J • April 2003

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Questions and answers

Kasey Keegan
February 12, 2025

what is the max weight that a person can weigh on thr totter 545

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1 comments:
Mr. Anderson
February 12, 2025

The maximum user weight for the CYBEX TROTTER Elite Treadmill is 400 lbs. (181 kg). The document does not mention a CYBEX TROTTER 545 specifically.

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Eldon
March 14, 2025

I have a Trotter MG 2100 machine and the seat adjustment pin came out and I can’t get it to engage. This would be the seat where you do the shoulder press and lat pull down exercises. I have taken the back Support seat off so I can see the hydraulic cylinder. I don’t see anything through the slot where the pin would go to have it catch anything. Right now the cylinder just goes up and down, but can only be used in the farthest down position as there is no locking mechanism for the cylinder. Thank you for any help you can provide!

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Summary of Contents for CYBEX TROTTER

  • Page 1 Part Number LT-16601-4 Rev J Cybex and the Cybex logo are registered trademarks of Cybex International, Inc. TROTTER and the TROTTER logo are registered trademarks of Cybex International, Inc. Stableflex and the Stableflex logo are registered trademarks of Cybex International, Inc.
  • Page 3 10 Trotter Drive Medway MA 02053 NOTE: The serial number can be found on the base of the Cybex TROTTER Elite. It is located at the front of the treadmill. You may wish to record the serial number in the Customer Service section of this manual.
  • Page 4 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 73 MEDWAY, MA POSTAGE WILL BE PAID BY ADDRESSEE ATTN: CUSTOMER SERVICE CYBEX INTERNATIONAL 10 TROTTER DRIVE MEDWAY, MA 02053-9934...

  • Page 5: About This Manual

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual About This Manual An Owner’s & Service Manual is shipped with each Cybex TROTTER Elite treadmill. To purchase additional copies of this manual or any other Cybex manual, please do one of the following: •...
  • Page 6 Cybex TROTTER Elite Treadmill Owner’s & Service Manual NOTE: For European customers only. Page ii...

  • Page 7: Table Of Contents

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Table of Contents Front Pages Setup & Assembly About this Manual ....i Warnings/Cautions ....5-1 FCC Compliance Information .
  • Page 8 This page intentionally left blank...

  • Page 9: Safety

    The power requirements for the TROTTER Elite treadmill include 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.

  • Page 10: Important Safety Instructions

    Cybex TROTTER Elite 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...
  • Page 11 • DO NOT attempt repairs, electrical or mechanical. Seek qualified repair personnel when servicing. If you live in the USA, contact Cybex Customer Service at 800-766-3211 (then press 64). If you live outside the USA, contact Cybex Customer Service at 508-533-4300.

  • Page 12: Warning Decals

    Service chapter in this manual or on Cybex web site at ecybex.com. Warning Decals Warning decals indicate a potentially hazardous situation, which, if not avoided, could result in death or serious injury. The warning decals used on the TROTTER Elite are shown below. Safety Page 1-4...
  • Page 13 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Underneath Motor Cover Safety Page 1-5...
  • Page 14 Cybex TROTTER Elite Treadmill Owner’s & Service Manual VARNING KOPPLA IFRÅN STRÖMMEN INNAN SERVICE UTFÖRS. 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 TROTTER Elite treadmill. However, there is a caution in the installation instructions for initial installation only. See below.

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

    Cybex TROTTER Elite 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.

  • Page 17: Technical Specifications

    Cybex TROTTER Elite 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 12.4 mph (0.8 to 20 kph) in 0.1 mph or 0.1 kph increments...
  • Page 18 Cybex TROTTER Elite Treadmill Owner’s & Service Manual This page intentionally left blank Specifications Page 2-2...

  • Page 19: Operation

    Cybex TROTTER Elite 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.

  • Page 20: Quick Operation Guide

    Cybex TROTTER Elite 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. NOTE: Times specified in this chapter reflect the treadmills defaults.
  • Page 21 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 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.
  • Page 22 / km wireless calorie goal 9 holes custom 2 heart rate receiver Cybex International, Inc. Medway, MA USA (508) 533-4300 www.eCybex.com Made in USA Safety Sentry ™ time stop quick start speed incline e-stop Figure 1 9.

  • Page 23: Stopping The Treadmill

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Stopping the Treadmill Press Stop once to pause your workout for 20 seconds (default setting) and to enter the Workout Review. The belt will stop and the elevation will return to 0%, but all workout settings and data will remain in memory for the pre-selected time.

  • Page 24: Control During Operation

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Control During Operation Control keys on the display are usable during operation and may be pressed at any time to make adjustments in speed, elevation, or data readouts. Changing Speed — Press the Speed —...

  • Page 25: Displaying Heart Rate

    20 seconds (default setting). Displaying Heart Rate In order for the TROTTER Elite to display your heart rate, you must either use a Polar compatible heart rate transmitter belt (not included) or hold the handgrips to use Contact Heart Rate.

  • Page 26: Heart Rate Led

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual NOTE: When wearing a Polar compatible transmitter, the contact heart rate will dominate only when the grips are held. Polar Compatible Reception — To use this feature, a Polar compatible heart rate transmitter belt must be worn.

  • Page 27: Use Of Programs

    With the TROTTER Elite, you may choose from six different programs. Four of those programs provide ten levels of difficulty for a choice of forty different preprogrammed options. You may also create your own program or use Manual Mode.

  • Page 28: Manual Mode

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Manual Mode Manual Mode is not a preprogrammed workout. Instead, it allows you to choose settings as you workout. You may choose your settings according to how you feel or your endurance level.

  • Page 29: Calorie Goal

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Calorie Goal Program Overview The Calorie Goal program uses a mixture of increased elevation or speed intervals to provide added work to this walking and light jogging program. The user selects the level they want to work at and the total number of calories they want to burn, the program will repeat until the calorie goal is obtained.

  • Page 30: 5K Run

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual 5K Run Program Overview This program is designed to help the user train for a 5K race in a systematic fashion. It uses a predefined speed for each level to establish the "race pace". Throughout the program the elevation changes from a baseline (0% incline) level into both incline and decline.
  • Page 31 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 5K Run Profiles Show Level 10 Repeating Segment 12.4 20.0 12.0 19.0 18.0 11.0 17.0 10.0 16.0 15.0 14.0 13.0 12.0 11.0 Speed 10.0 Warm Up Program Cool Down in Minutes Segments...

  • Page 32: Holes

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual 9 Holes Program Overview In this program, the user chooses their speed as they go. The level of the program uses variations in the elevation. As the level goes up so does the level of intensity. Like the golf course, there are uphill and downhill sections, which not only contribute to the intensity of the exercise but also provide the additional adaptation to covering varied terrain.
  • Page 33 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 9 Holes Profiles Show Level 10 Repeating Segment 12.4 20.0 12.0 19.0 18.0 11.0 17.0 10.0 16.0 15.0 14.0 13.0 12.0 11.0 Speed 10.0 User Selected Program Segments in Yards Elevation %...

  • Page 34: Heart Rate

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Heart Rate Program Overview The Heart Rate Control program is interactive. By selecting a predetermined heart rate, the treadmill will adapt the elevation and speed to keep the users heart rate at that level. This program is exceptionally useful for those individuals just starting out as well as the athlete.
  • Page 35 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Heart Rate Based on Age, Selective HR and Response to Exercise 12.4 20.0 12.0 19.0 18.0 11.0 17.0 10.0 16.0 15.0 14.0 13.0 12.0 11.0 Speed 10.0 Warm Program Segments Cool in Minutes...

  • Page 36: Custom Program 1

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Custom Program 1 NOTE: If this program doesn’t run as indicated in this description and profile it was likely written over by a new custom program. You can get this program back by using the CPA program or going to www.ecybex.com/education/cpa to download the...
  • Page 37 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Cardio Custom 1 Profiles Show Level 10 at 20 Minutes 12.4 20.0 12.0 19.0 18.0 11.0 17.0 10.0 16.0 15.0 14.0 13.0 12.0 11.0 Speed 10.0 Warm Program Segments Cool in Minutes...

  • Page 38: Custom Program 2

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Custom Program 2 The Weight Loss program will be on your treadmill at the time you receive it. See Figure 10. NOTE: If this program doesn’t run as indicated in this description and profile it was likely written over by a new custom program.
  • Page 39 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Weight Loss Custom 2 Profiles Show Level 10 at 20 Minutes 12.4 20.0 12.0 19.0 18.0 11.0 17.0 10.0 16.0 15.0 14.0 13.0 12.0 11.0 Speed 10.0 Warm Program Segments Cool in Minutes...

  • Page 40: Create A Custom Program

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Create a Custom Program In addition to the four programmed workouts included with the TROTTER Elite, you can also create your own workouts. You can even create a workout to mimic a route you normally run or walk outside.

  • Page 41: 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 42: Running Belt Maintenance

    Cybex TROTTER Elite 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.
  • Page 43 E. Walk on the belt to see if it still slips. If it does restart this procedure at step 1 A. If you have to do this procedure three times and it still slips check the drive belt tension in the Service chapter or call Cybex Customer Service. Follow the next step to be sure the belt is centered.
  • Page 44 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 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.
  • Page 45 Deck in the Service chapter. 7. Clean under the belt. A. 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 46: Other Preventive Maintenance

    Cybex TROTTER Elite 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.

  • Page 47: Service Schedule

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Service Schedule Preventive Maintenance Page 4-7...

  • Page 48: Log Sheet

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Log Sheet Serial Number Date of Installation Date of Data Collection Total Miles/Kilometers Total Hours Motor Current @ 3 mph (4.8 kph) Motor Voltage @ 12.4 mph (20 kph) - without load...

  • Page 49: Setup & Assembly

    Cybex TROTTER Elite 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.

  • Page 50: Electrical Power Requirements

    A. Lift up and remove the cardboard sleeve that surrounds the treadmill. B. Check to be sure that the following items are present. Check off ( ✔) each item as you find it. See Figure 1. If any of the parts are missing contact Cybex Customer Service. Setup &...
  • Page 51 TROTTER Elite Manual (in box) LT-16314 Assembly Poster NOTE: NA means not applicable. Figure 1 C. Check off ( ✔) each item in the CPA (Cybex Programming Advantage pack as you find it. See Figure 2. Item Qty Part Number Description LT-16975...
  • Page 52 Cybex TROTTER Elite Treadmill Owner’s & Service Manual D. Check off ( ✔) each item in the hardware pack as you find it. See Figure 3. Item Qty Part Number Description HS-16929 Screw, hex head whiz-lock 3-8-16 x 5-8 HS-16950...
  • Page 53 Cybex TROTTER Elite 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.
  • Page 54 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 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.
  • Page 55 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Figure 8 B. Using the hex key provided, tighten the two pivot screws on the handrail. See Figure Pivot Screws Figure 9 9. Remove the left side panel. A. Pull the left side panel away from the base. See Figure 10.
  • Page 56 Cybex TROTTER Elite 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 11. Grommet Wire Ties...
  • Page 57 Cybex TROTTER Elite 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 13.
  • Page 58 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Emergency Stop Button Emergency Stop Key Figure 14 15. Connect to your computer (optional). NOTE: Skip step 15A-15C if you are not using your CPA. A. Connect the CPA cable that comes...

  • Page 59: Testing The Treadmill Operation

    (I). 3. The control panel will light up and be in the Dormant Mode. NOTE: Cybex recommends that the treadmill be unplugged or the on/off (I/O) power switch turned off (O) when it is not in use. 4. Press the Quick Start key. The treadmill begins a countdown “3...2...1” and sounds a tone for each count.

  • Page 60: Setting Operation Options

    Cybex TROTTER Elite 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.
  • Page 61 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Safety Sentry — This is how long the running belt will keep moving if the user steps off the treadmill. Choices are between none seconds and 1 minute. Default is 20 seconds.
  • Page 62 Cybex TROTTER Elite Treadmill Owner’s & Service Manual This page intentionally left blank Setup & Assembly Page 5-14...

  • Page 63: Customer Service

    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 64 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 an RMA number and will send you an ARS label.

  • Page 65: Damaged Parts

    Cybex TROTTER Elite 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.
  • Page 66 Cybex TROTTER Elite Treadmill Owner’s & Service Manual This page intentionally left blank Customer Service Page 6-4...

  • Page 67: Service

    ! 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.

  • Page 68: Test Mode

    / km wireless calorie goal 9 holes custom 2 heart rate receiver Cybex International, Inc. Medway, MA USA (508) 533-4300 www.eCybex.com Made in USA Lower Safety Sentry ™ time Overlay stop quick start speed incline e-stop...

  • Page 69: Led Functions

    Cybex TROTTER Elite Treadmill Owner’s & 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 —...

  • Page 70: Error Codes

    Cybex TROTTER Elite Treadmill Owner’s & 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.
  • Page 71 Cybex TROTTER Elite Treadmill Owner’s & Service Manual motor cover of each Cybex Trotter Elite treadmill. By performing these procedures you can evaluate the performance of your drive motor and help prevent premature failure. Tools Required • Phillips head screwdriver •...

  • Page 72: Speed Sensor Adjustment

    E. Note the reading on the voltage meter then carefully remove both leads. Call Cybex Customer Service to find out if the reading is within an acceptable range.
  • Page 73 Cybex TROTTER Elite 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).

  • Page 74: Ir Compensation

    Cybex TROTTER Elite 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.

  • Page 75: Speed Calibration

    Cybex TROTTER Elite 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.

  • Page 76: Running Belt & Deck

    Cybex TROTTER Elite 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.

  • Page 77: Rear Roller

    Cybex TROTTER Elite 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.

  • Page 78: Front Roller

    Cybex TROTTER Elite 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.

  • Page 79: Drive Belt

    Cybex TROTTER Elite 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.
  • Page 80 Cybex TROTTER Elite 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.

  • Page 81: Drive Motor

    Cybex TROTTER Elite 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.
  • Page 82 Cybex TROTTER Elite 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.

  • Page 83: Motor Brushes

    Cybex TROTTER Elite 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.
  • Page 84 Cybex TROTTER Elite 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.
  • Page 85 A. Squeeze each rectangular brush covers, insert it into the holes and then release. B. Push the round brush cover into its hole until it is flush with the motor. NOTE: If a cover is damaged, order Cybex replacement part number EH-16954 for the round cover or EH-16955 for the rectangular cover.
  • Page 86 Cybex TROTTER Elite Treadmill Owner’s & Service Manual C. Using a straight-edge (such as the lower Nuts Motor Strap board shield), line up the face of the Screws Motor Exit flywheel pulley with the face of the front (Position Wire roller pulley until they are flush.
  • Page 87 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Tie Cables Away Wire Ties from Fan NOTE: The ferrite Ferrite is for internationally installed motors. Figure 18 E. Refer to the lower board shield Clips (3) to confirm the locations for...

  • Page 88: Elevation Motor

    Cybex TROTTER Elite 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.
  • Page 89 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 6. Calibrate the elevation motor. A. The switch should be at zero elevation Elevation Frame before adjusting the tube nut. If Motor necessary connect the elevation motor, bring the elevation up to 1% incline and then back down to 0%.

  • Page 90: Lower Control Board

    Cybex TROTTER Elite 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.
  • Page 91 Cybex TROTTER Elite 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.

  • Page 92: Power Cord

    Cybex TROTTER Elite 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.

  • Page 93: Power Switch

    Cybex TROTTER Elite 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.

  • Page 94: Line Filter

    Cybex TROTTER Elite 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).

  • Page 95: Upper Display Board

    Cybex TROTTER Elite Treadmill Owner’s & Service Manual Blue Brown Shown From Front of Switch with “I” Toward Black White 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.
  • Page 96 Cybex TROTTER Elite 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.

  • Page 97: Contact Heart Rate Board

    Cybex TROTTER Elite 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.
  • Page 98 Cybex TROTTER Elite Treadmill Owner’s & Service Manual 4. Remove the heart rate bracket. Screw A. Using a Phillips head Jumper Terminal screwdriver, remove the three screws that hold the lower back Starwasher of the console in place and gently pull the back off. NOTE:...

  • Page 99: Csafe Board

    Cybex TROTTER Elite 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.

  • Page 100: Display Cable

    Cybex TROTTER Elite 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.
  • Page 101 Cybex TROTTER Elite 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.
  • Page 102 Cybex TROTTER Elite Treadmill Owner’s & Service Manual NOTE: “Right” and “left” denote Top Console Back Cover user orientation. P3 and P8 Connectors on Upper Display Board Bottom Hole Screws (3) Screws (5) Left Junction Wire Covers Holder Display Cable...

  • Page 103: Display Overlays

    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 Trotter elite treadmill. Tools Required • Phillips head screwdriver •...

  • Page 104: Parts List

    Cybex TROTTER Elite 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.
  • Page 105 Cybex TROTTER Elite Treadmill Owner’s & Service Manual ITEM PART NO. DESCRIPTION AF-16382 Elevation, weldment HS-60022 Bolt Hhcs 0.375 x 2.25 blk zn G5 CW-16712 Wheel, Rubber, 3”Dia HN-60064 Nut, Jam 3-8In.-16 blk zn HS-60021 Bolt Hhcs 0.375 x 2 blk zn G5 HS-60023 Bolt Hhcs 0.375 x 2.5 blk zn G5...
  • Page 106 Cybex TROTTER Elite Treadmill Owner’s & Service Manual ITEM PART NO. DESCRIPTION AX-16728 Lower Rear Console Assembly PL-16409 Console, Rear Handle, Plastic PL-16407 Front Console, Plastic AC-16731-4 Entire Console Assembly, TROTTER Elite, English SW-17184-4 Switch Membrane, TROTTER Elite, Top, English...
  • Page 107 Cybex TROTTER Elite Treadmill Owner’s & Service Manual Page 7-41...

  • Page 108: Schematic

    ROW 1 SWITCH ROW 2 SWITCH ROW 3 SWITCH COL 1 SWITCH E-STOP MAGNET COL 2 SWITCH TROTTER Elite SC-450T Rev D BOTTOM SWITCH MEMBRANE E-STOP KEY SW-17187 Page 7-42 TROTTER Elite Schematic Cybex TROTTER Elite Treadmill Owner’s & Service Manual...

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