CYBEX | 515T | Service manual | CYBEX 515T Service manual

Cybex Sport+ (515T) Treadmill
Owner’s and Service Manual
Cardiovascular Systems
Part Number LT-18115-4 Rev B
www.cybexinternational.com
Cybex Sport+ (515T) Treadmill
Owner’s and Service Manual
Cardiovascular Systems
Part Number LT-18115-4 Rev B
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. 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 - 2006, 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.cybexinternational.com • techhelp@cybexintl.com • techpubs@cybexintl.com • LT-18115-4 • Rev B • April 2006
Cybex Sport+ Treadmill Owner’s and Service Manual
About This Manual
An Owner’s and 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.cybexinternational.com
fax your order to 508-533-5183
contact Cybex Customer Service at 800-766-3211 then press 63
or contact Cybex Customer Service at 508-533-4300
To contact Cybex with comments about this manual you may send email to
techpubs@cybexintl.com.
FCC Compliance Information
! WARNING: Changes or modifications to this unit not expressly approved by the party
responsible for compliance could void the user’s authority to operate
the equipment.
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation. This equipment generates,
uses and can radiate radio frequency energy and, if not installed and used in accordance with
the instructions, may cause harmful interference to radio communications. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception (which can be determined by
turning the equipment off and on) the user is encouraged to try to correct the interference by
one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
• Consult the dealer or an experienced radio TV technician for help.
Page i
Cybex Sport+ Treadmill Owner’s and Service Manual
Page ii
Cybex Sport Treadmill Owner’s & Service Manual
As a result of test reports and their evaluation by accredited laboratories, we are in possession of the
following certificates for products which carry this marking:
Canada, USA
CAN/CSA-C22.2 No.68-92,
UL Std. No. 1647, EN55022
Class B, FCC Part 15 Class B,
EN 60335-1
European Union
73/23/EEC, 89/336/EEC
References of harmonized standards on which this declaration of conformity is based:
EN 50081-1: 1992 Light Industry Class B Emissions: Electrical and Electronic Apparatus Intended
for Use in Residential, Commercial and Light-Industrial Environments
EN 50082-1:1997 Electromagnetic Compatibility (EMC) Generic Immunity Standard Part 1:
Residential, Commercial and Light Industry
EN 55022: 1998 (CISPR 22:1997), Class B Limits and Methods of Measurement of Radio
Interference Characteristics of Information Technology Equipment.
EN 60335-1: 1994 +A11 +A12 +A1 +A13 +A2 - “Safety of Household and Similar Electrical
Appliances: General Requirements”
EN 61000-4-2 Electromagnetic compatibility (EMC) - Part 4-2: Testing and measurement techniques Electrostatic discharge immunity test
EN 61000-4-3 Electromagnetic compatibility (EMC) - Part 4-3: Testing and measurement techniques
- Radiated, radio frequency, and electromagnetic field immunity test
EN 61000-4-4 Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques Section 4: Electrical fast transient/burst immunity test.
EN 61000-4-5 Electromagnetic compatibility (EMC)- Part 4-5: Testing and measurement techniques Surge immunity test
Worldwide Headquarters 10 Trotter Drive + Medway, MA 02053, USA + t 508.533.4300 + f 508.533.5500
151 24th Avenue NW + Owatonna, MN 55060, USA + t 507.455.0217 + f 507.455.3446
Page iii
Cybex Sport Treadmill Owner’s & Service Manual
EN 61000-4-6 Electromagnetic compatibility (EMC) - Part 4-6: Testing and measurement techniques
- Immunity to conducted disturbances, induced by radio-frequency fields
EN 61000-4-8 Electromagnetic compatibility (EMC) - Part 4-8: Testing and measurement techniques
- Power frequency magnetic field immunity test
EN 61000-4-11 Electromagnetic compatibility (EMC) - Part 4-11: Testing and measurement
techniques - Voltage dips, short interruptions and voltage variations immunity tests
EN 61000-3-2 Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current
emissions (equipment input current <= 16A per phase)
EN 61000-3-3 Electromagnetic compatibility (EMC) - Part 3-3: Limits - Limitation of voltage
changes, voltage fluctuations and flicker in public low-voltage supply systems, for equipment with
rated current <= 16 A per phase and not subject to conditional connection
EN 957-1: Stationary Training Equipment. General Safety Requirements and Test Methods
EN 957-6: Stationary training equipment. Treadmills, additional specific safety requirements and test
methods
FCC Part 15, Subpart B - Class B Radiated and Conducted Emissions
CAN/CSA-C22.2 No. 68-92 (Reaffirmed 1999) Safety of Household and similar electrical
appliances, General Instruction
ANSI / UL-1647 3rd Edition, 2000 Motor Operated Massage and Exercise Equipment
ASTM F2115 Standard specification for motorized treadmills
Page iv
Worldwide Headquarters 10 Trotter Drive + Medway, MA 02053, USA + t 508.533.4300 + f 508.533.5500
151 24th Avenue NW + Owatonna, MN 55060, USA + t 507.455.0217 + f 507.455.3446
Cybex Sport+ Treadmill Owner’s and Service Manual
Table of Contents
Front Pages
About this Manual . . . . . . . . . . . . . . . . . . . i
FCC Compliance Information . . . . . . . . . . i
Declaration of Conformity . . . . . . . . . . . . ii
Table of Contents . . . . . . . . . . . . . . . . . . . v
1 Safety
Important Voltage Information . . . . . . .
Grounding Instructions . . . . . . . . . . . . .
Important Safety Instructions . . . . . . . .
Warning Decals . . . . . . . . . . . . . . . . . . .
Caution Decals . . . . . . . . . . . . . . . . . . .
Emergency Stop Key (e-stop) . . . . . . . .
1-1
1-1
1-2
1-4
1-7
1-8
2 Technical Specifications
Specifications . . . . . . . . . . . . . . . . . . . . 2-1
Warnings/Cautions . . . . . . . . . . . . . . . . 5-1
Choosing and Preparing a Site . . . . . . 5-1
Electrical Power Requirements . . . . . . . 5-2
Assembling the Treadmill . . . . . . . . . . . 5-2
Tools Required . . . . . . . . . . . . . . . . . . . 5-2
Testing the Treadmill Operation . . . . . 5-11
Setting Operation Options . . . . . . . . . 5-12
6 Customer Service
Contacting Service . . . . . . . . . . . . . . . .
Serial Number and Voltage . . . . . . . . . .
Return Material Authorization (RMA) . .
Damaged Parts . . . . . . . . . . . . . . . . . . .
Ordering Parts . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-2
6-3
7 Service
3 Operation
Terms and Symbols Used . . . . . . . . . . 3-1
Quick Operation Guide . . . . . . . . . . . . . 3-2
Detailed Operation Guide . . . . . . . . . . . 3-2
Stopping the Treadmill . . . . . . . . . . . . . 3-4
Immobilization Method . . . . . . . . . . 3-5
Emergency Dismount . . . . . . . . . . . 3-5
Emergency Stop . . . . . . . . . . . . . . . 3-5
Safety Sentry . . . . . . . . . . . . . . . . . . . . 3-5
Control During Operation . . . . . . . . . . . 3-5
Data Readouts . . . . . . . . . . . . . . . . . . . 3-6
Displaying Heart Rate . . . . . . . . . . . . . . 3-7
Heart Rate Zone . . . . . . . . . . . . . . . . . . 3-8
Meaning of % Grade . . . . . . . . . . . . . . 3-8
Use of Programs . . . . . . . . . . . . . . . . . . 3-9
Manual . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Weight Loss . . . . . . . . . . . . . . . . . . . . 3-10
Cardio . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
4 Preventive Maintenance
Warnings/Cautions . . . . . . . . . . . . . . . .
Regular Maintenance Activities . . . . . .
Cleaning Your Treadmill . . . . . . . . . . . .
Running Belt Maintenance . . . . . . . . . .
Other Preventive Maintenance . . . . . . .
Service Schedule . . . . . . . . . . . . . . . . .
Log Sheet . . . . . . . . . . . . . . . . . . . . . . .
5 Setup and Assembly
4-1
4-1
4-1
4-2
4-6
4-7
4-8
Warnings/Cautions . . . . . . . . . . . . . . . . 7-1
Test Mode . . . . . . . . . . . . . . . . . . . . . . . 7-2
LED Functions . . . . . . . . . . . . . . . . . . . 7-3
Key Functions . . . . . . . . . . . . . . . . . . . . 7-3
Error Codes . . . . . . . . . . . . . . . . . . . . . . 7-4
Motor Current and Voltage . . . . . . . . . . 7-4
Speed Sensor Adjustment . . . . . . . . . . 7-6
IR Compensation . . . . . . . . . . . . . . . . . 7-8
Speed Calibration . . . . . . . . . . . . . . . . . 7-9
Running Belt and Deck . . . . . . . . . . . . 7-10
Rear Roller . . . . . . . . . . . . . . . . . . . . . 7-11
Front Roller . . . . . . . . . . . . . . . . . . . . . 7-12
Drive Belt . . . . . . . . . . . . . . . . . . . . . . 7-13
Drive Motor . . . . . . . . . . . . . . . . . . . . . 7-15
Motor Brushes . . . . . . . . . . . . . . . . . . 7-17
Elevation Motor . . . . . . . . . . . . . . . . . . 7-22
Lower Control Board . . . . . . . . . . . . . 7-24
Power Cord . . . . . . . . . . . . . . . . . . . . . 7-26
Power Switch . . . . . . . . . . . . . . . . . . . 7-27
Line Filter . . . . . . . . . . . . . . . . . . . . . . 7-28
Upper Display Board . . . . . . . . . . . . . 7-29
Contact Heart Rate Board . . . . . . . . . 7-31
Contact Heart Rate Grips . . . . . . . . . . 7-32
CSAFE Board . . . . . . . . . . . . . . . . . . . 7-34
Display Cable . . . . . . . . . . . . . . . . . . . 7-35
Display Overlays . . . . . . . . . . . . . . . . . 7-38
Parts List . . . . . . . . . . . . . . . . . . . . . . . 7-40
Exploded View . . . . . . . . . . . . . . . . . . 7-43
Schematic . . . . . . . . . . . . . . . . . . . . . . 7-44
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Cybex Sport+ Treadmill Owner’s and Service Manual
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Cybex Sport+ Treadmill Owner’s and 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. The power
requirements for the Cybex Sport+ 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 and 15 amps or
230 VAC ±5%, 50 Hz and 15 amps. See the serial number decal for the exact voltage
requirements of your treadmill.
! WARNING: Do not attempt to use this unit with a voltage adapter.
Do not attempt to use this unit with an extension cord.
Grounding Instructions
This treadmill must be grounded. If it should malfunction or break down, grounding provides a
path of least resistance for electric current to reduce the risk of electric shock. This product is
equipped with a cord having an equipment-grounding conductor and a grounding plug. The
plug must be plugged into an appropriate outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
! DANGER:
Improper connection of the equipmentgrounding conductor can result in a risk of
electric shock. Check with a qualified
electrician or service provider if you are in
doubt as to whether the treadmill is properly
grounded. Seek a qualified electrician to
perform any modifications to the cord or
plug. Cybex is not responsible for injuries or
damages as a result of cord or plug
modification.
115V
Euro Plug
NEMA 5-20 CEE 7/7
208/220V
NEMA 6-15
This treadmill is for use on a nominal 115 VAC
±5%, 60 Hz and 20 amps, 208/220 VAC; 60 Hz,
15 amps or 230 VAC ±5%, 50 Hz and 15 amps
and a grounded, dedicated circuit. Make sure
that the treadmill is connected to an outlet
having the same configuration as the plug. Do
not use a ground plug adapter to adapt the
power cord to a non-grounded outlet.
Safety
Page 1-1
Cybex Sport+ Treadmill Owner’s and 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.
• Obtain a medical exam before beginning any exercise program.
• Keep children away from the treadmill. Teenagers and disabled persons must be
supervised.
• Obtain instruction before using.
• Stop exercising if you feel faint, dizzy, or experience pain at any time and consult your
physician.
• Read and understand the Owner’s Manual and all warnings posted on the unit before using.
• Read and understand emergency stop procedures.
• DO NOT wear loose or dangling clothing while using.
• Keep all body parts, towels, and the like free and clear of moving parts.
• Use the treadmill handrails for support and to maintain balance.
• Stop and place the treadmill at 0 degrees incline (level) after each use.
• DO NOT use the unit if you exceed 400 lbs. (181 kg). This is the rated maximum user weight.
• Replace any warning labels if damaged, worn or illegible.
• Report any malfunctions, damage or repairs to the facility.
Facility Safety Precautions
• Instruct all users on how to clip the e-stop clip onto their clothing and carefully test it prior
to using the treadmill.
• Instruct all users to use caution when mounting and dismounting the treadmill.
• Disconnect all power before servicing the treadmill.
Safety
Page 1-2
Cybex Sport+ Treadmill Owner’s and 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. NOTE: Before
leaving the treadmill unattended, always wait until the treadmill comes to a complete stop
and is level. Then, turn all controls to the STOP or OFF position and remove the plug from
the outlet. Remove the e-stop key from the treadmill.
• Immobilize the treadmill (when not in use) by removing the e-stop key.
• Inspect the treadmill for worn or loose components before each use. Do not use until worn
or damaged parts are replaced.
• Maintain and replace worn parts regularly. Refer to “Preventive Maintenance” section of
Owner's Manual.
• DO NOT operate the treadmill if: (1) the cord is damaged; (2) the treadmill is not working
properly or (3) if the treadmill has been dropped or damaged. Seek service from a qualified
technician.
• DO NOT place the cord near heated surfaces or sharp edges.
• DO NOT use the treadmill outdoors.
• DO NOT operate the treadmill around or where aerosol (spray) or where oxygen products
are being used.
• Read and understand the Owner's Manual completely before using the treadmill.
• Ensure all users wear proper footwear on or around all Cybex equipment.
• Set up and operate the treadmill on a solid, level surface. Do not operate in recessed areas
or on plush carpet.
• Provide the following clearances: 19.7 inches (0.5 m) at each side, 39 inches (1.0 m) at the
back and enough room for safe access and passage at the front of the treadmill. Be sure
your treadmill is clear of walls, equipment and other hard surfaces.
• 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.
• Use Cybex factory parts when replacing parts on the treadmill.
• DO NOT modify the treadmill in any way.
• DO NOT use attachments unless recommended for the treadmill by Cybex.
Safety
Page 1-3
Cybex Sport+ Treadmill Owner’s and 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
www.cybexinternational.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. For location or part number of labels, see the parts list and exploded-view
diagram. This information can be found in the Service chapter in this manual or on Cybex web
site at www.cybexinternational.com.
Warning Labels
Warning decals indicate a potentially hazardous situation, which, if not avoided, could result in
death or serious injury. The warning decals used on the Cybex Sport+ are shown below.
Y COULD OCCUR
SERIOUS INJUR
AUTIONS
IF THESE PREC
VED
ARE NOT OBSER
Safety
Page 1-4
ngling clothing while using.
• DO NOT wear loose or da
port and to maintain balance.
• Use the handrails for sup
faint, dizzy, or experience pain.
l
e
e
f
u
o
y
f
i
g
n
i
s
i
c
• Stop exer
efore beginning any exercise program.
• Obtain a medical exam b
ergency stop procedures.
• Read and understand em
ls if damaged, worn or illegible.
• Replace any warning labe
damage or repairs to the facility.
• Report any malfunctions,
• Place your feet on the two top steps when starting or stopping the treadmill.
• Stop and place the treadmill to 0 degrees incline (level) after each use.
• Keep children away. Teenagers and disabled must be supervised.
• Obtain instruction before using.
• Keep all body parts, towels, and the like free and clear of moving parts.
• Read and understand the Owner's Manual and all warnings posted on the unit
before using.
• DO NOT use the unit if you exceed 400 lbs. (180 kg). This is the rated maximu
m user weight.
• Placez vos pelds su
r le s d e u x m a r c h e
s
au demarrage et à l'a
rrêt du tapis.
• Tenez les enfants é
l o ig n é s . L e s
adolescents et les ha
n d i c ap é s
doivent être surveille
s.
• Lisez les instruction
s
avant l'utilisation.
DE-17691-4
WARNING
Cybex Sport+ Treadmill Owner’s and 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.
1. Determine mileage.
Date Mileage Service Initials
A. Enter Test Mode by holding
down any key while turning
the treadmill to the on
(I) position.
dist
(except on all
B. Press
Cybex Sport models).
DIST appears on the display.
First 500 Miles
A Check Running Belt Tension
& Tracking.
Every 5000 Miles
A Check Running Belt Tension
& Tracking.
B Move Treadmill & Vacuum
Underneath.
C Remove Motor Cover to
Clean Underneath
with a Dry Cloth & Vacuum.
Every 10,000 Miles
D Replace Belt & Flip Deck.
E Check Motor Brushes
& Replace If Needed.
F Check Current Draw.
G Measure Motor Voltage at
Max Speed with No Load.
H Check Elevation Assembly
& Replace Worn Parts.
I Lubricate Elevation
Bushings.
Every 20,000 Miles
J Replace Belt & Deck.
DE-16609-4
Underneath
Motor Cover
Safety
Page 1-5
Cybex Sport+ Treadmill Owner’s and Service Manual
VARNING
KOPPLA
IFRÅN
STRÖMMEN
INNAN SERVICE
UTFÖRS.
Safety
Page 1-6
Cybex Sport+ Treadmill Owner’s and 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.
Safety
Page 1-7
Cybex Sport+ Treadmill Owner’s and 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. Without falling off the treadmill, carefully step backward until the e-stop falls off the
treadmill. NOTE: If the e-stop clip falls off your clothing then the test has failed. Reclip the
e-stop clip to your clothing and repeat this step.
3. Replace e-stop after successfully testing the e-stop key. See the illustration shown below.
+
e-stop
4. The treadmill is now ready to be used.
5. After use, remove the e-stop key from the treadmill.
NOTE: The e-stop key shall be removed to help prevent unauthorized use. Refer to the
Stopping the Treadmill section in the Operation chapter for more information about the
e-stop key.
Safety
Page 1-8
Cybex Sport+ Treadmill Owner’s and Service Manual
2 - Technical Specifications
Specifications
Length:
79” (200 cm)
Width:
32” (82 cm)
Running Area:
20” x 60” (51 cm x 152 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
Incline Range:
0 to 15% grade
Manual Mode:
Yes
Programs:
Quick Start plus Manual, Cardio and Weight Loss
Standard Features:
Safety Sentry™, Contact Heart Rate, CSAFE, frame color choices
include white texture, black texture, silver vein, black chrome
and platinum sparkle
Optional Features:
Full length handrails, unlimited custom colors available
Power Requirement: Grounded, dedicated circuit and one of the following:
• 115 VAC ±5, 60 Hz and 20 amps
• 208/220 VAC, 60 Hz 15 amps
• 230 VAC ±5, 50 Hz and 15 amps
Motor:
3.0 hp, DC. continuous duty
Emergency Stop:
Pull the emergency stop key (lanyard)
Maximum User Weight: 400 lbs. (181 kg)
32”
(82 cm)
79” (200 cm)
Specifications
Page 2-1
Cybex Sport+ Treadmill Owner’s and Service Manual
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Specifications
Page 2-2
Cybex Sport+ Treadmill Owner’s and 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 and 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. The control panel LEDs will flash when the treadmill is in Dormant Mode.
Program Setup Mode — This begins after pressing any program key. Upon entering a
program the LEDs flash, prompting the user to adjust the appropriate settings.
Active Mode — This begins immediately after pressing the Quick Start key. The beginning
of Active Mode is marked by the 3 second countdown and running belt acceleration. Active
Mode continues until you reach 60 minutes, disengage the e-stop key or press the Stop key.
Quick Start — This begins by pressing the Quick Start key. Quick Start skips the Program
Setup Mode and begins immediately in Manual Mode.
Manual Mode — This begins immediately after pressing the Quick Start key. In Manual
Mode you can customize your workout Speed, Incline and enter your Weight by pressing
those keys. You can also begin Manual Mode by pressing the Manual program key (and be
prompted to enter your weight).
Workout Review — This begins after pressing the Stop key once, at the end of a program or
when the treadmill detects that you are not there (see Safety Sentry in this chapter). The
workout statistics accumulated during the previous workout session will display for 20
seconds or until Stop is pressed again.
Pause Mode — This begins when the treadmill detects that you are not there and enters
Workout Review (see Safety Sentry in this chapter). While in Workout Review you can press the
Quick Start key to resume your workout. The time spent before pausing is remembered and
additional workout time is added to.
LM — These keys adjust Level or Weight up or down.
— These keys adjust Incline higher or lower.
+ — — These keys adjust Speed up (+) or down (—).
Operation
Page 3-1
Cybex Sport+ Treadmill Owner’s and 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. Clip the e-stop clip onto your clothing and test it as described under Emergency Stop in
the Safety chapter.
3. Press any program key or press Quick Start to skip the settings and begin Manual Mode
immediately.
4. If you pressed a program key to select a program, you will now be prompted for workout
Weight and Level as appropriate. Adjust these settings with the LM arrows and press
Enter to proceed.
5. The treadmill begins a countdown, “3...2...1,” after which it accelerates the belt to
1.0 mph (1.0 kph) (for Manual Mode) or the speed of the program that you selected.
6. Hold the handrails while you step onto the running belt and begin walking.
7. Press the Speed + — keys to change the belt speed at any time. The right display will
show the current speed.
8. Press the Incline
the current incline.
keys to change the incline at any time. The left display will show
9. Press the Stop key at any time.
Detailed Operation Guide
NOTE: Maximum user weight is 400 lbs. (181 kg).
1. Plug the treadmill power cord into a power outlet from 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.
2. Locate the on/off (I/O) power switch on the left side of the treadmill. Toggle it to the on
(I) position to supply power to the internal treadmill components and illuminate the
control panel.
Operation
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Cybex Sport+ Treadmill Owner’s and 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. Also, see Stopping the Treadmill in this chapter for further
information about the e-stop key. 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.
5. You now have the option to select a program or enter Manual Mode.
To select a program, press a program key and follow the prompts. Upon entering a
program the LEDs flash, prompting you to adjust the appropriate settings. This is referred
to as Program Setup Mode. NOTE: You cannot change the time on the Manual, Cardio
or Weight Loss programs. You can only change the level and enter your weight. If the
Quick Start key is pressed now, all defaults for that program will be accepted. After 10
seconds, if no key has been pressed, the first default will be accepted. After another 10
seconds the second default will be accepted and so on until the last default. The program
will not enter Active Mode until you press the Enter or Quick Start key. If no key has been
pressed for 20 seconds after displaying the last default, then the treadmill will return to the
Dormant Mode.
If you choose to enter Manual Mode instead of choosing a program, press the Quick
Start or the Manual key. NOTE: No prompts will occur when you press Quick Start.
While in Manual Mode, customize your workout Speed, Incline and enter your Weight by
pressing those keys.
NOTE: For the most accurate calorie count, you must set your correct weight before
beginning your workout (including clothing).
NOTE: You must press Enter after each adjustment.
6. The treadmill begins a countdown, “3...2...1” and sounds a tone for each count. When it
reaches one (1) the treadmill gives a longer tone and then starts accelerating the belt. In
Manual Mode the belt will begin accelerating to 1 mph (1.0 kph) and the incline will remain
at zero percent. In a program the belt will begin accelerating and the incline will change
to the corresponding speed and incline of the program and level you selected.
7. Hold the handrails while you step onto the running belt and begin walking.
8. Observe the three display windows. The top center window will scan (every three
seconds) through Distance, Calories, Mets, Pace and Heart Rate. Press the Scan key
to toggle this feature on or off. NOTE: Heart Rate is scanned only when you are holding
Operation
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Cybex Sport+ Treadmill Owner’s and 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.
Figure 1
9. Press the Speed + — keys to change the belt speed at any time. The right display will
show the set speed.
10. Press the Incline
keys to change the incline at any time. The left display will show
the current incline only while it is adjusting, then revert to time elapsed.
11. Press the Stop key at any time to stop your workout. Press Stop once to end your
workout and begin your Workout Review. As you press Stop once, the treadmill will return
to 0% incline. Press Stop twice to clear the Workout Review and return to Dormant Mode.
12. If the e-stop key is removed during a workout, the power shuts off immediately, causing
the belt to stop. The right window changes to “OFF” and the left window shows a flashing
pattern of “o” and “o”. Replacement of the e-stop key causes Workout Review to begin.
13. When you complete a program the treadmill begins a countdown, “3...2...1,” and sounds a
tone for each count. The belt slows to a stop and Workout Review displays in the center
window for 20 seconds or until you press the Stop key.
14. The treadmill returns to Dormant Mode.
Stopping the Treadmill
Press Stop once to pause your workout for up to 20 seconds and to enter the Workout
Review. The belt will stop and the elevation will return to 0%, but time accumulated will
remain in memory for 20 seconds. Press the Quick Start key within 20 seconds to continue
Operation
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Cybex Sport+ Treadmill Owner’s and 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.
This can be accomplished by removing the e-stop key from
the console, unclipping it from the cord and putting it in a
non-accessible place. See Figure 2.
The emergency dismount: Follow the steps listed below if Figure 2
you experience pain, feel faint or need to stop your treadmill
in an emergency situation:
1. Grip handrails for support.
2. Step onto the top steps.
3. Pull the e-stop key off the console.
The function of the emergency stop: The e-stop key functions
as the emergency stop. In an emergency situation, remove the estop key from the console and the treadmill will come to a stop.
On the console, the e-stop location looks like Figure 3.
e-stop
Figure 3
Safety Sentry
If you step off your treadmill during a workout, it may detect that you are not there. After the
pre-selected waiting period “run?” will appear on the center window for a few seconds then
Safety Sentry™ will stop the belt. If you press Quick Start within the time selected you can
resume your workout. NOTE: If you are less than 100 lbs. Safety Sentry may not detect you
are there and cause the treadmill to come to a stop. Safety Sentry is disabled above 11%
grade.
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.
Operation
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Cybex Sport+ Treadmill Owner’s and 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 - 12.4 mph (0.8 - 20 kph).
Changing Incline — Press the Incline
keys to change the elevation in increments of
1%. Elevation ranges from 0 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. NOTE:
Manual, Weight Loss and Cardio each have a preselected time period that cannot be changed.
Changing Data Readouts — Press Scan once and it will continually review each set of data.
Press Scan again to continue to display a set of data. If the grips are not being held heart rate
data will not be displayed. The display shows each set of data for 3 seconds before switching
to the next set.
Data Readouts
As you exercise, the treadmill keeps track of the following data:
dist
Distance — The total accumulated distance, in miles or kilometers, during
your workout. NOTE: Depending on the defaults you’ve chosen this
measurement will show in English or Metric.
cal
Calories — The total accumulated calories burned during your workout. Your
weight must be correctly set before beginning your workout for this
measurement to be most accurate.
mets
Metabolic Equivalent — Relates to the user's energy expenditure. A MET is a
basic unit of measurement that is used to compare relative work between
individuals and activities. ‘One MET’ is the amount of oxygen consumed at
rest. For example two METs would be twice that amount. If an individual were
working at four METs he/she would be consuming oxygen at a rate equal to
four times their resting consumption. METs can be used to compare walking
on a grade with running or even to cycling and other activities.
+
min
mi / km
Pace — At your current speed, how long it would take to cover a mile (or
kilometer), displayed in minutes:seconds.
+
-
Heart Rate — Your current heart rate. Heart rate will appear when a signal is
introduced. Use the handgrips for Contact Heart Rate.
Operation
Page 3-6
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-
+
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Cybex Sport+ Treadmill Owner’s and 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.
Displaying Heart Rate
In order for the Cybex Sport+ to display your heart rate, hold the handgrips to use Contact
Heart Rate.
Contact Heart Rate — Hold the handgrips on the console crossbar until a heart rate is
displayed, typically less than thirty seconds. For best results, hold the handgrips lightly and
ensure that your hands contact both the front and back sensors of each grip. NOTE: Hold
your hands as steady as possible as movement can cause interference on the contacts.
Factors that can interfere with the heart rate signal include:
• excessive movement
• body composition
• hydration
• too loose grip
• too tight grip
• running
• excessive dirt, powder or oil
• leaning or resting on grips
NOTE: Cybex does not recommend continuous holding onto the contact heart rate grips
during exercise.
Contaminants, such as hand lotions, oils or body powder, may come off on the contact heart
rate grips. These can reduce sensitivity and interfere with the heart rate signal. It is
recommended that the user have clean hands when using the contact heart rate.
Operation
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Cybex Sport+ Treadmill Owner’s and 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. Whether you are a new participant or one with a great
deal of experience, weight loss and other performance goals can be achieved by controlling
the intensity of your workout.
The American College of Sports
Medicine recommends that healthy
adults exercise between 55 and 85%
of their heart rate max. Your heart rate
max can be estimated by subtracting
your age from 220. Multiply that
estimated heart rate max by .55 to
estimate the lower end of your heart
rate training zone. Then multiply your
estimated heart rate max by .85 to
estimate the higher end of your
training zone. This heart rate training
zone gives you a range of intensities at
which to exercise.
This decal shows heart rate based on
percentage and age.
Heart Rate Zone
Beats
Per
Minute
Max
200
85%
180
65%
160
Cardio
140
Fat Burn
120
100
Warm-up
80
60
Resting
NOTE: A label is located on the
console to remind you what
the heart rate zone is while
you are working out.
See Figure 4.
Meaning of % Grade
Age 20
30
40
50
60
70
220 - Age = Max Heart Rate
DE-18135-4
Figure 4
A 1% grade is not the same as a 1 degree incline. The % grade is the relationship of the
measurement of rise over the measurement of run (also called slope). For example, a 1 foot
(meter) rise in height over a length of 100 feet (meters) is a 1% grade. Expressed as a
mathematical formula, the grade is calculated as follows:
1 ft. (m) / 100 ft. (m) = 0.01 = 1%
With respect to treadmills, the percent grade is roughly equal to the increase in height (rise) of
the treadmill divided by the length (run) of the treadmill.
Operation
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Cybex Sport+ Treadmill Owner’s and 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).
Use of Programs
! WARNING: Obtain a medical exam before beginning any exercise program. Begin
comfortably with a lower level and progress with higher levels as you
become acclimated.
With the Sport+, you may choose from three different programs. The program choices are
summarized as follows:
Quick Start
Manual Mode
Weight Loss
Cardio
You control speed, elevation. Maximum of 60 minutes.
You control speed, elevation. 30 minutes (fixed time).
10 Levels
30 minutes (fixed time)
10 Levels
20 minutes (fixed time)
Manual
Program Overview
Manual Mode is available both through Quick Start and through the Manual program where
you are prompted to make a user weight adjustment. NOTE: There is no diagram because
incline and speed are user-controlled.
Manual Mode allows you to choose settings as you workout. You may choose your settings
according to how you feel or your endurance level. Since you remain in control, Manual Mode
may be the best choice for beginners or for those who have not worked out in a long time.
NOTE: Manual Mode is not a preprogrammed workout.
Press the Quick Start key to workout in Manual Mode. You can also begin Manual Mode by
pressing the Manual program key. To increase or decrease the speed while in Manual Mode
use the Speed + — keys. To increase or decrease the incline while in Manual Mode use
the
arrows.
Operation
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Cybex Sport+ Treadmill Owner’s and 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.
Weight Loss
Program Overview
This program was designed to help individuals of all fitness levels achieve their weight loss
goals through a protocol that incorporates both low and moderate intensity activity. Because
walking has become a popular mode of exercise for those looking to lose weight, all levels of
this program are performed at walking speeds.
The core of the program is made up of five one-minute segments. The first segment
represents the baseline of the program and may also be considered to be a “rest” segment
later. In minutes two and three, elevation will be increased. In minute four, the program returns
to the first segment baseline or rest level. In the fifth minute, the speed will increase. The total
number of segments used is dictated by the time selected by the user.
Higher levels of the Weight Loss program incorporate jogging speeds in short segments. This
allows the advanced walker to alternate walking and jogging.
• At levels 1-6 walkers maintain walking speeds only.
• At levels 7-10, experienced walkers can jog intermittently.
By mixing the use of speed and elevation separately, the user receives the benefits of added
intensity intervals but the variety does not allow for either speed or elevation to dominate and
therefore overtax the user. See table below and Figure 5.
Level
1
2
3
4
5
6
7
8
9
10
Operation
Page 3-10
Base Speed
mph
3.4
3.4
3.7
3.7
3.8
3.8
4.0
4.0
4.2
4.2
WALK
Uphill Elevation
% Grade
2%
3%
4%
6%
4%
6%
6%
8%
8%
10%
Increased Speed
mph
3.5
3.5
3.8
3.8
4.0
4.0
4.5
5.0
5.5
6.0
WALK
WALK-JOG
Cybex Sport+ Treadmill Owner’s and Service Manual
Weight Loss
Profiles Show Level 10 at 20 Minutes
MPH
Speed
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Warm
Up
Elevation %
Program Segments
in Minutes
Cool
Down
Program Segments
in Minutes
Cool
Down
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
-1
-2
Warm
Up
Figure 5
Operation
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Cybex Sport+ Treadmill Owner’s and 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.
The speed range of the program includes walking speeds at the lower levels up through a
moderate jog in the higher levels.
Elevation is used to emphasize the high intensity portion of this program while decreased
elevation and a small increase in speed mark the recovery segment. High intensity and
recovery segments are always in a one-to-one time based ratio and make up the core eight
minutes of the program. See table below and Figure 6.
Base Speed / Peak Elevation
mph
% grade
Level 1
2
3
4
5
6
7
8
9
10
Operation
Page 3-12
3.2
3.5
3.8
4.0
4.2
5.0
5.5
6.0
6.2
6.5
2%
3%
4%
5%
5%
5%
5%
6%
6%
6%
Base Speed
mph
/ Peak Elevation
% grade
3.5
3.8
4.0
4.2
5.0
5.5
5.8
6.2
6.5
6.8
0%
0%
0%
0%
2%
2%
2%
2%
2%
2%
Cybex Sport+ Treadmill Owner’s and Service Manual
Cardio
Profiles Show Level 10 at 20 Minutes
MPH
Speed
—12.4
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—12.0
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7.0
6.0
5.0
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1.0
Warm
Up
Elevation %
Program Segments
in Minutes
Cool
Down
Program Segments
in Minutes
Cool
Down
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
-1
-2
Warm
Up
Figure 6
Operation
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Cybex Sport+ Treadmill Owner’s and Service Manual
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Operation
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Cybex Sport+ Treadmill Owner’s and 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.
! WARNING: Keep wet items away from inside parts of the treadmill. Electrical shock
could occur even if the treadmill is unplugged. Do not touch components
on the lower board. A charge can remain after unplugging the power cord
and turning off the treadmill.
! CAUTION: Be careful not to over tighten the belt. Over tightening the belt can cause
the belt to stretch and require replacement.
Regular Maintenance Activities
! WARNING: All maintenance activities shall be performed by qualified personnel.
Failure to do so could result in serious injury.
Preventive maintenance activities must be performed to maintain normal operation of your
treadmill. Keeping a log sheet of all maintenance actions will assist you in staying current with
all preventive maintenance activities. See Service Schedule and Log Sheet located at the end
of this chapter.
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. Contact Cybex Customer Service at
800-766-3211 or 508-533-4300 for any preventive maintenance or service concerns.
Cleaning Your Treadmill
When cleaning your treadmill spray a mild cleaning agent, such as a water and dishsoap
solution, on a clean cloth first and then wipe the treadmill with the damp cloth.
Preventive
Maintenance
Page 4-1
Cybex Sport+ Treadmill Owner’s and 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. After each workout, use a cloth to
wipe up any remaining perspiration from the handrails and painted surfaces.
Be careful not to spill or get excessive moisture between the edge of the display panel and
the console, as this might create an electrical hazard or cause failure of the electronics.
As Needed — Vacuum any dust or dirt that might accumulate under or around the treadmill.
Motors are especially susceptible to dust and dirt, and restricted airflow can prevent adequate
cooling that could shorten motor life. Cleaning this area should be done as often as indicated
in the Service Schedule.
! WARNING: 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.
To clean the motor components, you must loosen the six Phillips head screws that hold the
motor cover in place. Lift the cover straight up; the screws and side covers will stay in place.
Use a vacuum attachment or hand vacuum to clean the exposed elevation assembly, drive
motor, lower electronics and the surrounding areas.
Also use a dry cloth for the areas that you can't reach with the vacuum cleaner. If the machine
has not been used for some time or is excessively dirty, use a dry cloth to wipe all exposed
areas. Replace the cover and tighten the screws when finished.
Lift the rear of the treadmill and roll it back from its present position to vacuum the floor area
underneath the unit. Wipe clean the underside of the treadmill to prevent dirt and dust
build-up. When finished, return the treadmill to its normal position.
Contact Heart Rate Grips — Contaminants, such as hand lotions, oils or body powder, may
come off on the contact heart rate grips. These can reduce sensitivity and interfere with the
heart rate signal. It is recommended that the user have clean hands when using the contact
heart rate. Clean the grips using a cloth dampened with a cleaning solution containing alcohol.
The grips are the only part of the treadmill you should use a cleaning solution containing alcohol.
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. This should be done
Preventive
Maintenance
Page 4-2
Cybex Sport+ Treadmill Owner’s and 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.
Tension and Center the Belt — If the belt is slipping under each step perform this
procedure:
Tools Required
• 3/4" Socket wrench
1. Tension the belt.
A. Use a 3/4" socket wrench to turn each bolt 1/2 turn clockwise. See Figure 1.
NOTE: Be sure to adjust each bolt equally on each side.
Figure 1
B. Turn the power on and press the Quick Start key.
C. Press the Speed + to bring the speed up to 3.5-4 mph (5.6-6.4 kph). Allow the
treadmill to run for a minute.
D. Observe the belt to be sure it stays centered. If it is not centered follow step 2.
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.
! CAUTION: Be careful not to over tighten the belt. Over tightening the belt can cause
the belt to stretch and require replacement.
2. Center the belt.
NOTE: While centering the belt choose one bolt to adjust. Do not adjust both bolts.
Preventive
Maintenance
Page 4-3
Cybex Sport+ Treadmill Owner’s and 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. For example: If the belt moves to the right and the deck becomes exposed on
the left, tighten the bolt on the right side of the frame, tighten about 1/2 of a turn
(clockwise) and wait 30 seconds. If the belt does not move back to the center of the
treadmill, make another adjustment to the same bolt. Once the running belt has been
adjusted closer to the center of the treadmill use about 1/4 of a turn until the belt has
been stabilized.
B. After the belt has been centered, check the belt tension again. Make sure the running belt
tension is tight enough so that the belt does not slip or hesitate when stepped on. Walk
on the treadmill at 3.5-4 mph (5.6-6.4 kph) and every 4th to 5th step throw your weight
into your step to feel if the belt is slipping. If the belt does slip, use a wrench to equally
tighten both rear roller adjustment bolts 1/2 of a turn (clockwise). Adjust the belt until no
further slipping is felt. If the running belt continues to slip the drive belt could be loose.
Checking the Belt and Deck Surfaces — The running belt and deck should be checked
periodically for any excessive wear. In an effort to make sure that the running belt operates
properly, visually inspect the belt often to make sure that there are no tears or fraying in the
belt material.
Inspect the edges of the belt as described below. NOTE: It is necessary to remove the motor
cover and plastic side panels.
Tools Required
• Phillips head screwdriver
• Dry towel
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the
power outlet.
Motor
Cover
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 up and off the
treadmill. The screws will stay in
place. See Figure 2.
Screws
(3 Each Side)
3. Remove the end caps.
A. Using a Phillips head screwdriver,
remove the screw that holds each
end cap in place. See Figure 3.
Preventive
Maintenance
Page 4-4
Figure 2
Cybex Sport+ Treadmill Owner’s and 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. Look at the edges of the belt while you roll it by hand. If the belt has any rips or looks
excessively worn the belt needs to be replaced.
B. Run your hand under the belt on the top of the deck surface. If you feel excessive
ridges or cracks, or if the deck feels grooved yet highly polished, the deck should be
replaced. In time, a worn belt and deck can cause high current draw and ultimately,
motor failure. For instructions on replacing the belt and deck, see Running Belt and
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. This cleaning should be done
each time you check the belt and deck condition to prevent premature wear of the
deck, running belt and the drive motor system. See the Service Schedule in this
chapter.
Preventive
Maintenance
Page 4-5
Cybex Sport+ Treadmill Owner’s and 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. Place each side panel into position slightly under the end cap and use your hand to
push all along the bottom edge of the side panel to snap it in place. See Figure 3.
11. 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. Be sure the
screws are catching the center motor cover’s holes.
Other Preventive Maintenance
Other preventive maintenance activities must be completed by a qualified service technician
at the recommended intervals listed in the Service Schedule (shown on the next page). These
activities include:
•
•
•
•
•
Measure the motor brushes and replace worn motor brushes
Rotate and replace the running deck
Replace the running belt
Check the current draw
Measure motor voltage at maximum speed, with no load
NOTE: See the Service chapter of this manual for detailed procedures for the maintenance
activities listed above.
Elevation Motor Lubrication — In time the elevation motor pivot points may develop a
squeak. If a squeak is present, remove the elevation motor by following the Elevation Motor
procedure in the Service chapter. Lubricate the upper and lower bolts and the spacers with a
small amount of lithium grease. NOTE: You can buy lithium grease at an auto parts store.
Static Electricity — Depending upon where you live, you may experience dry air, causing a
common experience of static electricity. This may be especially true in the winter time. You
may notice a static build-up just by walking across a carpet and then touching a metal object.
The same can hold true while working out on your treadmill. You may experience a shock due
to the build-up of static electricity on your body and the discharge path of the treadmill. If you
experience this type of situation, you may want to increase the humidity to a comfortable level
through the use of a humidifier.
Preventive
Maintenance
Page 4-6
Cybex Sport+ Treadmill Owner’s and Service Manual
Service Schedule
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.
1. Determine mileage.
Date Mileage Service Initials
A. Enter Test Mode by holding
down any key while turning
the treadmill to the on
(I) position.
dist
(except on all
B. Press
Cybex Sport models).
DIST appears on the display.
First 500 Miles
A Check Running Belt Tension
& Tracking.
Every 5000 Miles
A Check Running Belt Tension
& Tracking.
B Move Treadmill & Vacuum
Underneath.
C Remove Motor Cover to
Clean Underneath
with a Dry Cloth & Vacuum.
Every 10,000 Miles
D Replace Belt & Flip Deck.
E Check Motor Brushes
& Replace If Needed.
F Check Current Draw.
G Measure Motor Voltage at
Max Speed with No Load.
H Check Elevation Assembly
& Replace Worn Parts.
I Lubricate Elevation
Bushings.
Every 20,000 Miles
J Replace Belt & Deck.
DE-16609-4
Preventive
Maintenance
Page 4-7
Cybex Sport+ Treadmill Owner’s and 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 (16.1 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:
Preventive
Maintenance
Page 4-8
Date of Installation
Cybex Sport+ Treadmill Owner’s and Service Manual
5 - Setup and 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.
! CAUTION: During this procedure STAY OFF THE RUNNING BELT! Stand with your feet
on the two steps.
Choosing and Preparing a Site
Before assembling the treadmill you must select a suitable site and have the proper electrical
outlet power available for optimum operation and safety. See the Electrical Power
Requirements section (located on the next page) for direction in locating your treadmill's
voltage requirements.
The area you select for the treadmill should be well lit and well ventilated. Locate the treadmill
on a structurally sound and level surface (do not place in recessed areas or on plush carpet) a
few feet away from walls and other equipment. Each side of the treadmill should have a 19.7”
(0.5 m) minimum space. Behind the treadmill should be 39” (1.0 m) minimum of space. Allow
enough clearance for safe access and passage during use of the machine. If the treadmill is
to be located above the first floor, place it near or above major support beams. If the area has
a heavy, plush carpet, the airflow around the base of the machine may be restricted or the
carpeting may interfere with the moving parts. To protect the carpeting and the machinery,
place a 3/4” (1.9 cm) thick wood base under the treadmill.
Do not install the treadmill in an area of high humidity, such as in the vicinity of a steam room,
sauna, indoor pool, or outdoors. Exposure to extensive water vapor, chlorine, and/or bromine
could adversely affect the electronics as well as other parts of the machine.
Setup
and
Assembly
Page 5-1
Cybex Sport+ Treadmill Owner’s and 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.
Assembling the Treadmill
! 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 assemble this treadmill.
Tools Required
• 9/16” Socket wrench with a 4” extension
• Phillips head screwdriver
• Hex key, 3/16” (supplied)
NOTE: The words “left” and “right” denote the treadmill user's orientation.
1. Read and understand all instructions thoroughly before assembling the treadmill.
NOTE: Each step number in the assembly instructions tells you what you will be doing. The
lettered steps following each step number describe the procedure required. Do not
continue with step 2 until you have carefully read all of the assembly instructions.
2. Verify you have received the correct package.
A. Read the sticker on the outside of the box and verify that the model number, color and
voltage are what you ordered. NOTE: During step 3 and 6 you will verify that the
contents of the box match the sticker.
3. Unpack and verify the contents of the boxes.
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
and
Assembly
Page 5-2
Cybex Sport+ Treadmill Owner’s and 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-18115-4
Sport+ Manual (in box)
NA
1
LT-17718
Assembly Poster
NOTE: NA means not applicable.
6
7
1
5
Figure 1
Setup
and
Assembly
Page 5-3
Cybex Sport+ Treadmill Owner’s and 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 .75
Hex key, 3/16”
Hardware - Actual Size
8x 2
2x 3
8x 2
8x 4
2x 3
8x 4
1x 1x
5
3
4
6
2
2
1
2
2
7
4
Figure 2
Setup
and
Assembly
Page 5-4
Cybex Sport+ Treadmill Owner’s and 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. Pivot the console and uprights into position.
A. Remove all plastic wrapping except the white wrapping on the uprights.
B. Ensure that the display cable does not get pinched in step C.
C. Raise the console and uprights into position (they will pivot into place). NOTE: Confirm
that no cables are pinched while raising the unit. See Figure 3.
D. Have a second person continue to hold the uprights in place until after step 7A so that
they do not fall.
Figure 3
Setup
and
Assembly
Page 5-5
Cybex Sport+ Treadmill Owner’s and 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. Using a 9/16” socket wrench with a 4” extension, attach the uprights with six of the 3-816 x 5-8 hex head whiz-lock screws. NOTE: Do not securely tighten the screws until
step 7C. See Figure 5.
C. Tighten all 9/16” screws used during steps 7A and 7B including the two pivot screws
(one on each side). See Figure 6.
2
2
2
Figure 4
Figure 5
8. Secure the handrail.
A. Using the hex key provided, secure the handrail with two
5-16-18 x 7-8 screws. See Figure 7. NOTE: You may
need to lift the console slightly to line up the holes.
Setup
and
Assembly
Page 5-6
Pivot Screws
(1 on Each Side)
Figure 6
Cybex Sport+ Treadmill Owner’s and 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.
Note: If installing the A/V option, refer to the 515T and 530T A/V bracket installation
instructions (supplied with the A/V bracket).
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. NOTE: Do not plug in the power cord at this time.
Setup
and
Assembly
Page 5-7
Cybex Sport+ Treadmill Owner’s and 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. Using a Phillips head screwdriver secure the left end cap. See Figure 11.
Arms
Grommet
Slot at
Front of
Treadmill
End
Cap
Screw
Figure 11
B. Wind the excess power cord onto the arms. See Figure 11.
C. Place the left side panel into position slightly under the end cap and use your hand to
push all along the bottom edge of the side panel to snap it in place.
Setup
and
Assembly
Page 5-8
Cybex Sport+ Treadmill Owner’s and 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. Confirm that your treadmill is on a level surface.
13. Attach emergency stop key.
A. Confirm that the emergency stop key is in place over the e-stop button. See Figure 13.
NOTE: The treadmill will not run without the key (or other metal) in place.
14. Visually inspect the treadmill.
A. Carefully examine the treadmill to ensure that the assembly is correct
and complete.
Setup
and
Assembly
Page 5-9
Cybex Sport+ Treadmill Owner’s and Service Manual
Emergency Stop Button
Emergency
Stop Key
Figure 13
Setup
and
Assembly
Page 5-10
Cybex Sport+ Treadmill Owner’s and 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. Without anyone on the treadmill, plug the power cord into a power outlet from a
grounded, dedicated circuit as described under Electrical Requirements in this chapter.
2. Locate the on/off (I/O) power switch on the left side of the treadmill. Toggle it to the on
position (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. After it reaches one (1), the treadmill gives a longer tone and then begins
accelerating the belt to reach 1 mph (1.0 kph).
5. The bottom left display will flash the time and the right display will show the actual speed.
6. Press and hold down the Speed + key until the treadmill reaches a speed of
approximately 4 mph (6.4 kph), as indicated on the display.
7. Observe the belt to see that it is running properly; it should stay centered
in the middle of the deck. If you have problems with the running belt operation, see
Running Belt Adjustments in the Preventive Maintenance chapter.
8. Run the treadmill through its full speed range. First press the Speed + key until the
treadmill reaches its highest speed, 12.4 mph (20 kph). Then press the Speed - key until
the treadmill is back to 1.0 mph (1.0 kph).
9. As you press the Incline
actual incline or speed.
or Speed + - keys, the respective displays will show the
10. When the treadmill reaches the set incline and speed, the displays will remain steadily
illuminated to indicate that the desired settings have
been reached.
Setup
and
Assembly
Page 5-11
Cybex Sport+ Treadmill Owner’s and Service Manual
11. Run the treadmill through its full % grade range. Press the Incline
treadmill reaches its highest grade (15%). Then press the Incline
is back to 0% grade.
key until the
key until the treadmill
12. Press Stop twice to stop the running belt, end the workout review, and return the display
to Dormant Mode.
Setting Operation Options
1. Enter Test Mode by holding down any key while turning on (I) power. NOTE: The display will
cycle through the setup and stored information automatically.
2. Place your finger on the + key (but do not press the key at this time) and watch as the
center display changes.
3. When “unit” appears on the display you will have 3 seconds to toggle the unit of
measurement to your preference by pressing the + key. Choose English or Metric units;
English is the default. NOTE: Metric appears as “nnE”.
4. When “line” appears on the display you will have 3 seconds to toggle the line frequency.
Choose 50 Hz or 60 Hz. NOTE: If you have an English console and a 50 Hz power line
frequency, then you must change the setting from 60 Hz to 50 Hz for the proper elevation
frequency. Line Frequency is the frequency of the power line that supplies power to
your treadmill.
5. To exit Test Mode press the Stop key twice.
Your treadmill is now ready for use. Follow the instructions in the Operation chapter of this manual
to learn how to operate the treadmill. You should begin with walking speeds first to be sure
everything is functioning properly.
Setup
and
Assembly
Page 5-12
Cybex Sport Treadmill Owner’s and Service Manual
6 - Customer Service
Contacting Service
Hours of phone service are Monday through Friday from 8:30 a.m. to 6:00 p.m. Eastern Standard Time.
For Cybex customers living in the USA, contact Cybex Customer Service at 800-766-3211.
For Cybex customers living outside the USA, contact Cybex Customer Service at 508-533-4300 or fax
508-533-5183.
Order parts and find information on the web at www.cybexinternational.com or by e-mail at
techhelp@cybexintl.com.
Serial Number and Voltage
Your serial number and voltage can be found on the front of your treadmill. For your
convenience record your serial number and voltage below so that you will have it ready if you
call Cybex Customer Service.
Serial Number
Voltage
Return Material Authorization (RMA)
The Return Material Authorization (RMA) system outlines the procedures to follow when
returning material for replacement, repair, or credit. The system assures that returned
materials are properly handled and analyzed. Follow the following procedures carefully.
Contact your authorized Cybex dealer on all warranty-related matters. Your local Cybex dealer
will request an RMA from Cybex, if applicable. Under no circumstances will defective parts or
equipment be accepted by Cybex without proper RMA and an Automated Return Service
(ARS) label.
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.
Customer
Service
Page 6-1
Cybex Sport Treadmill Owner’s and Service Manual
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. The ARS label and RMA number must be
clearly displayed on the outside of the package that contains the item(s) to be
returned. Include a description of the problem, the serial number of the treadmill and
the name and address of the owner in the package along with the part(s).
5. Forward the package through UPS to Cybex.
Attn: Customer Service Department
Cybex International, Inc.,
10 Trotter Drive
Medway, MA 02053
NOTE: Merchandise returned without an RMA number on the outside of the package or
shipments sent C.O.D. will not be accepted by the Cybex receiving department.
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. The carrier will
provide you with the required forms for filing such claims.
Concealed Damage — Damage not seen with a visual check upon receipt of a shipment but
noticed later must be reported to the carrier as soon as possible. Upon discovery of the
damage, a written or phone request to the carrier asking them to perform an inspection of the
materials must be made within ten days of the date of delivery. Keep all shipping containers
and packing materials: they will be needed as part of the inspection process. The carrier will
provide you with an inspection report and the necessary forms for filing a concealed damage
claim. Concealed damage is the carrier's responsibility.
Customer
Service
Page 6-2
Cybex Sport Treadmill Owner’s and Service Manual
Ordering Parts
Visit www.cybexinternational.com to shop for parts online or fax your order to 508-533-5183.
To speak with a customer service representative, call 800-766-3211 (for customers living
within the USA) or 508-533-4300 (for customers outside the USA).
Customer
Service
Page 6-3
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Customer
Service
Page 6-4
Cybex Sport+ Treadmill Owner’s and 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. A charge can remain after
unplugging the power cord and turning off the treadmill.
! CAUTION: The belt will be jerky during the next step. Hold the handrail to support
yourself.
! CAUTION: During this procedure STAY OFF THE RUNNING BELT! Stand with your feet
on the two steps.
! WARNING: Disconnect the power cord before beginning this procedure. Keep wet
items away from inside parts of the treadmill. Electrical shock could occur
even if the treadmill is unplugged. Do not touch components on the lower
board. A charge can remain after unplugging the power cord and turning
off the treadmill.
! CAUTION: If the drive motor is warm wait until it is cool to the touch before
proceeding. The inside components may be hot.
! WARNING: Keep the motor dry. Do not get the inside of the motor wet.
! WARNING: Wait until the armature LED is off before removing the motor brush covers.
! 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.
! CAUTION: A minimum of two people will be required to properly lift the treadmill.
Always use proper lifting methods when moving heavy items.
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Cybex Sport+ Treadmill Owner’s and 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. Unless otherwise
noted “right” and “left” denote user orientation
for all procedures.
Test Mode
To enter Test Mode press and hold down any key on the display while turning the power
switch to the on (I) position. When all keys are released the software revision “rx.x” is shown
on the display. The display automatically scrolls through the following data for three seconds
each:
rev, (revision) unit (unit of measurement), line (frequency), dist (distance or total miles), hour
(total hours), strt (number of starts), log (error codes 1-5). Afterward “TEST” appears on the
display. To exit Test Mode press Stop.
Stuck Key List
If Test Mode occurs without holding any keys, a key may be stuck closed or Error 7 may have
occurred. If “btn” (button) and a number is displayed you can determine which key is stuck
closed by referring to the list below. If a key is stuck closed you may need to replace the lower
display overlay. See Figure 1. Follow the Display Overlay procedure located in this chapter.
btn1
btn2
btn3
btn4
btn7
btn8
btn9
btn10
btn11
btn12
btn13
btn15
btn16
btn17
btn18
btn20
btn21
btn22
btn25
btn26
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Stop
Incline Down
Speed Pace
Weight
Scan
Incline Up
Speed +
Quick Start
Cal
Level
Enter
Weight Loss
Dist
Adjust Down
Heart Rate
Manual
Mets
Adjust Up
Cardio
Upper
Overlay
Lower
Overlay
Figure 1
Cybex Sport+ Treadmill Owner’s and 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:
Distance key LED: On when 0% elevation sensor is active above 0% and off below 0%
Calorie key LED: Off when e-stop key is removed
Pace key LED: Blinks on once per speed sensor pulse
Heart key LED: Blinks on when hand grips are held and contact heart rate is activated
Key Functions
While in Test Mode press the following keys for desired information:
Quick Start Starts the belt at 1.0 mph (1.0 kph).
Incline
Run elevation motor up.
Incline
Run elevation motor down.
Speed +
Increase drive motor speed.
Speed -
Decrease drive motor speed.
Stop
Press once to stop motor (if on). Press again to exit Test Mode.
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Cybex Sport+ Treadmill Owner’s and 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. Enter Test Mode and wait until logged errors 1-5
are automatically displayed for three seconds each. Up to five errors are stored at a time. The
most recent error is always first in the log and appears as “log1”. Press the Incline
key to
clear the error log (while reviewing it in Test Mode). Press Stop to exit Test Mode.
NOTE: A processor upset can cause a bAd#. See H then G.
Error Description
bAd0
bAd2
bAd3
Err1
Err2
Err3
Err5
Err6
Err7
Err9
ErrE
Bad checksum. See H then G.
Internal RAM error. See H then G.
Watchdog timeout. See H then G.
Belt didn't start (or no speed sense). See I, E, D, B then A.
Underspeed (2 mph for 2 seconds without correction in process). See I, E, C then B.
Speed sense lost. See I, E, A, B and C.
No 0 switch sense within timed limits. This is declared when the timed
elevation reaches -2% without tripping the index. See F and A.
Overspeed (1 mph for 1 second or 2 mph for 0.2 seconds without
correction). See I, E.
EEPROM error (memory lost, loads new defaults, enters Test Mode). See G.
Brush wear too low. Indicator has been activated for over 100 miles. See D.
0% always on (or switch disconnected or wired backwards). This means
that timed elevation has gone up 2% and the index is still sensed. See F.
Action
A
B
C
D
E
F
G
H
I
Check lower board
Check drive motor
Check belt and deck
Check motor brushes
Check speed sensor
Check elevation motor
Replace display board
Turn the treadmill to the off (O) position and back on (I)
Perform speed calibration procedure
Motor Current and Voltage
Motor current draw and motor voltage must be checked by a qualified service technician at
the recommended intervals listed in the Service Schedule in the Preventive Maintenance
chapter of this manual. For your convenience a service schedule decal is provided under the
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Cybex Sport+ Treadmill Owner’s and 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 (1.0 kph).
C. Without standing on the belt, bring the speed of the treadmill up to 3 mph (4.8 kph)
and take note of the load value in the top center display.
D. Have a second person walk on the belt at 3 mph (4.8 kph) and take note of the load
value in the top center display and the weight of the person. NOTE: Call Cybex
Customer Service to confirm that the load is within acceptable range. Loads over 200
are generally unacceptable.
E. Press Stop to exit Test Mode.
2. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
3. Remove the motor cover.
A. Using a Phillips head screwdriver,
loosen three screws on each motor
cover side (left and right). See Figure 2.
Motor
Cover
B. Lift the motor cover center up and off
the treadmill. The screws will stay in
place.
4. Check the belt and deck condition.
A. Follow the Checking Belt and Deck
Surfaces procedure on page 4-4 of the
Preventive Maintenance chapter of this
manual and then proceed with step 5.
Screws
(3 on each side)
Figure 2
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Cybex Sport+ Treadmill Owner’s and 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 12.4 mph
(20 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. Using a voltage meter, pierce the sharp end of the meter’s red lead into the plastic
coating of the motor’s red lead, and the meter’s black lead into the plastic coating of the
motor’s black lead.
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.
6. Attach 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.
Speed Sensor Adjustment
Tools Required
• Phillips head screwdriver
! WARNING: Disconnect the power cord before beginning this procedure.
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
2. Remove the motor cover.
A. Using a Phillips head screwdriver, loosen three screws on each motor cover side
(left and right).
B. Lift the motor cover center up and off the treadmill. NOTE: The screws will stay
in place.
3. Visually inspect the target disk on the flywheel.
A. Turn the flywheel slowly and look for dirt, scratches or other damage on the target
disk. NOTE: If the target disk or sensor is dusty use a soft dry cloth to wipe off the dust.
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Cybex Sport+ Treadmill Owner’s and 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. Bring the speed of the treadmill up to maximum speed, 12.4 mph (20 kph).
D. After reaching maximum speed take note of the actual speed that is displayed in the
lower left window. If it fluctuates in over 0.5 mph increments then your speed sensor
gap needs to be readjusted.
E. Press Stop and turn the power switch to the off (O) position.
F. Enter Test Mode again and check the error log for Error 3. If any new errors occurred,
readjust the speed sensor and test again. NOTE: If you are unsure whether an error is
new you can clear the error log by pressing the
key and then repeat steps 4A
through 5F.
G. Exit Test Mode by pressing Stop.
6. Attach 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.
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Cybex Sport+ Treadmill Owner’s and 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. Lift the motor cover center up and off the treadmill. The screws will stay in place. See
Figure 2.
3. Perform the IR compensation procedure.
A. Enter Test Mode by pressing and holding down any key on the display while turning
the power switch to the on (I) position. When the key is released “TEST” and the
software revision “rx.x” are shown on the display.
B. While standing on the ground, press Start and then press the Speed Up key once to
set the treadmill speed to 1.0 mph (1.0 kph).
! WARNING: Do not touch components on the lower board. A charge can remain after
unplugging the power cord and turning off the treadmill.
! CAUTION: The belt will be jerky during the next step. Hold the handrail to support
yourself.
C. Hold on to the handrails as you step on the running belt, begin walking and notice how
the belt feels, (the belt may surge, vibrate or slack). NOTE: If the belt doesn't need to
be adjusted skip to step 4A.
D. Pull up on the lower board shield. It will snap out. NOTE: Newer versions of the shield
will have a hole directly over the IR compensation. If you have the new shield, place the
plastic screwdriver through the hole to adjust the IR compensation instead of removing
the shield.
E. Locate the control called “IR COMP” on the lower board. NOTE: DO NOT use a metal
screwdriver. DO NOT adjust the other two controls that look identical to the IR
COMP control.
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Cybex Sport+ Treadmill Owner’s and 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. Place the lower board shield into position (if applicable) and snap it in.
4. Secure the motor cover.
A. Lower the motor cover into position. See Figure 1.
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.
Speed Calibration
1. Calibrate the speed.
A. Stay off the running belt during this procedure.
! CAUTION: During this procedure STAY OFF THE RUNNING BELT! Stand with your feet
on the two steps.
B. In Test Mode press and hold the Quick Start key for three seconds. The display will
show “C”. The running belt will accelerate and when completed the display will show
“CAL”. Press Stop to exit Test Mode. NOTE: This procedure should be completed
after replacing the upper display board, the lower control board or the drive motor. If
you press Stop during this procedure the calibration will not be stored. Exiting Test
Mode while the belt is moving may generate an error condition.
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Cybex Sport+ Treadmill Owner’s and 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.
Tools Required
•
•
•
•
•
Phillips head screwdriver
7/16” Open end or socket wrench
3/4” Open end or socket wrench
1/2” Socket wrench
9/16” Socket wrench with a 3” extension
! WARNING: Disconnect the power cord before beginning this procedure.
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
2. Remove the motor cover.
A. Using a Phillips head screwdriver, loosen the three screws on each motor cover side
(left and right). See Figure 2.
B. Lift the motor cover center up and off the treadmill. NOTE: The screws will stay in
place. See Figure 2.
3. Remove the end caps.
A. Using a Phillips head screwdriver, remove the screw that holds each end cap in place.
See Figure 4.
End
Caps
Screws
Figure 4
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Cybex Sport+ Treadmill Owner’s and 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.
A. Using a 3/4” open end or socket wrench,
loosen the two rear roller bolts (one roller
bolt on each side). NOTE: Loosen each
bolt evenly, making sure not to loosen
either bolt too many turns before moving
to the other bolt. See Figure 6.
B. While holding the rear roller, remove the
hardware from each side. NOTE: Pivot
the bolt, washers, spring and nut holder
out together. See Figure 6.
C. Lift one side of the rear roller and slide
the roller out of the running belt. See
Figure 6.
Rear Roller
Running Belt
Rear Roller Bolt, Washers, Spring and
Nut Holder
NOTE: Keep the Hardware Together
Figure 6
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Cybex Sport+ Treadmill Owner’s and 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. Using a 1/2” socket wrench, loosen but do not
remove the two screws on the motor saddle. See
Figure 8.
Drive
Belt
B. Place a 9/16” socket wrench with a 3” extension in
the right front roller access hole. Loosen but do not
remove the right front roller screw. See Figure 9.
NOTE: The right screw will stay on the front roller.
You do not need to remove it for this procedure.
C. Place a 9/16” socket wrench with a 3” extension in
the left front roller access hole. Remove the left front
roller screw. See Figure 9. NOTE: Leave the front roller
in place until
step 9C.
9. Remove the running deck and running belt.
A. If rotating or flipping the deck, make a note on the
deck so you know which way it was positioned.
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Page 7-12
Flywheel
Pulley
Motor Saddle Screws
Figure 8
Cybex Sport+ Treadmill Owner’s and 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.
Screw
Front Roller
Access Hole
Figure 9
C. Using a Phillips head screwdriver, secure each
deck stiffener with screws removed from step 10A.
Drive Belt
NOTE: If you are replacing the drive belt follow steps 11 through 14. If not, skip steps 11, 12
and 14 but follow step 13. See the Drive Motor procedure for an alternative way to
change the drive belt.
11. Release the drive belt tension.
A. Using a 1/2” socket wrench, loosen but do not remove the two screws on the motor
saddle. See Figure 8.
12. Remove the drive belt.
A. If you are changing the drive belt, slip the drive belt around the flywheel pulley and off
the motor. See Figure 8.
B. Slide the new drive belt around the flywheel pulley. NOTE: There will be some slack in
the drive belt until step 14 is complete.
13. Secure the front roller.
A. Slide the front roller into the running belt. NOTE: It doesn’t matter which way the
running belt goes.
B. Be sure the drive belt is around the flywheel pulley and the front roller before attaching
the front roller.
C. Using a 9/16” socket wrench with a 3” extension, attach 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.
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Cybex Sport+ Treadmill Owner’s and 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 8.
Drive Belt
Face of Front
Roller Pulley
Face of
Flywheel Pulley
15. Secure the running deck.
A. Place the deck in position as noted in step 9A. NOTE:
Make a note of the service you performed on the Service
Schedule under the motor cover.
B. Using a 7/16” open end or socket wrench, attach the ten
washers and screws that hold the deck to the treadmill
frame. See Figure 7.
Figure 10
16. Secure the rear roller.
A. Slide the rear roller into the running belt. See Figure 6.
B. Slide the hardware for each side into position. NOTE:
Place the end of the bolt in first and then hold the rear
roller up while you pivot the group of hardware into the
rear roller slot. Be sure the bronze bushing is touching
the head of the bolt. See Figure 11.
Bronze Bushing
C. Using a 3/4” socket wrench, tighten each rear roller
bolt evenly, making sure not to tighten either bolt too
many turns before moving to the other bolt. NOTE: Do
not overtighten the belt. You will tension and center the
belt in step 21. See Figure 11.
17. Secure the top steps.
A. Place each top step in position. See Figure 4.
B. Using a Phillips head screwdriver, secure the three
screws that hold each top step in place. See Figure 4.
NOTE: Be sure the bronze
bushing is touching the
head of the bolt.
Figure 11
18. Secure the side panels.
A. Place each side panel into position on the bottom edge and use your hand to push all
along the top edge of the side panel to snap it in place. See Figure 5.
19. Secure the end caps.
A. Using a Phillips head screwdriver, tighten the screw that holds each end cap in place.
See Figure 4.
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Cybex Sport+ Treadmill Owner’s and 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.
Drive Motor
NOTE: This procedure will cover the drive motor, drive belt and motor brushes.
Tools Required
•
•
•
•
•
•
•
Phillips head screwdriver
7/16” Open end wrench
7/16” Socket wrench with a deep socket
1/2” Socket wrench
3/4” Socket wrench
9/16” Socket end wrench with a 3” extension
Needle nose pliers
! WARNING: Disconnect the power cord before beginning this procedure. Keep wet
items away from inside parts of the treadmill. Electrical shock could occur
even if the treadmill is unplugged. Do not touch components on the lower
board. A charge can remain after unplugging the power cord and turning
off the treadmill.
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off
(O) position.
Nuts
B. Unplug the treadmill from the power outlet.
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. See Figure 2.
3. Release the drive belt tension.
A. Using a 1/2” socket wrench, loosen but (do not
remove) the two screws on the motor saddle. See
Figure 12. NOTE: The tension is now released. You
will remove motor ground cable in step 5A.
Screws
(Loosen)
Figure 12
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Cybex Sport+ Treadmill Owner’s and 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.
! WARNING: Do not touch components on the lower board. A charge can remain after
unplugging the power cord and turning off the treadmill.
A. Using a 1/2” socket wrench, remove the screw, split washer, flat washer and motor
ground wire from the motor saddle. See Figure 13.
B. Pull up on the lower board shield. It will snap out.
C. Disconnect the motor cable from the lower board and line filter. NOTE: You will
disconnect four wires (red, black, yellow and green). See Figure 13.
D. Carefully remove the drive motor.
NOTE: If you are replacing the drive belt with a new one follow step 6B - 8A. If not, skip to
step 8.
6. Remove the drive belt (optional).
A. Using a 3/4” socket wrench, loosen each rear roller bolt 10-12 revolutions to release
tension on the running belt.
B. Using a 9/16” socket wrench with a 3” extension, remove the two front roller screws.
See Figure 8.
C. Tilt the left side of the front roller up and then the right side.
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Cybex Sport+ Treadmill Owner’s and 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 9.
8. Secure the rear roller bolts.
A. Using a 3/4” socket wrench, tighten each rear roller bolt evenly, making sure not to
tighten either bolt too many turns before moving to the other bolt. NOTE: Do not
overtighten the belt. You will tension and center the belt in step 23C.
NOTE: If you are replacing the motor with a new one follow step 9. If not, skip to step 10.
9. Transfer the flywheel to the new motor.
A. Using a 7/16” socket wrench,
remove the flywheel, screw,
washers and motor (ansi
square) key from the old motor.
See Figure 14.
B. Place the flywheel in position on
the new motor and slide the
motor key into the slot on the
flywheel. See Figure 14.
C. Using a 7/16” socket wrench,
install the flat washer, split
washer and screw that hold the
flywheel on the motor and then
tighten securely (80 in-lbs). See
Figure 14.
Screw
Split Washer
Flat Washer
Motor
Key
Flywheel
Drive
Motor
Figure 14
Motor Brushes
NOTE: Motor brushes are wear items that will periodically need to be replaced. Both drive
motor brushes must be replaced as a pair. This will ensure even commutator contact
and brush wear. However, the one brush may wear faster than the other brush.
Therefore, always measure both brush lengths to determine whether you should
replace the pair. Check both brushes for cracks or chips.
NOTE: When “Err9” appears on screen it indicates motor brush wear. The treadmill will run
100 miles (161 kilometers) longer and then be inoperable until brushes are replaced.
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Cybex Sport+ Treadmill Owner’s and 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. Observe the “armature LED” on the lower board (labeled ILT4).
B. After the armature LED goes off proceed to step 5C.
11. Remove the drive brush access covers.
A. Squeeze each of the two rectangular brush covers to remove it from the motor. See
Figure 15.
B. Lift off the round brush cover. See Figure 15. If necessary carefully pry the cover up
using a flathead screwdriver.
800-766-3211 508-533-4300
Figure 15
12. Remove the brushes.
A. Using needle nose pliers, unplug the yellow brush wear indicator wire from the round
access hole and the brush wire from the rectangular hole.
B. Press each brush spring in and slowly pull it out. It will be spring loaded. NOTE:
Before you pull out the brushes, take note which way the brushes are orientated. You
will need to replace them in the same orientation.
C. Pull each brush out from the drive motor.
13. Examine the brushes and commutator.
Service
Page 7-18
A. Inspect the commutator by looking through the top brush holder into the motor. Slowly
spin the motor by turning the flywheel. Look for noticeable damage and for signs of
Cybex Sport+ Treadmill Owner’s and 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. Brush dust can be loosened from the brush holder area by
lightly filing the surfaces.
B. Inspect the brushes for signs of excessive wear or cracks. The motor brushes must be
replaced if one or both is worn to 0.4” (10.2 mm) or less in length, is broken or
chipped, has a broken spring or binds in the motor. NOTE: For your convenience the
decal shown in Figure 15 is under the motor hood cover.
NOTE: If a new brush does not slide in and out easily, the edges or corners of the brush can
be lightly filed down. The motor may make a clicking noise as new brushes wear in.
14. Replace the brushes.
NOTES:If a new brush does not slide in and out easily, the edges or corners of the brush can
be lightly filed down. The motor may make a clicking noise as new brushes wear in. If
you reinstall the original brushes it is good to install them facing their original position.
Reversing the orientation of the brush can cause a clicking noise during operation
until the brushes wear in.
A. Locate the brush with the two wires and slide it into the motor brush holder (located
nearest the round access hole).
B. Locate the brush with the one wire and slide it into the motor brush holder on the
opposite side.
C. Place a spring clip under each brush and push in and down. The spring hooks will
grasp on to the end of the brush holder.
D. Using needle nose pliers, plug the yellow brush wear indicator wire onto the fast-on
inside the round access hole.
E. Using needle nose pliers, plug each brush wire onto the fast-on inside the rectangular
access hole.
15. Secure the drive motor access panels.
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.
16. Align the drive motor.
A. Carefully lower the drive motor in position on the motor saddle. NOTE: Do not crush
the speed sensor or scratch the speed decal on the flywheel.
B. Turn the motor so the exit cable is positioned at a 3 o’clock angle toward the front
roller. See Figure 16.
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Cybex Sport+ Treadmill Owner’s and 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. Loop each strap through the motor
saddle and position each screw vertically
as shown in Figure 16. NOTE: The motor Figure 16
strap will be creased slightly where it
pressed against the motor saddle, be sure
the strap is in its original position.
Motor Saddle
B. Close each motor strap and use a 7/16” wrench with a deep socket to tighten each
nut securely (80 in-lbs). See Figure 16.
18. Align the drive belt.
A. Place the drive belt over the flywheel pulley and 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.
19. Connect the motor cables.
A. Connect the motor cable to the lower board and line filter as shown in Figure 13 (red
to A1, black to A2, yellow to BW and green to the line filter). NOTE: For internationally
installed treadmills only, the green cable goes on the ground stud tab.
B. Place the flat washer on the
motor saddle followed by the
ground terminal, split washer
and screw. See Figure 17.
NOTE: The ground
terminal must go
between the two
washers.
C. Using a 1/2” socket wrench,
tighten both screws on the
motor saddle.
Screw (2)
Split Washer (2)
Ground Terminal (1)
Flat Washer (2)
D. Using wire ties, tie the motor
cable to the base so that no
wires get pinched. See Figure
Figure 17
18. NOTE: Be sure that the
wires are tied away from the
fan and running belt. For internationally installed treadmills only, place the ferrite
(shown in Figure 18) removed in between the wire ties.
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Cybex Sport+ Treadmill Owner’s and 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. 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. Perform the appropriate
procedures (as noted below).
PL-17052-4
Figure 19
A. Follow the Speed Calibration procedure located in this chapter (required).
B. If you replaced the motor follow the IR Compensation procedure located in this
chapter.
C. If you loosened the tension on the running belt (step 8A) follow the Tension and Center
the Belt procedure located in the Preventive Maintenance chapter.
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Cybex Sport+ Treadmill Owner’s and 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. Unplug the treadmill from the power outlet.
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. See
Figure 2.
3. Place wooden blocks under the frame.
! CAUTION: A minimum of two people will be required to properly lift the treadmill.
Always use proper lifting methods when moving heavy items.
A. While two people are lifting the front of the treadmill, have a third person place a
wooden block under the each side of the frame to support the front end of the
treadmill. NOTE: This will get the weight of the treadmill off the elevation wheels and
provide support.
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.
A. Pull up on the lower board shield. It will snap out.
B. Disconnect the elevation motor cable from the lower board and remove it from the wire tie.
5. Remove the elevation motor.
A. Using a 9/16” open end wrench and a 9/16” socket wrench, remove the two bolts on
the elevation motor (one at the top and one at the bottom). NOTE: Hold the motor
while you remove the second bolt so that it doesn’t fall.
B. Carefully lift and remove the elevation motor from the treadmill.
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Cybex Sport+ Treadmill Owner’s and 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. Carefully place the elevation motor in
position on the treadmill. See Figure 20.
B. Slide both bolts into the slots and
attached the hex nuts as shown in
Figure 20.
Figure 20
C. Using a 9/16” open end wrench and a
9/16” socket wrench, securely tighten the nuts and two bolts installed in step 7B.
D. Connect the elevation motor cable to the lower board. NOTE: The board is labeled P3 at
the elevation port. The connector can only fit in one direction.
E. Place the lower board shield in position and push the clips down. NOTE: The clips will
snap in.
F. Tie the elevation cable with the tie from step 4B so that it is clear of the motor fan. Be
sure no wires get pinched.
8. Test the elevation motor.
A. Connect the main power cord into the power outlet and turn the power switch on (I).
B. Start the treadmill in Manual Mode and raise the elevation to 6%.
C. Carefully remove the wooden blocks from under the front end assembly. This will load
the elevation assembly.
D. Lower the elevation to zero percent.
E. Stop the treadmill and turn the main power switch in the front panel to the off (O)
position.
9. 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.
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Cybex Sport+ Treadmill Owner’s and 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. A charge can remain after unplugging the power cord and turning
off the treadmill.
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
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. See
Figure 2.
3. Disconnect the cables from the lower control board and bracket.
A. Pull up on the lower board shield. It will snap out.
B. Disconnect the cables from the lower control board. This includes: the elevation motor
cable; display cable (P1 and P2); AC line 1 (black); AC line 2 (white); drive motor (black
red, yellow) and speed sensor cable.
C. Using a 3/8” nutdriver or socket wrench, remove the one nut and one washer from the
ground wire on the lower control bracket.
4. Remove the lower control board bracket.
A. Using a Phillips head screwdriver, remove the four screws that hold the lower control
bracket to the base.
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.
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Cybex Sport+ Treadmill Owner’s and Service Manual
5. 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. Using a Phillips head screwdriver, secure the four screws that hold the bracket to the
base.
6. Connect the cables to the lower control board.
A. Connect the cables to the lower control board. This includes: the elevation motor
cable; display cable (P1 and P2); AC line 1 (black); AC line 2 (white); drive motor
(black, red, yellow) and speed sensor cable. See Figure 21.
Drive Motor Cable
Ground Access
(Red Black Yellow Speed Elevation
Wire
Hole
Sensor
Motor
and Green)
Cable
Cable
Line
Filter
Lower
Board
Speed
Sensor
Display
Cable
AC Line 1
AC Line 2
Elevation
Motor
Figure 21
B. Put the ground wire terminal on the stud on the lower board bracket.
C. Using a 3/8” nutdriver, secure the one nut over the ground wire terminal.
7. Secure the wires.
A. Check to see that all of the cables are connected firmly in their proper place.
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Cybex Sport+ Treadmill Owner’s and Service Manual
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.
8. Perform IR Compensation procedure.
A. Follow the IR Compensation procedure located in this chapter.
9. 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. Be sure the
screws are catching the center motor cover’s holes. See Figure 2.
10. Calibrate speed.
A. Follow the Speed Calibration procedure located in this chapter.
Power Cord
NOTE: This procedure will cover the power cable, line filter and power switch.
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. A charge can remain after unplugging the power cord and turning
off the treadmill.
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
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.
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Cybex Sport+ Treadmill Owner’s and Service Manual
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. Pull the left side panel out and off the treadmill.
Power Switch
5. Remove the power switch.
A. Using a Phillips head screwdriver, remove the two screws that hold the switch and its
plate to the treadmill.
B. Disconnect the four fast-on connectors that go into the power switch.
C. Using a 3/8” nutdriver, remove the one nut and one washer from the ground wire on
the lower control bracket.
6. Remove the power cord.
A. Remove the old power cord and discard the power cord (and power switch if
applicable). See Figure 22.
Shield
Power Cord
Power Switch
Plate
Grommet
Wire Tie
Figure 22
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Cybex Sport+ Treadmill Owner’s and 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. Using a Phillips head screwdriver, remove the two screws that hold the line filter to the
lower control bracket and discard the old line filter if applicable.
D. Place the new line filter in position on the lower control bracket.
E. Using a Phillips head screwdriver, secure the two screws that hold the line filter to the
lower control bracket.
8. Connect the line filter cables (if applicable).
A. Connect the white cable to the front right fast-on on the line filter and route it through
the access hole.
B. Connect the black cable to the front left fast-on on the line filter and route it through
the access hole.
C. Connect the ends of these two cables to the lower board. The white connects to the
fast-on labeled AC Line 1. The black connects to the fast-on labeled AC Line 2.
D. Connect the drive motor cable (green) to the line filter’s front left fast-on connector.
9. Route the power cord.
A. Route the power cord behind the base brackets and route the fast-ons out the power
switch access hole. NOTE: The power cord can exit the front or back of the treadmill.
Position it the way you intend to leave it.
10. Connect the power cable.
A. Hold the power switch and its plate so that the I (on) is toward the top. See Figure 23.
B. 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.
C. Connect the line filter fast-ons to the power switch.
• The white cable connects to the bottom right switch fast-on.
• The black cable connects to the bottom left switch fast-on
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Cybex Sport+ Treadmill Owner’s and 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. Using a Phillips head screwdriver, secure the switch plate to the treadmill with the I
(on) toward the top. See Figure 23.
Upper Display Board
Tools Required
• Phillips head screwdriver
• ESD (Electro Static Discharge) grounding strap
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
NOTE: The display board is susceptible to damage from a discharge of static electricity.
While handling parts underneath the console cover use an ESD grounding strap. This
eliminates the potential voltage (static) difference between you and the equipment you
are working on. Wear an ESD strap for the rest of this procedure.
2. Remove the console back from the handrail.
NOTE: If you have a cable plugged into the RJ-45 port disconnect it.
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Cybex Sport+ Treadmill Owner’s and Service Manual
A. Using a Phillips head screwdriver, remove the nine screws that hold the console back
to the console front.
B. Gently pull off the console back.
3. Remove the display board.
A. 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 24.
Upper Switch Membrane Ports
Display Cable Ports
Upper Display Board
Lower Display Board
Contact Heart
Rate Port
CSAFE Board
Connects to
Display Board
Heart Rate
Board
RJ-45 Port
Upper to
Lower Board
Jumper
Lower Switch
Membrane
Figure 24 NOTE: Sport models before October 2002 did not have the CSAFE board and RJ-45 port.
Early models of the upper display overlay did not have switch membranes.
B. Using a Phillips head screwdriver, remove the six screws that hold the display board to
the console.
4. Attach the display board.
A. Place the display board in position on the front console.
B. Using a Phillips head screwdriver, secure the six screws that hold the display board to
the console.
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Cybex Sport+ Treadmill Owner’s and 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, the
CSAFE board to display board jumper and the upper to lower board jumper. See Figure 24.
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. While being sure not to pinch any cables, use a Phillips head screwdriver to secure the
nine screws that hold the back cover to the console front.
8. Calibrate speed.
A. Follow the Speed Calibration procedure located in this chapter.
Contact Heart Rate Board
NOTE: This procedure will cover the contact heart rate board, grips and cable.
Tools Required
• Phillips head screwdriver
• ESD (Electro Static Discharge) grounding strap
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
NOTE: Wear an ESD strap for the rest of this procedure.
2. Remove the console back.
NOTE: If you have a cable plugged into the RJ-45 port disconnect it.
A. Using a Phillips head screwdriver, remove the nine screws that hold the console back to
the console front.
B. Gently pull off the console back.
3. Remove the heart rate board.
A. Using a Phillips head screwdriver, remove the three screws from the heart rate board.
B. If you’re not replacing the cable, disconnect the two cables and one molex placeholder from
the heart rate board. (You will re-attach the molex connector in step 4A). See Figure 25.
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Cybex Sport+ Treadmill Owner’s and Service Manual
4. Attach the new heart rate board.
A. Locate the side of the heart rate
board with the two holes and
place the molex placeholder
over the top three pins. See
Figure 25.
Molex
Placeholder
(Top)
Double
Connector
(Right)
Heart Rate
to Display
Board
Connector
(Bottom)
B. Place the heart rate board in
position with the two holes to
the left and, using a Phillips head Figure 25
screwdriver, attach the heart rate
board with the three screws removed in step 3A.
NOTE: If you are replacing the grips and cable follow steps 5 to 8. If not skip to step 9.
Contact Heart Rate Grips
Tools Required
• Knife or small flathead screwdriver
• Needle nose pliers
• Wire cutters
5. Remove the old heart rate grips and cable.
A. Using a knife or flathead screwdriver, pry up the four metal contacts from the two grips.
NOTE: The metal contacts are taped on securely and prying them up will destroy them.
B. Using a needle nose pliers, carefully disconnect the wire from each metal contact.
C. Using a Phillips head screwdriver, remove the two bolts and two nuts from each grip.
D. Pull the plastic housing and cap off each handrail (the housing is secured with
double-sided tape). See Figure 26.
E. Gently push each connector out of the rectangular hole in the plastic housing. See
Figure 26.
F. Remove any remaining double-sided tape from each handrail.
G. Remove the old o-ring from each
handrail. See Figure 26.
Double-sided
Tape
Cap
Plastic
Housing
H. Using wire cutters, cut the four wire
ties that hold the heart rate cable to
the handrail.
O-Ring
I. Pull the old heart rate cable out of
the handrail.
Wire Through
Rectangular Hole
Figure 26
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Cybex Sport+ Treadmill Owner’s and Service Manual
6. Route the new heart rate cable.
A. Connect the double connector into the right side of the heart rate board. See Figure 25.
B. Locate the short and long side of the heart rate
cable.
Black Wire
(Back)
C. Route the short cable end to the left (from
treadmill user’s viewpoint) and the long end to
the right.
D. Place the cable behind the handrail and tie with
four wire ties in the locations they were removed
in step 5D.
E. Fold the each cable and place it into the hole
that leads to the grip. See Figure 27.
Red Wire
(Front)
O-Ring
Cable
Enters NOTE: Front is from treadmill
Hole
user’s viewpoint.
Figure 27
F. Push each wire out a hole (red out the front hole
and black out the back hole). See Figure 27.
Small Holes
7. Secure the new plastic housing.
A. Slide an o-ring on each handrail and roll it over
the wires so that it is positioned just after the
hole where the wires emerge. See Figure 27.
B. Remove the protective paper from the loose
pieces double-sided tape and stick each one
between two small holes in the handrail. See
Figure 28.
Double-sided
Tape
Figure 28
C. Position each set of plastic housing so that the
grooves fit together snugly. NOTE: If the grooves
don't fit and the housing gets taped down in the
wrong position pulling it up will destroy the tape.
Do not let the plastic housing touch the doublesided tape until step 7E.
Cap
Double-sided
Tape
Wire Through
Rectangular
Hole
D. Place each plastic grip near the handrail and pull
each wire through a rectangular hole. See Figure
29. NOTE: Don’t let the wires slip back into their
Figure 29
holes.
E. Fit the three plastic parts in position (the housing (2) and the
cap (1)) and continue holding all plastic parts through the next
step. See Figure 29.
Nuts
F. While being careful not to overtighten and crack the housing,
place the nuts in their holes and secure them with the bolts.
NOTE: It is easier to place the nuts on the top and the bolts
from the bottom. See Figure 30.
Bolts
Figure 30
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Cybex Sport+ Treadmill Owner’s and Service Manual
8. Secure the new metal contacts.
A. Remove the protective paper from the four
metal contacts and from the eight strips of
tape on the plastic housing.
B. Locate the small bump on the metal contact
prong and on the connectors. See Figure 31.
Line Up Bumps
Prong on Metal Plate
C. Connect the each cable to a metal prong with
Figure 31
the bumps lined up. See Figure 31.
D. Push the excess wire into its rectangular hole.
E. Press each metal contact into the grooves (one groove at a time) on the plastic
housing. NOTE: They will snap in.
9. Connect the cables removed in step 3A.
A. Confirm that the two cables and one molex placeholder are firmly connected to the
heart rate board in their proper places. See Figure 25.
10. Secure the console back.
A. While being sure not to pinch any cables, use a Phillips head screwdriver to secure the
nine screws that hold the console back to the console front.
11. Connect the external power source.
A. Plug the treadmill into the power outlet.
12. Calibrate speed (if you replaced the display board).
A. Follow the Speed Calibration procedure located in this chapter.
CSAFE Board
Tools Required
• Phillips head screwdriver
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
2. Remove the console back.
NOTE: If you have a cable plugged into the RJ-45 port disconnect it.
A. Using a Phillips head screwdriver, remove the nine screws that hold the console back
to the console front.
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Cybex Sport+ Treadmill Owner’s and Service Manual
B. Gently pull off the console back.
3. Remove the old CSAFE board.
A. Pull the CSAFE connector out of the display board. See Figure 24.
B. Using a Phillips head screwdriver, remove the three screws that hold the CSAFE board
to the console.
4. Attach the new CSAFE board.
A. Gently push the CSAFE connector into its port on the display board. See Figure 24.
B. Using a Phillips head screwdriver, secure the CSAFE board with the three screws
removed during step 3B. NOTE: Do not overtighten.
5. Secure the console back.
A. While being sure not to pinch any cables, use a Phillips head screwdriver to secure the
nine screws that hold the console back to the console front.
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. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
NOTE: The display board is susceptible to damage from a discharge of static electricity.
While handling parts underneath the console cover use an ESD grounding strap. This
eliminates the potential voltage (static) difference between you and the equipment you
are working on. Wear an ESD strap for the rest of this procedure.
2. Remove the console back.
A. Using a Phillips head screwdriver, remove the nine screws that hold the console back
to the console front.
B. Gently pull off the console back.
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Cybex Sport+ Treadmill Owner’s and Service Manual
3. 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. See
Figure 2.
4. Remove the left junction covers.
A. Using a Phillips head screwdriver, remove the three screws that hold the left junction
covers in place.
5. Remove the display cable.
! WARNING: Do not touch components on the lower board. A charge can remain after
unplugging the power cord and turning off the treadmill.
A. Pull up on the lower board shield until the shield snaps out.
B. Disconnect the display cable (P1 and P2) from the lower board. See Figure 16 .
C. Disconnect the display cable (P3 and P8) from the upper display board. See Figure 19.
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. 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.
NOTE: Display cables have a revision number label so that you can verify that you have the
latest revision of the cable.
6. Attach the new display cable.
A. Locate the P1 and P2 end of the display cable.
B. Push the P2 connector down into the top handrail hole with the P1 connector pointing
up. See Figures 32 and 33.
Small P1
C. Push the display cable down through
Connector
the handrail and out the handrail’s
Up
bottom hole. NOTE: Twisting the cable
as you push will help it go through.
D. Push the display cable down through
the upright and out the exit hole.
NOTE: There is a black line on the
display cable to show you how far to
pull out the cable. When you see the
line, stop pulling the cable out.
Service
Page 7-36
Large P2
Connector
Down
Figure 32
Cybex Sport+ Treadmill Owner’s and Service Manual
E. Route the cable into the access hole.
F. Connect the display cable to the lower control board at P1 and P2.
NOTE: “Right” and “left” denote
user orientation.
Console
Back Cover
Bottom
Hole
Screws (9)
Left
Junction
Covers
P3 and P8
Connectors on
Upper Display
Board
Screws (3)
Wire
Holder
Display Cable
Upright
Shield
P1 and P2 on
Lower Board
Access
Hole
Screws (4)
Left Side Cover
Figure 33
7. Secure the cable.
A. Using a Phillips head screwdriver, open the clip described in step 5D and secure the
cable in the clip.
B. Locate the line on the display cable described in step 6D and tie the cable with the
wire tie near the bottom of the upright.
C. Open the wire holder at the junction, put the cable inside and close the wire holder.
Service
Page 7-37
Cybex Sport+ Treadmill Owner’s and Service Manual
D. Check to see that all of the connectors are connected firmly in their proper place.
E. Place the lower board shield in position and push the clips down. NOTE: The clips will
snap in.
8. Secure the left junction covers.
A. Using an Phillips screwdriver, tighten the three screws that hold the junction
covers in place.
9. 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.
10. Secure the console back.
A. While being sure not to pinch any cables, attach the 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. They are removed
and replaced the same on the Cybex Sport+ treadmill.
Tools Required
• Phillips head screwdriver
• ESD (Electro Static Discharge) grounding strap
• Razor blade
1. Disconnect the external power source.
A. Turn the main power switch on the left side to the off (O) position.
B. Unplug the treadmill from the power outlet.
2. Remove the console back.
A. Using a Phillips head screwdriver, remove the nine screws that hold the console back
to the console front.
B. Gently pull off the console back.
C. Loosen the six screws that hold the front console in place. NOTE: This allow clearance
for the switch membranes to fit behind the handrail.
NOTE: The display board is susceptible to damage from a discharge of static electricity. While
handling parts underneath the console cover use an ESD grounding strap. This
eliminates the potential voltage (static) difference between you and the equipment you
are working on. Wear an ESD strap for the rest of this procedure.
Service
Page 7-38
Cybex Sport+ Treadmill Owner’s and Service Manual
3. Remove the display overlay.
A. While wearing an ESD strap, disconnect the switch membranes (two upper and one
lower) from the display board. See Figure 19.
B. Use a razor blade to peel up a corner of the display overlay and pull off the overlay.
4. Attach the display overlay.
A. Remove the paper backing from the new display overlay.
B. Slide the ribbon cable through the (upper two or lower one) slot.
C. Carefully place the display overlay in position within the indentation on the console
front and firmly rub the display overlay so that it adheres to the console.
D. Route the ribbon cables under the frame tubes and connect them to the display
board.
5. Secure the console covers.
A. Using a Phillips head screwdriver, tighten the six screws that hold the console front
to the frame.
B. 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.
Service
Page 7-39
Cybex Sport+ Treadmill Owner’s and Service Manual
Parts List
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
21
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
40
41
42
43
44
45
46
47
48
48
49
50
51
52
52
53
54
55
56
57
Service
Page 7-40
PART NO.
AF-16240
HS-16929
HS-16950
HS-16939
PL-16256
PL-16465
PL-16464
HW-13799
AX-16721
HX-16706
HX-16707
HS-15682
AX-18118
AX-18119
AF-17677
AX-16722
DE-16705
HS-16875
EH-10291
EH-00986
PL-16737
AW-17273
AW-17272
AW-17274
PL-16738
DE-16992
Removed
PC-16496
PC-16497
HX-15678
EH-16809
HX-14416
DE-16928
HW-00590
HX-13771
HX-16510
FS-16511
HS-16509
HS-15480
HB-16367
HW-10028
HX-11049
AX-16723
AF-17591
AF-16382
HS-60022
CW-16712
HN-60064
DE-17144
HS-60021
HS-60023
MR-16412
MR-16541
SK-17079
FT-16825
FT-16826
EC-15783
EC-16948
HS-15732
HW-10856
HN-11925
PL-17052-4
HX-16943
DESCRIPTION
Frame, Weldment
Screw, 3-8-16 x 5-8Lg H x HD whiz-lock GR5
Screw, 5-16-18 x 7-8Lg H x Soc BTNHD w/patch, B-Zn
Screw, SEM 10-32 x .75 Pnhd Ext blk Zn
Cover, Motor
Cover, Upright Outer, Right
Cover, Upright Outer, Left
Washer, Flat
Deck Stiffener Assy
Tape Strip, 1.88 x 41.0 x .010thk
Tape Strip, 1.32 x 4.30 x .010thk
Screw, 5/16-18 x .50 FLHD Phil undercut ZN
Side Extrusion Assy, Cybex Sport+, Right
Side Extrusion Assy, Cybex Sport+, Left
Upright Weldment (Choose a Standard or Custom Color)
Top Platform Assy, (Choose a Standard or Custom Color)
Decal, Safety-walk
Screw, SEM ext 1-4-20 x 1-2 PNHD Phil
Anchor, Cable Tie
Cable Tie, (without anchor)
Plug, Power Cord Grommet
Power Cord 220V 60Hz (NOT SHOWN)
Power Cord 230V 50Hz (NOT SHOWN)
Power Cord 115V 60Hz (NOT SHOWN)
Plug, Power Cord Grommet
Decal, ETL UL-1647 Only
End Cap, Left, (Choose a Standard or Custom Color)
End Cap, Right, (Choose a Standard or Custom Color)
Bushing Deck 5/16-18 40 lb max shear 185 max comp
Grommet, 1.12 x .091-.125 nylon
Clip, Cable Retainer
Label, Disconnect Power, Multi-languages
Bushing Nylon 1-2” Nf810-5-0
Ring, Retain 5-8” .579 Fr.Id
Foot, Rubber, Rear
Plate, Rear Rubber Foot Mount
Screw, #10 x .5LG,T-S PLT, PNHD,TYB-B
Bolt, Tap 1/2-13unc x 6 H x HD GR5
Bushing, .50ID x .62OD x .31LG, flanged
Washer, B 1-2 Narrow Zinc
Spring 1" O.D.360 Max Ld.
Rear Roller Hardware Assembly
Nut Holder Bracket
Elevation, Weldment
Bolt, Hhcs 0.375 x 2.25 blk zn G5
Wheel, Rubber, 3" Dia
Nut, Jam 3-8”-16 blk zn
Decal, International only, (specify language)
Bolt, Hhcs 0.375 x 2 blk zn G5
Bolt, Hhcs 0.375 x 2.5 blk zn G5
Motor, Elevation 115 VAC
Motor, Elevation 230 VAC
Tube Nut, Motor, Elevation Kit
Sleeve, Elevation Mounting, Top
Sleeve, Elevation Mounting, Bottom
Filter, Line 20 Amp Spade
Filter, Power Line 20 Amp 20EQ1
Screw, SEM 8-32 unc x .62 PNHD phil pl
Washer, (for ground)
Nut, Keps 10-32 Hex Stl Zinc
Cover, Lower Controller English
Clip, Christmas Tree, Single Head
Cybex Sport+ Treadmill Owner’s and Service Manual
ITEM
NO.
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
100
101
101
102
103
104
105
107
108
109
110
111
112
113
114
115
116
117
118
119
120
PART NO.
SK-17253
SK-17252
SK-17251
DE-16608-4
DE-16610-4
DE-16609-4
DE-19198
DE-17691-4
DE-18100-4
DE-18135-4
EH-16977
AW-17704
HW-40004
AX-17762
HS-16849
HW-00165
Removed
HB-16426
HX-16425
FT-16352
AW-16830
HW-10772
HW-10761
HS-00156
AF-17792
SK-17246
SK-17245
DE-16542
FM-16463
HX-11593
HW-16966
HW-00180
HS-15757
PC-16379
PC-16380
PC-16328
PC-16327
DK-16932
BD-16853
HW-00431
HS-16628
AL-16245-1
AL-16235-1
BD-16829
PL-17659
DE-17712
AC-18125-4
PL-17658
SW-17212-4
SW-17187-4
AX-16944
PL-17686
AD-16560
AD-18130
FS-16841
AD-17690
EC-17763
AW-17707
AF-17684
SK-17827
HX-17788
HX-15499
HX-16931
HS-10716
EH-00472
HX-17696
DESCRIPTION
Lower Control Assy, 115V
Lower Control Assy, 230V
Lower Control Assy, 230V 50Hz, International use only
Brush Replacement Gauge, English
Label, Error Codes, English
Label, Service Schedule English
Decal, Logo
Label, User Precautions, 15 x 1.3”
Label, Start Instructions, Profiles, English
Label, HR Zone, English
Fan, Drive Motor, Leeson
Motor Ground Wire
Washer, Wavy
Motor Base Plate Assy
Screw, 5-16-18 x 2.0LG H x HD,GR5,Tap
Washer, Lock Ex 5-16 Zinc
Bushing, Flanged,1.0ID x 1.12OD x .75LG
Ring, Retaining Ext Crescent
Shaft, Motor Mount
Cable, Opto Sensor, Armored
Washer, Flat No. 4
Washer, Lock Ex No.6 Zinc
Screw, 4-40 x 0.62 Pnhd Phil
Clamp, Motor Drive (includes nut)
Motor, 3.0 Hp 110v, PMDC 3500RPM GR
Motor, 3.0 Hp 220v, PMDC 3500RPM WH
Disc, Speed Sensor
Flywheel, Drive Pulley Machined
Key, Ansi Square 3-16 x 1 3-16
Washer, Flat .280 x 1.0 x .125 Steel, Zinc
Washer, Lock Split 1/4
Bolt, Tap 1/4-28 x 1.0 H x HD PLTD
Cover, Junction Outer, Right, (Choose a Standard or Custom Color)
Cover, Junction Inner, Right, (Choose a Standard or Custom Color)
Cover, Junction Inner, Left, (Choose a Standard or Custom Color)
Cover, Junction Outer, Left, (Choose a Standard or Custom Color)
Deck, Plywood 23.3 x 51.5 x 1.0 (Double Sided)
Belt, Running, 20.63 x 58 Commercial
Washer, 1-4 x .75 x .062 Zinc
Screw, .25-20 x 1.5 Hxhd Grade 8
Roller, Front Assy
Roller, Rear Assy
Drive, Belt, 8 Rib
Console, Back, Plastic
Decal, Logo, Cybex Intl, 9 x 7”
Entire Console, Cybex Sport+, English
Front Console, Plastic
Switch Membrane, Cybex Sport+ Top, English
Switch Membrane, Cybex Sport+ Bottom, English
Lanyard, E-stop Assembly
Tab, Bookholder
PCA, Handset Display with w/o Heart Rate
PCA, Cybex Sport+ Display Board, 4 Layer
Mount, E-stop Magnet
PCA, CSAFE Port Board, W-TVS
PCA Salutron Serial Output
Cable, CHR to display with ferrite
Handrail, Weldment
Kit, Assembly, Contact Heart Rate Grip, Pair
Double-sided Tape
Grip Handlebar
Clamp, Cable, 5-16 dia Standard
Screw 4-40 x 0.38 PNHD Phil
Wire Tie Ty-23M
Clamp, Cable 5-8 Dia.
Service
Page 7-41
Cybex Sport+ Treadmill Owner’s and Service Manual
ITEM
NO.
121
122
123
124
125
126
127
128
129
130
PART NO.
HS-16940
FS-16990
SW-10523
HS-41187
HS-15706
HX-17711
ET-17165
DE-16784
DE-17714
HX-17822
DESCRIPTION
Screw, Sems 10-32 x 3-8 PNHD ext, BL ZN
Plate, Switch, Power On-Off
Switch, On-Off
Screw, 8-16 x 5-16 Plastite
Screw, 8-16 x .50 PNHD STL BLK Phil
Plug, Hole Plastic 7-16 Black
Tab, Faston .250 Series AMP, International Only
Decal, Side Stripe
Decal, Cybex, Side
O-Ring
NS LT-18115-4
Owner’s and Service, Manual Cybex Sport+, English
NS LT-17718
Poster, Assembly
NS LT-18129
Warranty Sheet, Cybex Sport+, Pink
NS HX-00438
Hex Key 3-16"
NS EH-16954
Cap, Motor Brush Access, Round
NS EH-16955
Cover, Motor Brush Access
NS SK-17269
Brush Kit, Pair, High Voltage, 2.5 and 3.0hp Leeson Motor
NS CK-18942
Handrail Extension Kit, Left and Right - Complete kit with instructions
NS CK-19088
Handrail Extension Kit, Left Only - Complete kit with instructions
NS CK-19089
Handrail Extension Kit, Right Only - Complete kit with instructions
NS HS-16921
Bolt, 5/8-11 x 4.75, Black Zinc - Bottom hardware
NS AX-16273
Clamp Assy, Handrail Ext.
NS HX-16852
Grip, Handrail Extension
NS HS-16935
Screw, Set 1-2 13 x 1-2, Knurl pt - Top Hardware
NS FT-16278
Spacer, Handrail Ext - Bottom hardware
NS AW-16572
Jumper, Switch-Filter, White
NS AW-16938
Jumper, Switch-Filter, Black
NS AW-16578
Jumper, Filter-cntl, White
NS AW-16579
Jumper, Filter-cntl, Black
NS AW-16561
Cable, Univ. Tread Display
NS AW-17706
Cable, Contact HR Grip
NS AW-17732
Cable, 4” Ribbon C-SAFE
NS DE-18101
Cybex Sport+ Decal for Side Extrusions
NS CN-10418
Connector, Molex (Placeholder)
NOTE: NS = Not Shown
Service
Page 7-42
114
127
Cybex Sport+ Treadmill Owner’s and Service Manual
Page 7-43
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)
N/C < 16%
LINE
AW-17163 (INTL)
BLK
WHT
INTERNAL
MAX ELEV.
SWITCH
NEUTRAL
AW-17164 (INTL)
GND
NEUT
LINE
UP
OPTICAL SPEED SENSOR CABLE
AW-16830
J3
RPM SIGNAL
GND
A2 (BLK)
AD-17214 CONTROL BOARD 115V
AD-17215 CONTROL BOARD 230V
(DT9) AC ON
(DT1) DOWN
ARM VOLT
(DT13) UP
PWM
M.C. SIG
(DT5) DC VOLTAGE
CURR LIMIT
-15V BOARD PWR
P1
1
CATHODE GREEN
EMITTER BLUE
OPTO
TACH
1
2
4
P2
6
4
3
1
5
3
2
5
P2
6
1
2
3
4
8
6
4
5
FLEXTAIL 'A'
7
5
3
2
6
7
n/c
n/c
n/c
n/c
n/c
ROW 2 SWITCH
ROW 4 SWITCH
COL 1 SWITCH
COL 3 SWITCH
8
FLEXTAIL 'B'
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
FERRITE EC-15004
(INTERNATIONAL ONLY)
WHT / RED
2
3
n/c
n/c
n/c
n/c
ROW 1 SWITCH
ROW 3 SWITCH
n/c
COL 2 SWITCH
COL 4 SWITCH
SEE NOTE 1
4
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S13
S14
1
WHITE
WHT / YLW
WHT / ORG
GRAY
BLUE
GREEN
ORANGE
YELLOW
WHT / BLK
VIOLET
CONSOLE CABLE
AW-16561
(-)
BROWN
1
BLACK
BLACK
RED
YELLOW
P1
(+)
COLLECTOR WHITE
DISPLAY CONNECTORS
RED
A1 (RED)
BW
GND
DIAGNOSTIC LEDS
ANODE ORANGE
S
LINE
20A / 250V / SB (115V)
15A / 250V / SB (220/240V)
1
8
2
7
3
6
4
5
1
4
2
3
2
P-TACH
3
1
CHASSIS
GND
N/C
B+
TXD
RXD
N/C
N/C
E
3A
5V +
4
J1
ELEVATION
AC
LINE 2
AC
LINE 1
ELEV
1 CD CARRIER DETECT
2 RD RECEIVE DATA
3 TD TRANSMIT DATA
4 DTR DATA TERMINAL READY
5 GND
6 DSR DATA SET READY
7 RTS REQUEST TO SEND
8 CTS CLEAR TO SEND
9 RI RING DETECT
8
8
9
J102
7
7
8
GRAY
BROWN
YELLOW
GREEN
RED
BLACK
ORANGE
BLUE
5
6
6
MR-16412 ELEV. MOTOR 115V
MR-16541 ELEV. MOTOR 220V
7
4
5
5
6
3
4
ELEV NEUTRAL
4
2
3
ELEV DWN
3
1
2
ELEV UP
2
ADAPTER, SERVICE PROGRAMMING
CN-16924
1
CHASSIS GROUND
1
DWN
CSAFE CONNECTOR
ZERO SWITCH
AW-17113
(WHT)
TREADMILL
CHASSIS
CA-16813
10uF, 370VAC
CAPACITOR
COM
INTERNAL
ZERO
SWITCH
GND REF
INTERNATIONAL ONLY
GREEN (GREEN / YELLOW)
ELV-MOTOR
N/C < 0%
TR-16814 (x2)
5mH CHOKE
AW-17112
(BLK)
BLACK (BROWN)
AW-16578 (WHT)
WHITE (BLUE)
DOMESTIC ONLY
POWER SWITCH
SW-10523
AW-16579 (BLK)
THERMAL
AX-16812
POWER FACTOR
CORRECTION
ASSY
2
PCA, CSAFE DUAL PORT
EC-17690
CSAFE CABLE
2
1
6
5
8
7
P3
7
+9v REG
ELEV. UP
REF. GND
CIRCUIT GND
E-STOP
ELEV. DOWN
5
8
+5V
3
1
6
J3
CHR SYSTEM
7
GND
8
+5V
6
SIG
4
1
2
3
AD-18130
J2
ASSY. SINGLE-COLOR DISP. BOARD
4
SHIELD
ROW 1 LED
ROW 3 LED
ROW 5 LED
COL 2 LED
ROW 2 SWITCH
ROW 4 SWITCH
COL 1 SWITCH
COL 3 SWITCH
1
2
3
4
5
6
7
8
9
SHIELD
ROW 2 LED
ROW 4 LED
COL 1 LED
ROW 1 SWITCH
ROW 3 SWITCH
ROW 5 SWITCH
COL 2 SWITCH
COL 4 SWITCH
1
2
3
4
5
6
7
8
9
B
SHIELD
ROW 1
ROW 2
ROW 3
COL 1
COL 2
1
2
3
4
5
6
C
A
SWITCH, SPORT TOP MEMBRANE
SW-17212
STOP
GND
+5V
SIG
GND (BLACK)
+5V (RED)
S12
3
Zero Switch
4
2
J8
GND REF.
+12v UNREG
1
1
1
1
6
5
PWM
GND
SPEED SIGNAL
2
FLASH
4
3
Brush Wear
3
RXD 1
Motor Current
6
5
4
TXD 1
1
7
6
5
7
6
5
4
4
3
2
2
7
3
4
3
8
5
3
3
1
R
B+
6
5
4
3
2
1
2
3
2
1
3
2
REF.
P8
3
RJ45
J1 (OUTSIDE)
ELEV. UP
AD-16560 DISPLAY, HANDSET W/O WHR
ELEV. DN
SPEED UP
SIG (GREEN)
1
6
5
4
3
2
RED
1
CABLE,CHR GRIP
1
CTS
2
BLACK
L
4
2
3
AW-17706
REF.
2
1
RED
GND
2
SHIELD
BLACK
RXD 1
FLASH
N/C
FLASH
RXD 1
TXD 1
B+
CTS
GND
CHASSIS
PCA, SALUTRON SERIAL OUTPUT
EC-17763
CHASSIS
GND
N/C
B+
TXD 2
RXD 2
N/C
N/C
TXD 1
J6
1
RIGHT
5
B+
RJ45
J3 (INSIDE)
LEFT
6
CTS
MR-16634 3.0Hp 220V VDC
2
7
TXD 2
6
5
AW-17732
J2
MR-16633 3.0Hp 110V VDC
4
3
AW-17707
CABLE, CHR TO DISPLAY
FLEXTAIL 'C'
E-STOP
SPEED DN
E-STOP MAGNET
SHIELD (NOT USED)
ROW 1 SWITCH
ROW 2 SWITCH
ROW 3 SWITCH
COL 1 SWITCH
COL 2 SWITCH
1
2
3
4
5
6
START
X
SCALE
BOTTOM SWITCH MEMBRANE
E-STOP KEY
Page 7-44
Cybex Sport+ Schematic
SW-17187
Cybex Sport+ Treadmill Owner’s and Service Manual
10 Trotter Drive Medway, MA 02053 • 508-533-4300 • FAX 508-533-5183
www.cybexinternational.com • Techhelp@cybexintl.com • techpubs@cybexintl.com
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