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Cybex Treadmill Pro+ Service Manual

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

8. Cybex Pro+ Treadmill Service Manual Page iv This page intentionally left blank.

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15. Safety Page 1-7 Cybex Pro+ Treadmill Service Manual Caution Decals Caution decals indicate a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. There are no caution decals used on the Cybex Pro+ treadmill. However, there is a caution in the installation instructions for initial installation only. See below.

14. Safety Page 1-6 Cybex Pro+ Treadmill Service Manual

3. 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 obligatio n to notify any person of such revisions or changes. © 2008, Cybex International, Inc. All rights reserved. Printed in United States of America. 10 Trotter Drive Medway, MA 02053 • 888-462-9239 • 508-533-4300 • FAX 508-533-5183 www.cybexinternational.com • [email protected] • LT-21649-4 A • October 2008 Cybex Pro+ Treadmill Service Manual Cardiovascular Systems Part Number LT-21649-4 A

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29. Cybex Pro+ Treadmill Service Manual Service Page 4-1 4 - Service Warnings/Cautions All warnings and cautions listed in this chapter are as follows: ! WARNING: All maintenance activities shall be performed by quali fi ed personnel. Failure to do so could result in serious injury. ! CAUTION: Use only Cybex replacement parts when servicing. Failure to do so could result in personal injury. ! WARNING: Disconnect the power cord before beginning this procedure. ! 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.

7. Front Pages About this Manual . . . . . . . . . . . . . . . . . . i FCC Compliance Information . . . . . . . . . i Table of Contents . . . . . . . . . . . . . . . . . iii 1 Safety Important Voltage Information . . . . . . . 1-1 Grounding Instructions. . . . . . . . . . . . . 1-1 Important Safety Instructions . . . . . . . . 1-2 Warning Decals . . . . . . . . . . . . . . . . . . 1-4 Caution Decals. . . . . . . . . . . . . . . . . . . 1-7 Emergency Stop Key (e-stop) . . . . . . . 1-8 2 Preventive Maintenance Warnings/Cautions. . . . . . . . . . . . . . . . 2-1 Regular Maintenance Activities . . . . . . 2-1 Cleaning Your Treadmill . . . . . . . . . . . 2-2 Running Belt Maintenance. . . . . . . . . . 2-3 Other Preventive Maintenance . . . . . . 2-6 Service Schedule . . . . . . . . . . . . . . . . . 2-7 3 Customer Service Contacting Service. . . . . . . . . . . . . . . . 3-1 Serial Number and Voltage . . . . . . . . . 3-1 Return Material Authorization (RMA). . 3-2 Damaged Parts . . . . . . . . . . . . . . . . . . 3-3 Ordering Parts . . . . . . . . . . . . . . . . . . . 3-4 Table of Contents 4 Service Warnings/Cautions. . . . . . . . . . . . . . . . 4-1 Test Mode . . . . . . . . . . . . . . . . . . . . . . 4-2 LED Functions . . . . . . . . . . . . . . . . . . . 4-3 Key Functions . . . . . . . . . . . . . . . . . . . 4-3 Error Codes . . . . . . . . . . . . . . . . . . . . . 4-4 Motor Current and Voltage . . . . . . . . . 4-5 Speed Sensor Adjustment . . . . . . . . . . 4-6 IR Compensation . . . . . . . . . . . . . . . . . 4-8 Speed Calibration . . . . . . . . . . . . . . . . 4-9 Running Belt and Deck . . . . . . . . . . . 4-10 Rear Roller. . . . . . . . . . . . . . . . . . . . . 4-11 Front Roller . . . . . . . . . . . . . . . . . . . . 4-13 Drive Belt . . . . . . . . . . . . . . . . . . . . . . 4-13 Drive Motor . . . . . . . . . . . . . . . . . . . . 4-15 Motor Brushes . . . . . . . . . . . . . . . . . . 4-17 Elevation Motor . . . . . . . . . . . . . . . . . 4-21 Lower Control Board . . . . . . . . . . . . . 4-23 Power Cord . . . . . . . . . . . . . . . . . . . . 4-25 Power Switch . . . . . . . . . . . . . . . . . . . 4-26 Line Filter . . . . . . . . . . . . . . . . . . . . . . 4-27 Upper Display Board . . . . . . . . . . . . . 4-28 Contact Heart Rate Board . . . . . . . . . 4-30 Contact Heart Rate Grips . . . . . . . . . 4-31 CSAFE Board . . . . . . . . . . . . . . . . . . 4-32 Display Cable. . . . . . . . . . . . . . . . . . . 4-33 Display Overlays . . . . . . . . . . . . . . . . 4-36 Parts List . . . . . . . . . . . . . . . . . . . . . . 4-38 Exploded View . . . . . . . . . . . . . . . . . . 4-41 Schematic . . . . . . . . . . . . . . . . . . . . . 4-42 Page iii

28. Cybex Pro+ Treadmill Service Manual Customer Service Page 3-4 Ordering Parts Fax orders to 508-533-5183 . To speak with a customer service representative, call 888-462-9239 (for customers living within the USA) or 508-533-4300 (for customers outside the USA). Use only Cybex replacement parts when servicing. Failure to do so could result in personal injury. Cybex will void warranty if non-Cybex replacement parts are used. CAUTION

66. Cybex Pro+ Treadmill Service Manual Service Page 4-38 Parts List ITEM QTY. PART NO. DESCRIPTION 1 1 SK-19500 Frame, Weldment 2 14 HS-16929 Screw, 3/8 - 16 x 5/8”, Lg H x HD Whiz-lock, GR5 3 6 HS-16950 Screw, 5/16 - 18 x 7/8”, Lg H x Soc BTNHD w/patch, B-Zn 4 6 HS-19454 Screw, SEMS, 10-32 X 1.0”, PNHD, BLK ZN, EXT 5 1 AX-16724-X Motor Cover assembly* 6 1 PL-16465 Cover, Upright Outer, Right 7 1 PL-16464 Cover, Upright Outer, Left 8 2 HW-19634 Washer, Flat, .344 ID X 1.0 OD X .125”, Thick, Zinc 9 8 HS-16939 Screw, SEM 10-32 x .75”, Pnhd Ext blk Zn 12 2 HS-21379 Screw, 1/4 - 20 X .50”, FLHD PHIL, Undercut, ZN 13 1 AX-17765 Side Extrusion Assy, Cybex Pro+, Right 14 1 AX-17767 Side Extrusion Assy, Cybex Pro+, Left 15 1 AF-17677 Upright Weldment (Choose a Standard or Custom Color) 16 2 AX-17829 Top Platform Assy, (Choose a Standard or Custom Color) 17 2 DE-16705 Decal, Safety-walk 18 5 HS-16875 Screw, SEM ext 1/4 - 20 x 1/2”, PNHD Phil 19 8 EH-10291 Anchor, Cable Tie 20 11 EH-00986 Cable Tie, (without anchor) 21 1 PL-16737 Grommet, Power Cord 22 1 PL-16738 Plug, Power Cord 23 1 DE-16992 Decal, ETL UL-1647 Only 24 1 DE-14486 Decal, Serial Number 25 1 SCK-16496 End Cap, Left, (Choose a Standard or Custom Color) 26 1 SCK-16497 End Cap, Right, (Choose a Standard or Custom Color) 27 2 HX-19991 Bumper, Deck, 2.10 X 2.34 X 1.55” 28 1 EH-16809 Grommet, 1.12 X .091 - .125”, Nylon 29 2 AF-17591 Nut Holder Bracket 30 1 DE-20427 Label, Disconnect Power, Multi- languages 31 2 HW-00590 Bushing Nylon 1/2” Nf810-5-0 32 6 HX-13771 Ring, Retain 5/8” .579 Fr.Id 33 2 HX-16510 Foot, Rubber, Rear 34 4 FS-16511 Plate, Rear Rubber Foot Mount 35 8 HS-16509 Screw, #10 x .5LG, T-SPLT, PNHD, TYB-B 36 2 HS-15480 Bolt, Tap 1/2-13unc x 6 H x HD GR5 37 2 HB-16367 Bushing, .50ID x .62OD x .31LG, flanged 38 4 HW-10028 Washer, B 1-2 Narrow Zinc 39 2 HX-11049 Spring 1” O.D.360 Max Ld. 40 1 AX-16723 Rear Roller Hardware Assembly 41 1 AF-16382 Elevation, Weldment 42 2 HS-60022 Bolt, Hhcs 0.375 x 2.25 blk zn G5 43 2 CW-16712 Wheel, Rubber, 3” Dia 44 2 HN-17935 Nut, Lock, 3/8 - 24, GRD C, STL, ZN 45 1 DE-17144-X Decal, International only* 46 1 HS-17936 Bolt, 3/8 - 24 X 2.0”, HXHD CAP, G8, YEL ZN 47 1 HS-17937 Bolt, 3/8 - 24 X 2.75”, HXHD CAP, G8, YEL ZN ITEM QTY. PART NO. DESCRIPTION 48 1 MR-16412 Motor, Elevation, 115 VAC 48 1 MR-16541 Motor, Elevation, 230 VAC 49 1 SK-17079 Tube Nut, Motor, Elevation Kit 50 1 FT-16825 Sleeve, Elevation Mounting, Top 51 1 FT-16826 Sleeve, Elevation Mounting, Bottom 53 6 HS-15732 Screw, SEM 8-32 unc x .62”, PNHD phil pl 54 1 HW-10856 Washer, (for ground) 55 1 HN-11925 Nut, Keps 10-32 Hex Stl Zinc 56 1 PL-17052-X Cover, Lower Controller* 57 3 HX-16943 Clip, Christmas Tree, Single Head 58 1 AX-16835 Lower Controller Assembly, 115 VAC 58 1 AX-16836 Lower Controller Assembly, 220 VAC 59 1 DE-16608-X Label, Brush Replacement Gauge* 60 1 DE-16610-X Label, Error Codes* 61 1 DE-16609-X Label, Service Schedule* 62 1 DE-19531 Decal, IS3 63 1 DE-17691-X Label, User Precautions, 15 x 1.3”* 64 1 DE-17693-X Label, Start Instructions, Profiles* 65 1 DE-18135-X Label, HR Zone, Heart Icons* 65 1 SW-18194-4 Membrane, A/V, All languages 67 2 HX-14416 Clip, Cable Retainer 68 1 HW-40004 Washer, Wave 69 1 AX-18883 Motor Base Plate Assy 70 2 HS-16849 Screw, 5/16 - 18 x 2.0”, LG HXHD, GR5, Tap 71 2 HW-00165 Washer, Lock Ex 5-16 Zinc 73 2 HB-16426 Bushing, Flanged,1.0ID x 1.12OD x .75LG 74 6 HX-16425 Ring, Retaining Ext Crescent 75 1 FT-16352 Shaft, Motor Mount 76 1 EC-19647 Speed Sensor 80 2 AF-19605 Clamp, Motor Drive (includes nut) 81 1 AX-19636 Drive Motor, 3.0HP, 110 VDC, McMillan 81 1 AX-19637 Drive Motor, 3.0HP, 220 VDC, McMillan 88 1 SCK-16379 Cover, Junction Outer, Right, (Choose a Standard or Custom 89 1 SCK-16380 Cover, Junction Inner, Right, (Choose a Standard or Custom Color) 90 1 SCK-16328 Cover, Junction Inner, Left, (Choose a Standard or Custom Color) 91 1 SCK-16327 Cover, Junction Outer, Left, (Choose a Standard or Custom Color) 92 1 DK-16932 Deck, Plywood 23.3 x 51.5 x 1.0”, (Double Sided) 93 1 BD-17026 Belt, Running, 20.63 x 60”, Commercial 94 10 HW-00431 Washer, 1/4 x .75 x .062”, Zinc 95 10 HS-16628 Screw, .25-20 x 1.5”, Hxhd Grade 8 96 1 AL-19035 Roller, Front Assy 97 1 AL-19036 Roller, Rear Assy 98 1 BD-16829 Drive, Belt, 8 Rib 99 1 PL-17659 Console, Back, Plastic 100 1 DE-17712 Decal, Logo, Cybex Intl, 9 x 7” 101 1 PL-17658 Front Console, Plastic 102 1 SW-18304-X Membrane, Pro+, Top* 103 1 SW-18305-X Membrane, Pro+, Bottom* 104 1 AX-20943 Lanyard, E-stop Assembly

25. Cybex Pro+ Treadmill Service Manual Customer Service Page 3-1 3 - Customer Service Contacting Service Hours of phone service are Monday through Friday from 8:30 a.m. to 6:00 p.m. Eastern Standard Time. For Cybex customers living in the USA, contact Cybex Customer Service at 888-462-9239 . For Cybex customers living outside the USA, contact Cybex Customer Service at 508-533-4300 or fax 508-533-5183 . Find information on the web at www.cybexinternational.com or by e-mail at [email protected] Serial Number and Voltage Your serial number and voltage can be found on the front of your treadmill. See Figure 1. For your convenience record your serial number and voltage below so that you will have it ready if you call Cybex Customer Service. Serial Number Voltage Serial Number Figure 1

27. Cybex Pro+ Treadmill Service Manual Customer Service Page 3-3 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 fi ling 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 fi ling a concealed damage claim. Concealed damage is the carrier's responsibility.

67. Cybex Pro+ Treadmill Service Manual Service Page 4-39 ITEM QTY. PART NO. DESCRIPTION 105 2 PL-17686 Tab, Bookholder 106 1 HX-16931 Clamp, Cable, 5-16 dia Standard 107 1 AD-16559 PCA, Pro+, Lower Display, English 107 1 AD-16559-Q PCA, Pro+, Lower Display, International 108 1 SK-17171 PCA, Pro+, Upper Display, English 108 1 AD-18199-Q PCA, Pro+, Upper Display, International 110 1 AD-19366 PCA, CSAFE Port Board, W-TVS 111 1 EC-17763 PCA Salutron Serial Output 112 1 AW-17707 Cable, CHR to display with ferrite 113 1 AF-17684 Handrail, Weldment 116 2 HX-15499 Grip Handlebar 118 6 HS-10716 Screw 4-40 x 0.38 PNHD Phil 119 4 EH-00472 Wire Tie Ty-23M 120 1 FS-16841 Mount, E-stop Magnet 121 2 HS-16940 Screw, Sems 10-32 x 3/8”, PNHD ext, BL ZN 122 1 FS-16990 Plate, Switch, Power On-Off 123 1 SW-10523 Switch, On-Off 124 12 HS-41187 Screw, 8/16 x 5/16”, Plastite 125 17 HS-15706 Screw, 8/16 x .50”, PNHD STL BLK Phil 126 1 HX-17711 Plug, Hole Plastic 7-16 Black 127 1 HX-19040 Clamp, Cable, 3/4” Diameter 128 1 HX-17697 Tape, Double Sided, Die Cut, .062”, Thick 129 1 HX-16842 Magnet, E-stop 130 2 AX-19669 Grip, Heartrate Grip, Top 131 2 AX-19670 Grip, Heartrate Grip, Bottom 132 2 PL-20360 Endcap, Heartrate Grip 133 4 HS-20306 Screw, 6 - 20 X 1.12”, PNHD PHIL 134 1 AX-16812 Power Factor Correction Assembly 135 1 AX-21397 Assembly, Deck Stiffener, Pivot, Left 136 1 AX-21396 Assembly, Deck Stiffener, Pivot, Right 137 2 HS-19108 Screw, 5/16 - 18 X 34”, LG, HXHD, Whiz-lock, GR5 138 1 FM-19439 Shaft, Deck Pivot 139 2 HN-20041 Nut, 1/4 - 20, Propeller, .305” OD 140 2 HW-20044 Washer, Belleville, 15 X 8.2 X 1.0 MM, .5MM Thick 141 2 HS-18358 Bolt, 5/16 - 18 X .1.25”, SCHD CAP, BLK ZN 142 1 DE-19451 Decal, WEEE Symbol 143 2 DE-17714 Decal, Cybex, 13.8 X 2.2” 144 1 DE-16784 Decal, Side Stripe 145 2 DE-17713 Cybex Pro+ Decal for Side Extrusions 146 2 HN-60064 Nut, Jam 3-8”-16 blk zn 147 1 EC-15004 Ferrite, Clamp-on, .40” ID 200 1 AF-20678 Bracket, SLANT Mount,TV Arm 201 1 CP-20665 Monitor, CYBEX, 15” SECAM/PAL 201 1 CP-20794 Monitor, CYBEX, 15” ASTC 202 1 HX-20032 Cap, Domed, Plastic 203 2 PL-20015 Cap, Black 204 3 FT-19980 Tube, Spacer, .375 Dia , .28” Wall 205 1 HS-20036 Screw, 5/16-18 x 1.50”, ScHd, Stl, Zn 206 2 HS-41107 Bolt, 5/16-18 x 1.50”, Bh, SS, Bl 207 2 HX-20782 Bushing, T- Type,Rubber, Ring Mount, Vibration Isolator 208 8 HW-20779 Washer, Flat, 1.44 x .325”, SS 209 6 HX-20778 Bushing,Rubber, Ring Mount, Vibration Isolator 210 1 HW-53018 Washer, 5/16”, Split ITEM QTY. PART NO. DESCRIPTION 211 4 HS-20731 Screw, M4x10 ScHd Stl, Blk 212 4 HW-21285 Washer, Lock, M4 Zn 213 4 HW-20214 Washer, Flat, M4 NS 1 AW-16561 Cable, Univ. Tread Display NS 1 AW-16572 Jumper, Switch-Filter, White, US NS 1 AW-16578 Jumper, Filter-cntl, White NS 1 AW-16579 Jumper, Filter-cntl, Black NS 1 AW-16638 Power Cord, 230 VAC, 50Hz NS 1 AW-16639 Power Cord, 220 VAC, 60Hz NS 1 AW-16640 Power Cord, 115 VAC, 60HZ NS 1 AW-16938 Jumper, Switch-Filter, Black, US NS 1 AW-17163 Jumper, Switch-Filter, Black, Intl. NS 1 AW-17164 Jumper, Switch-Filter, White. Intl. NS 1 AW-17694 Cable, Audio, 1/4” to 3.5mm, 18” NS 1 AW-17694 Cable & Audio Jack 1/4 in to 3.5 mm NS 1 AW-17706 Cable, Contact HR Grip NS 1 AW-17732 Cable, 4” Ribbon C-SAFE NS 1 AW-19117 Cable, 515T / 530T, A/V, I/O NS 1 AW-19502 Cable, AV Keypad Extension NS 1 AW-19502 Cable, Ribbon, AV Keypad Extension NS 1 AW-19523 Power Cord, 230 VAC, 50Hz, 13A, UK NS 1 AW-19648 Cable, Speed Sensor NS 1 AW-20111 Cable E5, RJ45 NS 1 AX-16273 Clamp Assy, Handrail Ext. NS 1 AX-16956 Kit, Install Hardware NS 0 AX-17174 Handrail Extension Kit, Left Only - Complete kit with instructions NS 0 AX-17175 Handrail Extension Kit, Right Only Complete kit with instructions NS 0 AX-17217 Handrail Extension Kit, Left and Right - Complete kit with instructions NS 1 CN-17687 Adapter, 1/4” Plug to 1/8” Jack NS 1 FT-16278 Handrail Extension, Spacer, Bottom hardware NS 1 HS-16921 Handrail Extension, Bolt, 5/8-11 x 4.75, Bottom hardware NS 2 HS-16935 Handrail Extension, Screw, Set 1/2 13 x 1/2”, Top Hardware NS 1 HX-00438 Allen Wrench, 3/16” NS 2 HX-16852 Handrail Extension, Grip NS 1 LT-03051 Sign, Facility Safety NS 1 LT-17718 Poster, Assembly NS 1 LT-21250 Product Registration Sheet NS 1 LT-17730-X Owner’s Manual, Cybex Pro+* NS 1 LT-17446 Warranty Sheet, Cybex Pro+, Pink NS 1 SK-17827 Kit, Assembly, Contact Heart Rate Grip, Pair NS 1 SK-18554 Brush Kit, Pair, 110 or 220 VDC, w/ spring clips NOTE: NS = Not Shown * Language Key 1-German 2-French 3-Spanish 4-English 6-Japanese 7-Swedish 8-Russian

12. Safety Page 1-4 Cybex Pro+ Treadmill Service Manual Ensure all User and Facility safety precautions are observed. • Carefully read and understand the following before using the Cybex Pro+ treadmill: • Warning Decals • Caution Decals • To replace any worn or damaged decals do one of the following: Fax orders to 508-533-5183 or contact Cybex Customer Service at 888-462-9239. If you live outside of the USA, call 508-533-4300. For location or part number of labels, see the parts list and exploded-view diagram. Warning Decals Warning decals indicate a potentially hazardous situation, which, if not avoided, could result in death or serious injury. The warning decals used on the Cybex Pro+ are shown below.

69. 7 25 18 22 23 26 18 16 16 93 92 95 94 2 2 96 98 81 76 80 56 58 1 28 123 44 44 51 50 46 47 122 74 68 69 42 43 146 43 42 2 75 74 73 73 74 73 41 146 62 61 59 60 70 71 8 48 49 97 40 5 55 20 147 19 30 24 9 20 54 45 57 134 9 21 121 20 19 35 32 27 137 31 67 139 140 141 12 137 34 33 34 35 144 145 143 53 14 138 142 136 135 13 32 6 36 38 37 39 29 17 17 116 116 201 200 202 207 208 207 204 208 213 212 211 209 203 206 209 210 205 208 204 AV Option 104 101 64 65 103 102 130 113 125 100 99 118 110 125 133 131 130 133 131 132 111 127 53 112 53 124 120 126 129 128 107 108 106 125 119 105 124 124 20 2 2 2 2 63 91 88 89 90 3 4 15 67 Cybex Pro+ Treadmill Service Manual Page 4-41

17. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-1 2 - Preventive Maintenance Warnings/Cautions All warnings and cautions listed in this chapter are as follows: ! WARNING: All maintenance activities shall be performed by quali fi ed 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 quali fi ed 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 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 888-462-9239 or 508-533-4300 for any preventive maintenance or service concerns.

40. Cybex Pro+ Treadmill Service Manual Service Page 4-12 7. Remove the deck. Using a 7/16” open-end or socket wrench, remove the ten screws and ten washers that hold the A. deck in place. See Figure 7. 8. Remove the deck stiffeners. Using a 1/2” Socket wrench, remove the two whiz-lock screws that secure the deck pivot shaft to A. the frame. See Figure 8. Figure 7 Screws (5 on Each Side) Washers (5 on Each Side) Running Deck Deck Support (1 on Each Side) Running Belt Figure 8 Flat Head Screw Bolt Washer Deck Bushing Propeller Nut Deck Pivot Shaft Retaining Ring Whiz-lock Screw Deck Stiffener, Left Deck Stiffener, Right Frame

70. 1 3 2 2 3 1 1 1 3 2 2 3 CN-17687 ADAPTER, 1/4"-1/8" AW-17694 CABLE, AUDIO 1/4" AW-19502 CABLE, AV KEYPAD EXTENSION VOL- SW3 VOL+ SW4 CH- SW2 AUX SW5 CH+ SW1 1 2 3 4 5 6 7 SW-18194 MEMBRANE, AV KEYPAD A/V MONITOR CP-19879 HA-20175 HEADPHONES AC POWER CONVERTER AW-20111 CABLE, 5E BONDED-PAIR RJ45 8 8 1 1 3 3 5 5 7 7 2 2 4 4 6 6 AW-19117 CABLE, A-V I-O POWER CORD, 250VAC, 3A POWER CORD, JAPAN WR-14012 (Ger. Sp. Swe.) CABLE, POWER CORD, 230V, 10A AW-20193 AW-20192 ROW 4 SWITCH COL 1 SWITCH ROW 2 SWITCH COL 3 SWITCH FLEXTAIL 'A' ROW 1 LED ROW 3 LED ROW 5 LED COL 2 LED SHIELD YELLOW 2 3 6 2 1 3 4 5 2 REF. 1 R 3 1 L 2 REF. 1 LEFT FRONT SIGNAL LEFT REAR SIGNAL SHIELD RIGHT REAR SIGNAL LEFT RIGHT FRONT SIGNAL RIGHT 3 RED BLACK E-STOP KEY SIG (GREEN) +5V (RED) GND (BLACK) 2 1 3 S N GND SIG VCC WIRELESS E-STOP 3 1 Brush Wear CHR SYSTEM SIG +5V 2 1 GND 3 J2 PWM SPEED SIGNAL Motor Current GND REF. +12v UNREG 5 4 4 3 1 2 2 5 6 6 2 ROW 1 LED AD-17105 PCA, 520-530T DISPLAY Zero Switch ELEV. UP REF. GND E-STOP CIRCUIT GND ELEV. DOWN 1 3 5 +9v REG +5V 7 3 ROW 4 LED COL 1 LED ROW 1 SWITCH COL 4 SWITCH COL 2 SWITCH ROW 5 SWITCH ROW 3 SWITCH 6 8 7 9 4 5 B ROW 5 LED ROW 3 LED COL 2 LED ROW 2 LED ROW 4 SWITCH ROW 2 SWITCH COL 3 SWITCH COL 1 SWITCH SHIELD 1 2 9 5 7 8 6 4 3 A 5 3 1 2 4 2 4 7 6 8 6 8 SHIELD 1 LINE 1 LINE 2 A1 (RED) A2 (BLK) BW LINE ELEV AC AC DISPLAY CONNECTORS AD-17215 CONTROL BOARD 230V AD-17214 CONTROL BOARD 115V J3 5 7 6 8 1 2 3 4 -15V BOARD PWR M.C. SIG CURR LIMIT PWM DIAGNOSTIC LEDS ARM VOLT (DT9) AC ON (DT13) UP (DT5) DC VOLTAGE (DT1) DOWN 4 4 2 1 3 2 1 3 5 6 5 6 ELEVATION 2 1 3 4 5 2 1 3 4 5 7 6 8 7 6 8 RPM SIGNAL GND GND TACH 3 4 2 5V + J1 1 G H TOP SWITCH MEMBRANE / EMBEDDED LEDs S8 S16 S4 5 S17 4 3 S5 S9 S18 S19 S6 S10 S7 S11 2 1 9 S13 1 S1 2 5 6 8 7 3 4 1 X S14 S2 2 S15 S3 3 4 I J S12 8 9 7 COL 2 SWITCH COL 4 SWITCH ROW 5 SWITCH FLEXTAIL 'B' 3 5 4 6 X 1 2 ROW 1 SWITCH ROW 3 SWITCH ROW 4 LED COL 1 LED ROW 2 LED SHIELD E C F A B SIG +5V GND WHITE WHT / YLW GRAY WHT / ORG BLUE GREEN ORANGE WHT / BLK RED VIOLET BLACK YELLOW BROWN WHT / RED J102 7 5 3 1 CSAFE CONNECTOR RED BROWN BLUE BLACK ORANGE GREEN YELLOW GRAY N/C RXD N/C 2 N/C GND TXD B+ 4 6 CHASSIS 8 1 2 3 4 5 6 7 8 9 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 ADAPTER, SERVICE PROGRAMMING P1 P2 P1 P2 CN-16924 20A / 250V / SB (115V) 15A / 250V / SB (220/240V) 3A ELV-MOTOR DWN COM UP GND 1 7 4 2 3 5 6 8 N/C < 0% GND REF ZERO SWITCH CHASSIS GROUND ELEV UP ELEV DWN ELEV NEUTRAL THERMAL INTERNAL ZERO SWITCH SWITCH MAX ELEV. INTERNAL N/C < 16% AW-17706 CABLE,CHR GRIP AW-17707 CABLE, CHR TO DISPLAY E-STOP MAGNET AD-16559 DISPLAY, HANDSET W/WHR J3 J8 P8 P3 PCA, SALUTRON SERIAL OUTPUT EC-17763 MR-16412 ELEV. MOTOR 115V MR-16541 ELEV. MOTOR 220V C 5 COL 1 COL 2 6 ROW 2 ROW 3 SHIELD ROW 1 2 3 4 1 ROW 1 SWITCH ROW 2 SWITCH COL 2 SWITCH COL 1 SWITCH ROW 3 SWITCH SHIELD (NOT USED) 2 3 4 6 5 1 START SPEED DN X ELEV. UP SPEED UP ELEV. DN STOP BOTTOM SWITCH MEMBRANE FLEXTAIL 'C' AW-16561 CONSOLE CABLE SW-18304 SW-18305 AW-16579 (BLK) AW-16578 (WHT) DOMESTIC ONLY NEUT LINE LINE FILTER LINE NEUTRAL (INTERNATIONAL ONLY) FERRITE EC-15004 ( - ) ( + ) INTERNATIONAL ONLY AW-17112 (BLK) CAPACITOR 10uF, 370VAC CA-16813 AW-17113 (WHT) AX-16812 TR-16814 (x2) 5mH CHOKE CORRECTION ASSY POWER FACTOR AW-16938 (DOM) AW-17163 (INTL) BLK WHT 15A INTERNATIONAL - EC-18896 (DSC1000-4-10-4.7) 20A DOMESTIC 220V - EC-19869 (RP220-20-4.7) 20A DOMESTIC 115V - EC-19869 (RP220-20-4.7) 109 - 125V 60 Hz (AW-16640 POWER CORD) 208 - 240V 60 Hz (AW-16639 POWER CORD) 208 - 240V 50 Hz (AW-16638 POWER CORD) AW-17164 (INTL) AW-16572 (DOM) CHASSIS TREADMILL POWER SWITCH SW-10523 BLACK (BROWN) WHITE (BLUE) GREEN (GREEN / YELLOW) . BLACK RED BLACK RED BLACK BLACK RED RED PCA, 530T DISPLAY AV AD-18199 CHASSIS CSAFE CABLE AW-17732 CSAFE CABLE AW-17732 J1 (OUTSIDE) RJ45 TXD 1 RXD 1 2 2 4 4 GND B+ CTS 6 6 1 1 3 3 5 5 7 7 8 8 1 3 2 5 4 6 6 4 5 2 3 1 RXD 1 FLASH FLASH RXD 1 GND GND TXD 1 TXD 1 B+ B+ CTS CTS 1 1 3 2 2 3 5 5 4 4 6 6 7 J2 J2 7 TXD 2 TXD 2 7 7 1 1 3 2 2 3 5 5 4 4 6 6 7 7 J6 J6 GND FLASH RXD 1 TXD 1 B+ CTS CTS B+ TXD 1 RXD 1 FLASH GND 1 1 3 2 2 3 5 5 4 4 6 6 TXD 2 AV TXD 2 AV 7 7 A/V 2 1 6 5 4 3 7 8 8 RJ45 J3 (INTERNAL) 1 1 2 2 4 4 6 6 3 3 5 5 7 7 1 1 3 3 2 2 AUDIO J4 3.5mm FOR ADAPTER USE ONLY CHASSIS GND B+ CTS TXD 1 RXD 1 AUDIO/FLASH AUDIO AUDIO/FLASH AUDIO AD-19366 CSAFE AUDIO PCA, CSAFE AUDIO ADAPTER AD-17690 (OLD) PCA, CSAFE ADAPTER AW-19648 OPTICAL SPEED SENSOR CABLE BLACK OPEN WHITE P-TACH 4 3 2 RED 1 RED WHITE BLACK 3 2 1 1 2 3 EC-19647 SPEED SENSOR OPTO 208 - 240V 50 Hz (AW-19523 POWER CORD) UK Page 4-42 Cybex Pro+ Treadmill Service Manual Cybex Pro+ Schematic

26. Cybex Pro+ Treadmill Service Manual Customer Service Page 3-2 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. 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.

5. Cybex Pro+ Treadmill Service Manual About This Manual An Owner’s Manual is shipped with each unit. To purchase additional copies of the Owner’s Manual or any other Cybex manual, please do one of the following: Fax orders to 508-533-5183 • Contact Cybex Customer Service at 888-462-9239 or 508-533-4300 • To contact Cybex with comments about this manual send an email to [email protected] FCC Compliance Information ! WARNING: Changes or modi fi cations 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

65. Cybex Pro+ Treadmill Service Manual Service Page 4-37 5. Secure the console covers. Using a Phillips screwdriver, tighten the six screws that hold the console front to the frame. A. While being sure not to pinch any cables, secure the console back to the console with the fi ve B. Phillips screws. 6. Test the new display overlay. Turn the main power switch to the on (I) position. A. Plug the treadmill into the power outlet. B. Try each key to be sure that it functions properly. C.

16. Safety Page 1-8 Cybex Pro+ Treadmill Service Manual Emergency Stop Key (e-stop) The e-stop key functions as the emergency stop. In an emergency situation, remove the e-stop key and the treadmill will come to a stop. Before using the treadmill, clip the e-stop key as described below. 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. 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.

62. Cybex Pro+ Treadmill Service Manual Service Page 4-34 Pull up on the lower board shield until the shield snaps out. A. Disconnect the display cable (P1 and P2) from the lower board. See Figure 27 . B. Disconnect the display cable (P3 and P8) from the upper display board. See Figure 27. C. Using a Phillips screwdriver, loosen the wire retaining screw that holds the display D. cable in place near the display board. Remove the cable from the wire ties at the junction and near the bottom of the upright. E. Figure 27 Shield Display Cable Screws (4) Screws (9) Screws (3) Left Junction Covers P3 and P8 Connectors on Upper Display Board Console Back Cover P1 and P2 on Lower Board Left Side Cover NOTE: “Right” and “left” denote user orientation. Access Hole Bottom Hole Wire Holder Upright

9. Safety Page 1-1 Cybex Pro+ Treadmill Service Manual 1- Safety IMPORTANT: Read all instructions and warnings before using the treadmill. Important Voltage Information Before plugging the power cord into an electrical outlet, verify that the voltage requirements for your area match the voltage of the treadmill that you have received. The power requirements for the Cybex Pro+ treadmill include a grounded, dedicated circuit, rated for one of the following: 115 VAC ±5%, 60 Hz and 20 amps; 208/220 VAC, 60 Hz, 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 equipment-grounding conductor can result in a risk of electric shock. Check with a quali fi ed electrician or service provider if you are in doubt as to whether the treadmill is properly grounded. Seek a quali fi ed electrician to perform any modi fi cations to the cord or plug. Cybex is not responsible for injuries or damages as a result of cord or plug modi fi cation. 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 con fi guration as the plug. Do not use a ground plug adapter to adapt the power cord to a non-grounded outlet. 115V Euro Plug 208/220V NEMA 5-20 CEE 7/7 NEMA 6-15

30. Cybex Pro+ Treadmill Service Manual Service Page 4-2 ! WARNING: All maintenance activities shall be performed by quali fi ed personnel. Failure to do so could result in serious injury. For any service related concerns, call Cybex Customer Service at 888-462-9239 (for Cybex customers living within the USA). For customers living outside the USA, call 508-533-4300 or fax 508-533-5183. 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 “PRO” and the software revision “rx.x” are shown 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. You may need to replace the upper and/or lower display overlay. See Figure 1. If “KEY#” is displayed you can determine which key is stuck closed by referring to the number list below. Upper Overlay Lower Overlay Figure 1 1 Stop 2 Incline Down 3 Speed Down 4 Weight 5 Distance 7 Heart Rate 8 Manual Up 9 Incline 10 Speed Up 11 Quick Start 12 Center Up 13 9 Holes 14 Level 15 Mets 16 5K 17 Enter 18 Cardio 19 Center Down 20 Calories 21 HR Control 22 Time 23 Scan 24 Age 25 Min Mi/Km 26 Weight Loss

57. Cybex Pro+ Treadmill Service Manual Service Page 4-29 3. Remove the display board. Disconnect these cables from the display board: the display cable (2 connectors), the two upper A. switch membranes, the lower switch membrane, the contact heart rate cable, the CSAFE board to display board jumper and the upper to lower board jumper. See Figure 23. Using a Phillips screwdriver, remove the six Phillips screws that hold the display board to the B. console. 4. Attach the display board. Place the display board in position on the front console. A. Using a Phillips screwdriver, secure the six screws that hold the display board to the console. B. 5. Connect the cables. Connect these cables into the display board: the display cable (2 connectors), the two upper A. switch membranes, the lower switch membrane, the contact heart rate cable, the CSAFE board to display board jumper and the upper to lower board jumper. See Figure 23. 6. Check the connections. Check to see that all of the cables are connected fi rmly in their proper place. A. CSAFE Board to Display Board Jumper Upper Display Board Lower Display Board Contact Heart Rate Port Lower Switch Membrane Upper to Lower Board Jumper Heart Rate Board Display Cable Ports Figure 23 RJ-45 Port Upper Switch Membrane Ports

32. Cybex Pro+ Treadmill Service Manual Service Page 4-4 Error Codes Error codes notify you of a problem condition and are displayed on the center of the console. These codes can also help to indicate the part of the treadmill most likely to be causing the problem. Errors that present a hazard to the user provide a measure of safety by causing a one second beep, stopping the treadmill and locking out operation of the treadmill. A log of errors can be viewed and cleared. Enter Test Mode and press the Pace (Min/km) key to display the log. The most recent error is always fi rst in the log. Press the Pace key again to cycle to the next the error stored. Up to 10 errors can be stored. Press the Scan key twice to clear the error log. Press Stop to exit Test Mode . NOTE: A processor upset can cause a bAd#. See H then G. Error Description bAd0 Bad checksum. See H then G. bAd2 Internal RAM error. See H then G. bAd3 Watchdog timeout. See H then G. Err1 Belt didn't start (or no speed sense). See I, E, D, B then A. Err2 Underspeed (2 mph for 2 seconds without correction in process). See I, E, C then B. Err3 Speed sense lost. See I, E, A, B and C. Err5 No 0 switch sense within timed limits. This is declared when the timed elevation reaches -2% without tripping the index. See F and A. Err6 Overspeed (1 mph for 1 second or 2 mph for 0.2 seconds without correction). See I, E. Err7 EEPROM error (memory lost, loads new defaults, enters Test Mode ). See G. Err9 Brush wear too low. Indicator has been activated for over 100 miles. See D. ErrE 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 Check lower board B Check drive motor C Check belt and deck D Check motor brushes E Check speed sensor F Check elevation motor G Replace display board H Turn the treadmill to the off (O) position and back on (I) I Perform speed calibration procedure

18. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-2 Cleaning Your Treadmill When cleaning your treadmill spray a mild cleaning agent, such as a water and dishsoap solution, on a clean cloth fi rst and then wipe the treadmill with the damp cloth. NOTE: Do not spray cleaning solution directly on the treadmill. Direct spraying could cause damage to the electronics and may void the warranty. ! 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 air fl ow can prevent adequate cooling that could shorten motor life. Cleaning this area should be done as often as indicated in the Service Schedule, more often in dusty environments. ! 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 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 fi nished. Lift the rear of the treadmill and roll it back from its present position so as to vacuum the fl oor area underneath the unit. Wipe clean the underside of the treadmill to prevent dirt and dust build-up. When fi nished, 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.

45. Cybex Pro+ Treadmill Service Manual Service Page 4-17 Using a 9/16” socket wrench with a 3” extension, insert the two screws that fasten the front roller B. 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. Using a 3/4” socket wrench, tighten each rear roller bolt evenly, making sure not to tighten either A. bolt too many turns before moving to the other bolt. NOTE: Do not overtighten the belt. Follow the Tension and Center the Belt procedure located in the Preventive Maintenance chapter. 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. 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 excessive motor brush wear. The treadmill will run 100 miles (161 kilometers) longer and then be inoperable until brushes are replaced. ! CAUTION: If the drive motor is warm wait until it is cool to the touch before proceeding. The inside components of the drive motor 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 9-13. If not, skip to step 14. ! WARNING: Wait until the armature LED is off before removing the motor brush covers. 9. Check the armature LED. Observe the “armature LED” on the lower board (labeled ILT4). A. After the armature LED goes off proceed to step 10. B.

13. Safety Page 1-5 Cybex Pro+ Treadmill Service Manual NOTE: This is the minimum recommended service. 1. Determine mileage. A. B. First 500 Miles A Check Running Belt Tension & Tracking. Every 5000 Miles A B C Every 10,000 Miles D E F G H I Ev ery 20,000 Miles J Service Schedule All maintenance activities shall be performed by qualified personnel. Failure to do so could result in serious injury. dist Date Mileage Service Initials DE-16609-4 Enter Test Mode by holding down any key while turning the treadmill to the on (I) position. Press (except on all Cybex Sport models). DIST appears on the display. Check Running Belt Tension & Tracking. Move Treadmill & Vacuum Underneath. Remove Motor Cover to Clean Underneath with a Dry Cloth & Vacuum. Replace Belt & Flip Deck. Check Motor Brushes & Replace If Needed. Check Current Draw. Measure Motor Voltage at Max Speed with No Load. Check Elevation Assembly & Replace Worn Parts. Lubricate Elevation Bushings. Replace Belt & Deck.

19. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-3 Figure 1 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 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. Use a 3/4” socket wrench to turn each bolt 1/2 turn clockwise. See Figure 1. A. NOTE: Be sure to adjust each bolt equally on each side. Turn the power on and press the B. Quick Start key. Press the C. Speed + - keys to bring the speed up to 3.5-4 mph (5.6-6.4 kph). Allow the treadmill to run for a minute. Observe the belt to be sure it stays centered. If it is not centered follow step 2. D. Walk on the treadmill at 3.5-4 mph (5.6-6.4 kph) and every 4th to 5th step throw your weight into E. 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. 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.

21. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-5 4. Remove the side panels. Pull each side panel out and off the treadmill. See Figure 3. A. 5. Remove the top steps. Using a Phillips screwdriver, remove A. the three screws that hold each top step in place. See Figure 4. Grasp each top step and lift it out and B. off the treadmill. See Figures 3 and 4. 6. Check the belt and deck condition. Look at the edges of the belt while A. you roll it by hand. If the belt has any rips or looks excessively worn the belt needs to be replaced. Run your hand under the belt on the top of the deck surface. If you feel excessive ridges or B. cracks, or if the deck feels grooved yet highly polished, the deck should be fl ipped to an unused surface or replaced. In time, a worn belt and deck can cause high current draw and ultimately, motor failure. NOTE: When replacing the deck, replace the belt at the same time. For instructions on replacing the belt and deck, see Running Belt and Deck in the Service chapter. 7. Clean under the belt. To minimize the effect of friction between the deck and the running belt, Cybex recommends A. 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. End Caps Side Panel Screws Figure 3 Side Panel Top Steps Figure 4 Screws (3 Under Each Top Step)

39. Cybex Pro+ Treadmill Service Manual Service Page 4-11 Figure 6 Rear Roller Bolt, Washers, Spring and Nut Holder NOTE: Keep the Hardware Together Rear Roller Side Panel Figure 5 Side Panel Top Steps Running Belt Screws (3 Under Each Top Step) 4. Remove the side panels. Pull each side panel out and off the treadmill. See Figure 5. A. 5. Remove the top steps. Using a Phillips screwdriver, remove the three screws that hold one of the top steps A. in place. Repeat this step for the other side. See Figure 5. Grasp each top step and slide it out and off the treadmill. See Figure 5. B. Rear Roller 6. Remove the rear roller. Using a 3/4” open end or socket wrench, loosen A. 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. While holding the rear roller, remove the hardware B. from each side. NOTE: Pivot the bolt, washers, spring and nut holder out together. See Figure 6. Lift one side of the rear roller and slide the roller C. out of the running belt. See Figure 6.

38. Cybex Pro+ Treadmill Service Manual Service Page 4-10 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 screwdriver • 7/16” Open end wrench • 3/4” Open end or 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. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen the three screws on each motor cover side A. (left and right). See Figure 2. Lift the motor cover center up and off the treadmill. B. NOTE: The screws will stay in place. See Figure 2. 3. Remove the end caps. Using a Phillips screwdriver, remove the screw that holds each end cap in place. A. See Figure 4. Figure 4 Screws End Caps

54. Cybex Pro+ Treadmill Service Manual Service Page 4-26 Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. B. Remove the left plastic side cover. C. 3. Remove the left end cap. Using a Phillips screwdriver, remove the screw that holds the left end cap in place. A. See Figure 4. 4. Remove the left side panel. Pull the left side panel out and off the treadmill. A. Power Switch 5. Remove the power switch. Observe the “armature LED” on the lower board (labeled ILT4). A. After the armature LED goes off proceed to step 3C. B. Using a Phillips screwdriver, remove the two screws that hold the switch and its plate C. to the treadmill. Disconnect the four fast-on connectors that go into the power switch. D. Using a 3/8” nutdriver, remove the one nut and one washer from the ground wire on the E. lower control bracket. 6. Remove the power cord. Remove the old power cord and discard the power cord (and power switch if applicable). A. See Figure 21. Figure 21 Shield Grommet Power Cord Power Switch Plate Wire Tie

20. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-4 2. Center the belt. NOTE: While centering the belt choose one bolt to adjust. Do not adjust both bolts. With the treadmill running at 5 mph (8 kph) observe the running belt. If the belt tracks off center to A. 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. After the belt has been centered, check the belt tension again. Make sure the running belt tension B. is tight enough so that the belt does not slip or hesitate when stepped on. Refer to step 1E. 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 screwdriver • Dry towel • 1. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three A. screws on each motor cover side (left and right). See Figure 2. Lift the motor cover up and off the treadmill. B. The screws will stay in place. See Figure 2. 3. Remove the end caps. Using a Phillips screwdriver, remove the A. screw that holds each end cap in place. See Figure 3. Motor Cover Screws (3 Each Side) Figure 2

52. Cybex Pro+ Treadmill Service Manual Service Page 4-24 4. Remove the line fi lter. Using a Phillips screwdriver, remove the two screws that hold the line fi lter to the lower control A. board bracket. NOTE: You should not need to disconnect the cables that are connected to the line fi lter. 5. Remove the lower control board bracket. Using a Phillips screwdriver, remove the four screws that hold the lower control bracket to the A. base. Remove the entire bracket with its lower board. B. NOTE: Cybex may want this part back for evaluation. Contact Cybex Customer Service at 888-462-9239. 6. Replace the lower control board and bracket. NOTE: Wear an ESD strap for the rest of this procedure. Position the lower control board bracket in place on the base. A. NOTE: The elevation motor connector and ground stud will be positioned toward the back left corner. Using a Phillips screwdriver, secure the four screws that hold the bracket to the base. B. 7. Connect the cables to the lower control board. Connect the cables to the lower control board. This includes: the elevation motor cable; display A. cable (P1 and P2); AC line 1 (black); AC line 2 (white); drive motor (black, red and yellow) and speed sensor cable. See Figure 20. Figure 20 Elevation Motor Cable Display Cable Speed Sensor Cable Line Filter Elevation Motor AC Line 1 AC Line 2 Lower Board Ground Wire Drive Motor Cable (Red, Black and Yellow)

59. Cybex Pro+ Treadmill Service Manual Service Page 4-31 Contact Heart Rate Grips Tools Required Phillips screwdriver • Needle nose pliers • Wire cutters • 5. Remove the old heart rate grips and cable. Using a Phillips screwdriver, remove A. the two screws from each lower grip. See Figure 25. Using a needle nose pliers, carefully B. disconnect the wire from each metal contact. Pull the grips and cap off each C. handrail. Using wire cutters, cut the four wire D. ties that hold the heart rate cable to the handrail. Pull the old heart rate cable out of the handrail. E. 6. Route the new heart rate cable. Connect the double connector into the right side of the A. heart rate board. See Figure 24. Locate the short and long side of the heart rate cable. B. Route the short cable end to the left (from treadmill C. user’s viewpoint) and the long end to the right. Place the cable behind the handrail and tie with four D. wire ties in the locations they were removed in step 5D. Fold the each cable and place it into the hole that leads E. to the grip. See Figure 26. Push each wire out a hole (red out the front hole and black out the back hole). See Figure 26. F. Figure 25 Cap Screws (2) Figure 26 NOTE: Front is from treadmill user’s viewpoint. Cable Enters Hole Red Wire (Front) Black Wire (Back) Upper Grip Lower Grip

46. Cybex Pro+ Treadmill Service Manual Service Page 4-18 10. Remove the drive motor brush access covers. Squeeze each of the two rectangular brush covers to remove it from the motor. See Figure 15. A. Lift off the round brush cover. See Figure 15. If necessary carefully pry the cover up using a fl at B. head screwdriver. 11. Remove the brushes. Using needle nose pliers, unplug the yellow brush wear indicator wire from the round access hole A. and the brush wire from the rectangular hole. Press each brush spring in and slowly pull it out. It will be spring loaded. B. 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. Pull each brush out from the drive motor. C. 12. Examine the brushes and commutator. Inspect the commutator by looking through the top brush holder into the motor. Slowly spin the A. motor by turning the fl ywheel. Look for noticeable damage and for signs of 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 fi t in the brush holder hole. Brush dust can be loosened from the brush holder area by lightly fi ling the surfaces. Inspect the brushes for signs of excessive wear or cracks. The motor brushes must be replaced if B. 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. 13. Replace the brushes. NOTE: If a new brush does not slide in and out easily, the edges or corners of the brush can be lightly fi led 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. Figure 15 Drive Motor Brush Access Cover Round Brush Cover

11. Safety Page 1-3 Cybex Pro+ Treadmill Service Manual DO NOT • operate electrically powered treadmills in damp or wet locations. Keep the running belt clean and dry at all times. • DO NOT • leave the treadmill unattended when plugged in and running. 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 quali fi ed 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, 79 inches (2.0 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 quali fi ed repair personnel when servicing. If you live in the USA, contact Cybex Customer Service at 888-462-9239. If you live outside the USA, contact Cybex Customer Service at 508-533-4300. 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.

44. Cybex Pro+ Treadmill Service Manual Service Page 4-16 Slip the drive belt around the fl ywheel pulley and off the B. motor. See Figure 14. 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. Observe the “armature LED” on the lower board (labeled A. ILT4). After the armature LED goes off proceed to step 5C. B. Pull up on the lower board shield. It will snap out. C. Disconnect the motor cables from the lower board. D. NOTE: You will disconnect three wires (red, black and yellow). See Figure 14. Remove the ferrite from the drive motor cables (International units only). E. Carefully remove the drive motor. F. 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). Using a 3/4” socket wrench, loosen each rear roller bolt 10-12 revolutions to release tension on A. the running belt. Using a 9/16” socket wrench with a 3” extension, remove the two front roller screws. See Figure 9. B. Tilt the left side of the front roller up and then the right side. C. If you are replacing the drive belt, slip the drive belt off the front roller pulley and discard it. D. 7. Attach the front roller. Slide the new drive belt around the front roller. A. Figure 13 Screws (Loosen) Nuts Figure 14 Lower Board Drive Motor Cable Line Filter Flywheel Pulley Drive Belt Red Yellow Black

37. Cybex Pro+ Treadmill Service Manual Service Page 4-9 Retest by walking on the belt and adjusting the IR COMP control until the running belt does not G. surge, vibrate or feel too slack. NOTE: You should not be able to stop the belt with your feet easily. Press H. Stop . Place the lower board shield into position (if applicable) and snap it in. I. 4. Secure the motor cover. Lower the motor cover into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. NOTE: Be sure the screws are catching the center motor cover's holes. Speed Calibration NOTE: This procedure is required after replacing the upper display board, the lower control board or the drive motor. If you’ve replaced the lower board, perform the IR Compensation procedure fi rst, then the Speed Calibration procedure. 1. Calibrate the speed. Stay off the running belt during this procedure. A. ! CAUTION: During this procedure STAY OFF THE RUNNING BELT! Stand with your feet on the two steps. In B. Test Mode press and hold the Quick Start key for three seconds. The display will show “CAL” then “SAV”, “CAL”. The running belt will accelerate and when completed the display will show “PRO”. 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.

22. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-6 8. Secure the top steps. Place each top step in position. See Figure 4. A. Using a Phillips screwdriver, tighten the three screws that hold each top step in place. See B. Figure 4. 9. Secure the end caps. Using a Phillips screwdriver, tighten the screw securing each end cap in place. See Figure 3. A. 10. Secure the side panels. Place each side panel into position slightly under the end cap and use your hand to A. push all along the bottom edge of the side panel to snap it in place. See Figure 3. 11. Secure the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. Be sure the B. screws are catching the center motor cover’s holes. Other Preventive Maintenance Other preventive maintenance activities must be completed by a quali fi ed 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. 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 humidi fi er. A worn running belt looses it’s ability to dissipate static electricity and should be replaced as needed.

10. Safety Page 1-2 Cybex Pro+ Treadmill Service Manual Important Safety Instructions (Save These Instructions) ! DANGER: To reduce the risk of electric shock, always unplug this treadmill from the electrical outlet immediately after using it and before cleaning it. ! WARNING: Serious injury could occur if these precautions are not observed. To reduce the risk of burns, fi res, electric shock, or injury: User Safety Precautions DO NOT • wear loose or dangling clothing while using the treadmill. Use the treadmill handrails for support and to maintain balance. • Stop exercising if you feel faint, dizzy, or experience pain at any time. • Obtain a medical exam before beginning any exercise program. • Read and understand emergency stop procedures. • Replace any warning labels if damaged, worn or illegible. • Report any malfunctions, damage or repairs to the facility. • Place your feet on the two top steps when starting or stopping the treadmill. • Stop and place the treadmill at 0 degrees incline (level) after each use. • Keep children away from the treadmill. Teenagers and disabled persons must be supervised • while using. Obtain instruction before using. • Keep all body parts, hair, towels, water bottles 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. (181 kg). This is the rated maximum user weight. 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. • Use a dedicated line when operating the treadmill. • Connect the treadmill to a properly grounded outlet only. •

36. Cybex Pro+ Treadmill Service Manual Service Page 4-8 IR Compensation NOTE: This procedure is required after replacing the lower control board or the drive motor. Tools Required Phillips screwdriver • Plastic (or non-conductive), fl at head screwdriver • 1. Please read instructions thoroughly before performing this procedure. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). See A. Figure 2. Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. B. 3. Perform the IR compensation procedure. Enter A. 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 “PRO” and the software revision “rx.x” are shown on the display. While standing on the side rails, press B. 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. Hold on to the handrails as you step on the running belt, begin walking and notice how the belt C. feels, (the belt may surge, vibrate or slack). NOTE: If the belt doesn't need to be adjusted skip to step 4A. Pull up on the lower board shield. It will snap out. D. 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. Locate the control called “IR COMP” on the lower board. E. NOTE: DO NOT use a metal screwdriver. DO NOT adjust the other two controls that look identical to the IR COMP control. Using a plastic small fl at head screwdriver, turn the IR control slightly in one direction as follows: F. • Turn clockwise to remove the slack from the belt • Turn counter-clockwise to remove the vibration or surging from the belt

35. Cybex Pro+ Treadmill Service Manual Service Page 4-7 Using a 7/16” Open end wrench, tighten the mounting nut that attaches the speed sensor bracket to B. the drive motor. See Figure 3. Ensure that the gap between the speed sensor and drive motor fan is even on both sides. See C. Figure 3. 5. Test for speed errors. Connect the power cord to a power outlet. A. Enter B. Test Mode. Bring the speed of the treadmill up to maximum speed, 12.4 mph (20 kph). C. After reaching maximum speed take note of the actual speed that is displayed in the lower left D. window. If it fl uctuates in over 0.5 mph increments then your speed sensor gap needs to be inspected. Slowly adjust the speed down to 1.0 MPH (1.0 KPH). E. Press F. Stop and turn the power switch to the off (O) position. Enter G. Test Mode again and check the error log for Error 3. If Error 3 occurred readjust the speed sensor and test again. NOTE: If you are unsure whether an error is new you can clear the error log by pressing the Scan key and then repeat steps 4A through 5F. Exit H. Test Mode by pressing Stop . 6. Attach the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. Gap Speed Sensor Drive Motor Fan Figure 3 Sensor Bracket Mounting Nut Speed Sensor Bracket Drive Motor Fan Mounting Nut

48. Cybex Pro+ Treadmill Service Manual Service Page 4-20 17. Align the drive belt. Con fi rm that the drive belt fi lls all grooves in the drive motor fl ywheel pulley and there are open A. grooves on the inside of the front roller. See Figure 11. NOTE: Failure to align the drive belt could cause squeaking. 18. Connect the motor cables. Connect the motor cable to the lower board as shown in Figure 14 (red to A1, black to A2, yellow A. to BW). Using a 1/2” socket wrench, tighten both screws on the motor saddle. B. Using wire ties, tie the motor C. cable to the base so that no wires get pinched. See Figure 17. 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 17) in between the wire ties. Refer to the lower board shield D. to con fi rm the locations for the connectors and check to see that all of the cables are connected fi rmly. See Figure 18. Place the lower board shield in E. position and push the clips down. NOTE: The clips will snap in. See Figure 18. Figure 17 Tie Cables Away from Fan Fan Wire Ties NOTE: The ferrite is for internationally installed motors. Ferrite Figure 18 PL-17052-4 Lower Board Shield Clips (3)

64. Cybex Pro+ Treadmill Service Manual Service Page 4-36 Display Overlays NOTE: This procedure will cover the upper and/or lower display overlay. They are removed and replaced the same on the Cybex Pro+ treadmill. Tools Required Phillips screwdriver • ESD (Electro Static Discharge) grounding strap • Razor blade • 1. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the console back. Using a Phillips screwdriver, remove the nine screws that hold the console back to the console A. front. Gently pull off the console back. B. Loosen the six screws that hold the front console in place. C. NOTE: This allows clearance for the switch membranes to fi t 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. 3. Remove the display overlay. While wearing an ESD strap, disconnect the switch membranes (two upper and one lower) A. from the display board. See Figure 23. Use a razor blade to peel up a corner of the display overlay and pull off the overlay. B. 4. Attach the display overlay. Remove the paper backing from the new display overlay. A. Slide the ribbon cable through the (upper two or lower one) slot. B. Carefully place the display overlay in position within the indentation on the console front and fi rmly C. rub the display overlay so that it adheres to the console. Route the ribbon cables under the frame tubes and connect them to the display board. D.

51. Cybex Pro+ Treadmill Service Manual Service Page 4-23 Carefully remove the wooden blocks from under the front end assembly. This will load the B. elevation assembly. Lower the elevation to zero percent. C. Stop the treadmill and turn the main power switch in the front panel to the off (O) position. D. 8. Secure the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. NOTE: Be sure the screws are catching the center motor cover’s holes. Lower Control Board NOTE: You will remove and replace the entire lower bracket in this procedure. Tools Required Phillips 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. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). See A. Figure 2. Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. B. 3. Disconnect the cables from the lower control board and bracket. Observe the “armature LED” on the lower board (labeled ILT4). A. After the armature LED goes off proceed to step 3C. B. Pull up on the lower board shield. It will snap out. C. Disconnect the cables from the lower control board. This includes: the elevation motor cable; D. display cable (P1 and P2); AC line 1 (black); AC line 2 (white); drive motor (black, red and yellow) and speed sensor cable. Using a 3/8” nutdriver or socket wrench, remove the one nut and one washer from the ground E. wire on the lower control bracket.

56. Cybex Pro+ Treadmill Service Manual Service Page 4-28 Connect these two power cord cables to the power switch: B. 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. Connect the line fi lter fast-ons to the power switch. C. The white cable connects to the bottom right switch fast-on. • The black cable connects to the bottom left switch fast-on • With the ground wire through the access hole to the lower control bracket, put the ground D. wire terminal on the stud on the lower board bracket. Using a 3/8” nutdriver, secure the one nut and one washer over the ground wire terminal. E. Using a Phillips screwdriver, secure the switch plate to the treadmill with the I (on) F. toward the top. Upper Display Board Tools Required Phillips screwdriver • ESD (Electro Static Discharge) grounding strap • 1. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 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. Using a Phillips screwdriver, remove the nine screws that hold the console back to the console A. front. Gently pull off the console back. B.

47. Cybex Pro+ Treadmill Service Manual Service Page 4-19 Locate the brush with the two wires and slide it into the motor brush holder (located nearest the A. round access hole). Locate the brush with the one wire and slide it into the motor brush holder on the opposite side. B. Place a spring clip under each brush and push in and down. The spring hooks will grasp on to C. the end of the brush holder. Using needle nose pliers, plug the yellow brush wear indicator wire onto the fast-on inside the D. round access hole. Using needle nose pliers, plug each brush wire onto the fast-on inside the rectangular access E. hole. 14. Secure the drive motor access panels. Squeeze each rectangular brush covers, insert it into the holes and then release. A. Push the round brush cover into its hole until it is fl ush with the motor. B. 15. Align the drive motor. Carefully lower the drive motor in position on the motor saddle. A. Turn the motor so the exit cable is positioned at a 3 o’clock angle toward the front roller. See B. Figure 16. Using a straight-edge (such as the lower board shield), line up the face of the fl ywheel pulley with C. the face of the front roller pulley until they are fl ush. See Figure 11. NOTE: Do not put the drive belt on until step 17A. 16. Secure the motor straps. NOTE: Tighten motor strap to 80 in-lbs. Loop each strap through the motor saddle A. and position each screw vertically as shown in Figure 16. NOTE: The motor strap will be creased slightly where it pressed against the motor saddle, be sure the strap is in its original position. Close each motor strap and use a 7/16” wrench B. with a deep socket to tighten each nut securely (80 in-lbs). See Figure 16. Figure 16 Motor Strap Screws (Position Vertically) Motor Saddle Nuts Motor Exit Wire (Position at 3 O’clock)

61. Cybex Pro+ Treadmill Service Manual Service Page 4-33 Gently push the CSAFE connector into its port on the display board. See Figure 23. A. Using a Phillips screwdriver, secure the CSAFE board with the three screws removed B. during step 3B. NOTE: Do not overtighten. 5. Secure the console back. While being sure not to pinch any cables, use a Phillips screwdriver to secure the nine screws A. that hold the console back to the console front. Display Cable Tools Required Phillips 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. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 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. Using a Phillips screwdriver, remove the nine screws that hold the console back to the console A. front. Gently pull off the console back. B. 3. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). See A. Figure 2. Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. B. 4. Remove the left junction covers. Using a Phillips screwdriver, remove the three screws that hold the left junction A. 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.

58. Cybex Pro+ Treadmill Service Manual Service Page 4-30 7. Secure the console back. While being sure not to pinch any cables, use a Phillips screwdriver to secure the A. nine screws that hold the back cover to the console front. 8. Calibrate speed. Follow the A. 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 screwdriver • ESD (Electro Static Discharge) grounding strap • 1. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 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. Using a Phillips screwdriver, remove the nine screws that hold the console back to the console A. front. Gently pull off the console back. B. 3. Remove the heart rate board. Using a Phillips screwdriver, remove the three screws from the heart rate board. A. If you’re not replacing the cable, disconnect the two cables and one molex placeholder from the B. heart rate board. (You will re-attach the molex connector in step 4A). See Figure 24. 4. Attach the new heart rate board. Locate the side of the heart rate A. board with the two holes and place the molex placeholder over the top three pins. See Figure 24. Viewing from the front of the unit, B. place the heart rate board in position with the two holes to the left and, using a Phillips 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. Figure 24 Molex Placeholder (Top) Heart Rate to Display Board Connector (Bottom) Double Connector (Right)

23. Cybex Pro+ Treadmill Service Manual Preventive Maintenance Page 2-7 Service Schedule All maintenance activities shall be performed by quali fi ed personnel. Failure to do so could result in serious injury. NOTE: This is the minimum recommended service. 1. Determine mileage. While in A. Dormant Mode enter Test Mode by holding down any key while turning the treadmill to the on (I) position. Press the B. DIST button to display “DIST” and miles or kilometers will be displayed. Record Mileage. C. NOTE: To exit Test Mode, press the Stop key . First 500 miles (800 km). Check running belt tension and tracking. • Every 5,000 miles (8,000 km). Check running belt tension and tracking. • Move treadmill and vacuum underneath. • Remove motor cover to clean underneath with a dry cloth and vacuum. • Every 10,000 miles (16,090 km). Replace running belt and fl ip deck. • Check motor brushes and replace if needed. • Check current draw. • Measure motor voltage at max speed with no load. • Check elevation assembly and replace worn parts. • Lubricate elevation pivot points. • Every 20,000 miles (32,180 km). Replace running belt and deck. •

49. Cybex Pro+ Treadmill Service Manual Service Page 4-21 19. Secure the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. NOTE: Be sure the screws are catching the center motor cover's holes. 20. Perform the appropriate procedures. If you loosened the tension on the running belt (step 6A) follow the A. Tension and Center the Belt procedure located in the Preventive Maintenance chapter. If you replaced the motor follow the B. IR Compensation procedure located in this chapter. Follow the C. Speed Calibration procedure located in this chapter (required). Elevation Motor Tools Required Phillips 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. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). See A. Figure 2. Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. B. 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. While two people are lifting the front of the treadmill, have a third person place a wooden block A. 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.

60. Cybex Pro+ Treadmill Service Manual Service Page 4-32 7. Install the new heart rate grips. Using the needle nose pliers, carefully connect the heart rate wire to each grip. A. NOTE: Ensure that the red heart rate wire is connected to the top grip and the black heart rate wire is connected to the bottom grip. See Figures 25 and 26. Place the top grips, bottom grips and cap in the correct position on the handrail. See Figure 25. B. Using a Phillips screwdriver, install the two screws securing the bottom grips. See C. Figure 25. 9. Connect the cables removed in step 3A. Con fi rm that the two cables and one molex placeholder are fi rmly connected to the heart A. rate board in their proper places. See Figure 24. 10. Secure the console back. While being sure not to pinch any cables, use a Phillips screwdriver to secure the nine screws A. that hold the console back to the console front. 11. Connect the external power source. Plug the treadmill into the power outlet. A. 12. Calibrate speed (if you replaced the display board). Follow the A. Speed Calibration procedure located in this chapter. CSAFE Board Tools Required Phillips screwdriver • 1. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the console back. NOTE: If you have a cable plugged into the RJ-45 port disconnect it. Using a Phillips screwdriver, remove the nine screws that hold the console back to the console A. front. Gently pull off the console back. B. 3. Remove the old CSAFE board. Pull the CSAFE connector out of the display board. See Figure 23. A. Using a Phillips screwdriver, remove the three screws that hold the CSAFE board to the console. B. 4. Attach the new CSAFE board.

55. Cybex Pro+ Treadmill Service Manual Service Page 4-27 Line Filter NOTE: If you are replacing the line fi lter follow steps 7 and 8. If not skip to step 9. 7. Replace the line fi lter (optional). Disconnect the two fast-ons that go from the line fi lter to the lower board (cables labeled A. AC Line 1 and AC Line 2 on the lower board). Using a Phillips screwdriver, remove the two screws that hold the line fi lter to the lower control B. bracket and discard the old line fi lter if applicable. Place the new line fi lter in position on the lower control bracket. C. Using a Phillips screwdriver, secure the two screws that hold the line fi lter to the lower control D. bracket. 8. Connect the line fi lter cables (if applicable). Connect the white cable to the front right fast-on on the line fi lter and route it through the A. access hole. Connect the black cable to the front left fast-on on the line fi lter and route it through the B. access hole. Connect the ends of these two cables to the lower board. The white connects to the fast-on C. labeled AC Line 1. The black connects to the fast-on labeled AC Line 2. 9. Route the power cord. Route the power cord behind the base brackets and route the fast-ons out the power switch A. 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. Hold the power switch and its plate so that the I (on) is toward the top. See Figure 22. A. Figure 22 Shown From Front of Switch with “I” Toward the Top Access Hole Power Cord Behind Base Brackets Black White Brown Blue

43. Cybex Pro+ Treadmill Service Manual Service Page 4-15 20. Secure the end caps. Using a Phillips screwdriver, tighten the screw that holds each end cap in place. See A. Figure 4. 21. Secure the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. NOTE: Be sure the screws are catching the center motor cover’s holes. 22. Adjust the running belt tension and tracking. Follow the A. 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 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. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). A. See Figure 2. Lift the motor cover center up and off the treadmill. The screws will stay in place. See Figure 2. B. 3. Release the drive belt tension. Using a 1/2” socket wrench, loosen (but do not remove) the two screws on the motor saddle. See A. Figure 13. NOTE: The tension is now released. 4. Remove the old drive motor. Using 7/16” open end wrench, remove the nut on each motor strap and remove the motor straps A. from the motor saddle. See Figure 13.

33. Cybex Pro+ Treadmill Service Manual Service Page 4-5 Motor Current and Voltage Motor current draw and motor voltage must be checked by a quali fi ed 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 motor cover of each Cybex Pro+ treadmill. By performing these procedures you can evaluate the performance of your drive motor and help prevent premature failure. Tools Required Phillips screwdriver • Voltage meter • 1. Measure current draw. Enter A. Test Mode by holding down any key on the display while turning the power switch to the on (I) position. Press the B. Quick Start key. The belt will move at 1 mph (1.0 kph). Without standing on the belt, bring the speed of the treadmill up to 3 mph (4.8 kph), Press the C. METs key and take note of the load value in the top center display. Have a second person walk on the belt at 3 mph (4.8 kph) and take note of the load value in the D. top center display and the weight of the person. NOTE: Call Cybex Customer Service to con fi rm that the load is within acceptable range. Loads over 200 are generally unacceptable. Press E. Stop to exit Test Mode . 2. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 3. Remove the motor cover. Using a Phillips screwdriver, loosen A. three screws on each motor cover side (left and right). See Figure 2. Lift the motor cover center up and B. off the treadmill. The screws will stay in place. 4. Check the belt and deck condition. Follow the A. Checking Belt and Deck Surfaces procedure on page 4-4 of the Preventive Maintenance chapter of this manual and then proceed with step 5. Figure 2 Screws (3 on Each Side) Motor Cover

31. Cybex Pro+ Treadmill Service Manual Service Page 4-3 LED Functions LEDs are used to indicate the status of many of the treadmill inputs. After entering Test Mode refer to the following list to check that these LEDs are functioning properly: Heart LED – Blinks on with every signal from the contact heart rate receiver. Weight LED – Blinks on when CSAFE data is being received. Level LED – Blinks on when CSAFE data is being transmitted. Lower Left Window – The numbers indicate actual elevation. A '-' sign indicates the treadmill is below 0% grade. The decimal point before the numbers shows the activation of the 0% switch in the elevation motor (on above 0%). If dashes are shown in the display, the treadmill is either above or below the 0% switch, requiring it to be manually run through the switch to begin indicating actual elevation. The right most decimal point indicates the status of the E-stop relay, on when the E-stop relay is on, off when it is deactivated. NOTE: The right most decimal point may be dif fi cult to see. Lean your head to the left to see this. Lower Right Window – The numbers indicate actual belt speed. The right most decimal point indicates the pulses from the speed sensor on the motor. 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). Also will run calibration if held for 3 seconds. Heart Rate Program key – Lights all of the LEDs for a short period of time. Weight Loss key – Lights only the columns. 9 Holes key – Lights only the rows. Incline  – Run elevation motor up. Incline  – Run elevation motor down. Speed + – Increase drive motor speed. Speed - – Decrease drive motor speed. Distance – Press once for odometer information (DST) to appear in the speed window. Press again for hourmeter information (HRS) to appear in the speed window. Press three times for number of starts information (USES) to appear in the speed window. Press four times for brush wear mileage up to 100 miles since activated or “0” if it has not been activated (BRSH). Min Mi/Km – Displays and cycles through error log. Up to 10 errors can be stored. Scan – Clears error log when pressed twice while in error log mode. Mets – Value of motor load in A/D counts. The number range is relative to motor current and goes from 0-225. (LOAD). Calories – Displays motor pulse width (PWM) value. Enter – Required to save setup values.

41. Cybex Pro+ Treadmill Service Manual Service Page 4-13 Using a Phillips screwdriver, remove the fl at head screw securing each deck stiffener to the deck B. bushing. See fi gure 8. 9. Inspect the deck bushings. Inspect the deck bushings under the deck stiffeners for cracks or wear. A. NOTE: Replace the rubber mounts if the rubber is cracked or worn. Using a Phillips screwdriver, secure each deck stiffener with the fl at head screws removed in step B. 8B. Using a 1/2” Socket wrench, install the two whiz-lock screws that secure the deck pivot shaft to C. the frame. See Figure 8. Front Roller 10. Remove the front roller. Place a 9/16” socket wrench with a 3” extension in A. the left front roller access hole. Remove the left front roller screw. See Figure 9. Place a 9/16” socket wrench with a 3” extension in B. the right front roller access hole. Remove the right front roller screw. Slide the drive belt off of the front roller and remove C. the front roller. 11. Remove the running deck and running belt. Lift one side of the deck and slide it out of the A. running belt. Drive Belt NOTE: If you are replacing the drive belt follow steps 12-13 and 15. If not, skip to step 14. See the Drive Motor procedure for an alternative way to change the drive belt. 12. Release the drive belt tension. Using a 1/2” socket wrench, loosen but do not remove A. the two screws on the motor saddle. See Figure 10. 13. Remove the drive belt. If you are changing the drive belt, slip the drive belt A. around the fl ywheel pulley and off the motor. See Figure 10. Slide the new drive belt around the fl ywheel pulley. B. NOTE: There will be some slack in the drive belt until step 15 is complete. Figure 10 Motor Saddle Screws Drive Belt Flywheel Pulley Figure 9 Screw Front Roller Access Hole

50. Cybex Pro+ Treadmill Service Manual Service Page 4-22 4. Disconnect the elevation motor cable. ! WARNING: Do not touch components on the lower board. A charge can remain after unplugging the power cord and turning off the treadmill. Pull up on the lower board shield. It will snap out. A. Disconnect the elevation motor cable from the lower board and remove it from the wire tie. B. 5. Remove the elevation motor. Using a 9/16” open end wrench and a 9/16” socket wrench, remove the two bolts on the A. 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. Carefully lift and remove the elevation motor from the treadmill. B. 6. Secure and Calibrate the elevation motor. Carefully place the elevation motor in A. position on the treadmill. See Figure 19. Slide the upper bolt into the frame and B. elevation motor and thread the nut onto the top bolt. See Figure 19. NOTE: When viewing from the front of the unit the top bolt goes from the right to the left. Using a 9/16” open end wrench and a 9/16” C. socket wrench, securely tighten the top mounting bolt and nut. Connect the elevation motor cable to the D. lower board. NOTE: The board is labeled P3 at the elevation port. The connector can only fit in one direction. Connect the main power cord into the E. power outlet and turn the power switch on (I). NOTE: Wait for the elevation tube to turn and fi nd the zero switch. Once the motor stops, turn the tube with your F. fi ngers until it measures 12.517” (31.8 cm) from the center of the top hole to the center of the bottom hole. See Figure 19. Slide the bottom mounting bolt into the frame and elevation tube. G. See Figure 19. NOTE: When viewing from the front of the unit the bottom bolt goes from the left to the right. Using a 9/16” open end wrench and a 9/16” socket wrench, securely tighten the lower mounting H. nut and bolt. Place the lower board shield in position and push the clips down. I. NOTE: The clips will snap in. Tie the elevation cable with the tie from step 4B so that it is clear of the motor fan. Be sure no wires J. get pinched. 7. Test the elevation motor. Start the treadmill in A. Manual Mode and raise the elevation to 6%. Figure 19 Bolts Nuts 12.517” (31.8 cm) Tube Frame Elevation Motor

63. Cybex Pro+ Treadmill Service Manual Service Page 4-35 Using wire cutters, cut the cable at its center near the junction and pull both ends out of the F. 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. Connect the display cable (P3 and P8) to the A. upper display board. See Figure 27. Locate the P1 and P2 end of the display B. cable. See Figure 28. Push the P2 connector down into the top C. handrail hole with the P1 connector pointing up. See Figure 28. Push the display cable down through the D. handrail and out the handrail’s bottom hole. NOTE: Twisting the cable as you push will help it go through. Push the display cable down through the E. 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. Route the cable into the access hole. F. Connect the display cable to the lower control board at P1 and P2. G. 7. Secure the cable. Using a Phillips screwdriver, open the clip described in step 5D and secure the cable in A. the clip. Locate the line on the display cable described in step 6D and tie the cable with the wire tie B. near the bottom of the upright. Open the wire holder at the junction, put the cable inside and close the wire holder. C. Check to see that all of the connectors are connected fi rmly in their proper place. D. Place the lower board shield in position and push the clips down. E. NOTE: The clips will snap in. 8. Secure the left junction covers. Using a Phillips screwdriver, tighten the three screws that hold the junction covers in place. A. 9. Secure the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. NOTE: Be sure the screws are catching the center motor cover’s holes. 10. Secure the console back. While being sure not to pinch any cables, attach the console back to the console front with A. the fi ve Phillips screws. Figure 28 Large P2 Connector Down Small P1 Connector Up

34. Cybex Pro+ Treadmill Service Manual Service Page 4-6 5. Check the motor voltage. Plug the treadmill back in and turn it to the on (I) position. A. Enter B. Test Mode. Without standing on the belt, Bring the speed of the treadmill up to maximum speed, C. 12.4 mph (20 kph). Using a voltage meter, contact the meter’s red lead to the connector of the motor’s red lead and the D. meter’s black lead to the motor’s black lead on the lower board. Note the reading on the voltage meter then carefully remove both leads. Call Cybex Customer E. Service to fi nd out if the reading is within an acceptable range. Exit F. Test Mode by pressing Stop . 6. Attach the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. B. Speed Sensor Adjustment Tools Required Phillips screwdriver • 1/4” Socket wrench • 7/16” Open end wrench • ! WARNING: Disconnect the power cord before beginning this procedure. 1. Disconnect the external power source. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). A. Lift the motor cover center up and off the treadmill. B. NOTE: The screws will stay in place. 3. Visually inspect the drive motor fan. Turn the fl ywheel slowly and look for dirt or damage to the drive motor fan. A. NOTE: If the drive motor fan or speed sensor is dusty use a soft dry cloth to wipe off the dust. Using a 1/4” Socket wrench, tighten the mounting screw that attaches the drive motor fan to the A. drive motor shaft. See Figure 3. 4. Visually inspect the speed sensor. Inspect the speed sensor and look for dirt or damage to the speed sensor or speed sensor A. mounting bracket. NOTE: If the speed sensor is dusty use a soft dry cloth to wipe off the dust.

53. Cybex Pro+ Treadmill Service Manual Service Page 4-25 Put the ground wire terminal on the stud on the lower board bracket. B. Using a 3/8” nutdriver, secure the one nut and one washer over the ground wire terminal. C. 8. Secure the line fi lter. Using a Phillips screwdriver, secure the two screws that hold the line fi lter to the lower control A. board bracket. 9. Secure the wires. Check to see that all of the cables are connected fi rmly in their proper place. A. Tie the wires back with the wire ties on the base and be sure no wires get pinched. B. Place the lower board shield in position and push the clips down. C. NOTE: The clips will snap in. 10. Perform IR Compensation procedure. Follow the A. IR Compensation procedure located in this chapter. 11. Calibrate speed. Follow the A. Speed Calibration procedure located in this chapter. 12. Secure the motor cover. Lower the motor cover center into position. See Figure 2. A. Using a Phillips screwdriver, tighten the three screws on each side. Be sure the screws are B. catching the center motor cover’s holes. See Figure 2. Power Cord NOTE: This procedure will cover the power cable, line fi lter and power switch. Tools Required Phillips 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. Turn the main power switch on the left side to the off (O) position. A. Unplug the treadmill from the power outlet. B. 2. Remove the motor cover. Using a Phillips screwdriver, loosen three screws on each motor cover side (left and right). See A. Figure 2.

42. Cybex Pro+ Treadmill Service Manual Service Page 4-14 14. Secure the front roller. Slide the front roller into the running belt. A. NOTE: It doesn’t matter which way the running belt goes. Be sure the drive belt is around the fl ywheel pulley and the front B. roller before attaching the front roller. Using a 9/16” socket wrench with a 3” extension, attach the two C. 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. Con fi rm that the drive belt fi lls all grooves in the drive motor D. fl ywheel pulley and there are open grooves on the inside of the front roller. See Figure 11. NOTE: Failure to align the drive belt could cause squeaking. 15. Secure the drive belt tension. NOTE: Follow this step only if you replaced the drive belt. Using a 1/2” socket wrench, tighten the two screws on the A. motor saddle. See Figure 10. 16. Secure the running deck. Place the deck in position as noted in step 11A. A. NOTE: Make a note of the service you performed on the Service Schedule under the motor cover. Using a 7/16” open end or socket wrench, attach the ten B. washers and screws that hold the deck to the treadmill frame. See Figure 7. 17. Secure the rear roller. Slide the rear roller into the running belt. See Figure 6. A. Slide the hardware for each side into position. B. NOTE: Place the end of the bolt in fi rst 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 12. Using a 3/4” socket wrench, tighten each rear roller bolt C. 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 22. See Figure 12. 18. Secure the top steps. Place each top step in position. See Figure 5. A. Using a Phillips screwdriver, secure the three screws that hold each top step in place. See B. Figure 5. 19. Secure the side panels. Place each side panel into position on the bottom edge and use your hand to push all along the A. top edge of the side panel to snap it in place. See Figure 5. Bronze Bushing Figure 12 Figure 11 Open grooves on Front Roller Drive Motor Flywheel Pulley NOTE: Be sure the bronze bushing is touching the head of the bolt. Drive Belt

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