CYBEX LT-16602-4 Owner'S Service Manual Download Page 92

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Secure the left junction covers.

Using a Phillips screwdriver, tighten the three screws that hold the junction covers
in place.

Secure the motor cover.

Lower the motor cover center into position. See Figure 2.

Using a Phillips head screwdriver, tighten the three screws on each side.

NOTE:

sure the screws are catching the center motor cover’s holes.

Cybex Sport Treadmill Owner’s & Service Manual

Service
Page 7-36

Figure 29

Shield

Display Cable

Screws (4)

Screws (5)

Screws (3)

Left

Junction

Covers

P3 and P8 Connectors on

Upper Display Board

Top 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

Summary of Contents for LT-16602-4

Page 1: ...ual We reserve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes 2003 C...

Page 2: ......

Page 3: ...__________________________ Serial Number ____________________________________________________________ Installation Date mm dd yy ______ ______ ______ By __________________________ Date of Purchase ___...

Page 4: ...SERVICE CYBEX INTERNATIONAL 10 TROTTER DRIVE MEDWAY MA 02053 9934 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 73 MEDWAY MA POSTAGE WILL BE PAID...

Page 5: ...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 generat...

Page 6: ...Cybex Sport Treadmill Owner s Service Manual Page ii NOTE For European customers only...

Page 7: ...Treadmill 4 1 Running Belt Maintenance 4 2 Other Preventive Maintenance 4 6 Service Schedule 4 7 Log Sheet 4 8 Table of Contents 5 Setup Assembly Warnings Cautions 5 1 Choosing Preparing a Site 5 1 E...

Page 8: ...This page intentionally left blank...

Page 9: ...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 accorda...

Page 10: ...understand the Owner s Manual and all warnings posted on the unit before using Read and understand emergency stop procedures DO NOT wear loose or dangling clothing while using Keep all body parts tow...

Page 11: ...ek service from a qualified technician DO NOT place the cord near heated surfaces or sharp edges DO NOT use the treadmill outdoors DO NOT operate the treadmill around or where aerosol spray or where o...

Page 12: ...ustomer Service at 800 766 3211 If you live outside of the USA call 508 533 4300 For location or part number of labels see the parts list and exploded view diagram This information can be found in the...

Page 13: ...Cybex Sport Treadmill Owner s Service Manual Underneath Motor Cover Safety Page 1 5...

Page 14: ...Cybex Sport Treadmill Owner s Service Manual VARNING KOPPLA IFR N STR MMEN INNAN SERVICE UTF RS Safety Page 1 6...

Page 15: ...if not avoided may result in minor or moderate injury There are no caution decals used on the Cybex Sport treadmill However there is a caution in the installation instructions for initial installatio...

Page 16: ...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...

Page 17: ...ty Sentry Contact Heart Rate CSAFE frame color choices include white texture black texture silver vein black chrome and platinum sparkle Optional Features Full length handrails unlimited custom colors...

Page 18: ...Cybex Sport Treadmill Owner s Service Manual This page intentionally left blank Specifications Page 2 2...

Page 19: ...Start key Quick Start skips the Program Setup Mode and begins immediately in Manual Mode Manual Mode This begins immediately after pressing the Quick Start key In Manual Mode you can customize your wo...

Page 20: ...oceed 5 The treadmill begins a countdown 3 2 1 after which it accelerates the belt to 1 0 mph 1 6 kph for Manual Mode or the speed of the program that you selected 6 Hold the handrails while you step...

Page 21: ...the last default The program will not enter Active Mode until you press the Enter or Quick Start key If no key has been pressed for 20 seconds after displaying the last default then the treadmill wil...

Page 22: ...s to OFF and the left window shows a flashing pattern of o and o Replacement of the e stop key causes Workout Review to begin 13 When you complete a program the treadmill begins a countdown 3 2 1 and...

Page 23: ...op key off the console The function of the emergency stop The e stop key functions as the emergency stop In an emergency situation remove the e stop key from the console and the treadmill will come to...

Page 24: ...l dist cal min mi km Distance The total accumulated distance in miles or kilometers during your workout NOTE Depending on the defaults you ve chosen this measurement will show in English or Metric Cal...

Page 25: ...s For best results hold the handgrips lightly and ensure that your hands contact both the front and back sensors of each grip NOTE Hold your hands as steady as possible as movement can cause interfere...

Page 26: ...t rate max by 55 to estimate the lower end of your heart rate training zone Then multiply your estimated heart rate max by 85 to estimate the higher end of your training zone This heart rate training...

Page 27: ...10 Levels 30 minutes fixed time Cardio 10 Levels 20 minutes fixed time Manual Program Overview Manual Mode is available both through Quick Start and through the Manual program where you are prompted...

Page 28: ...considered to be a rest segment later In minutes two and three elevation will be increased In minute four the program returns to the first segment baseline or rest level In the fifth minute the speed...

Page 29: ...15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 1 0 3 0 4 0 5 0 2 0 6 0 8 0 9 0 10 0 7 0 12 0 13 0 14 0 11 0 15 0 17 0 18 0 19 0 20 0 16 0 1 0 3 0 4 0 5 0 2 0 6 0 8 0 9 0 10 0 11 0 12 0 7 0 12 4 MPH KPH Wa...

Page 30: ...a moderate jog in the higher levels Elevation is used to emphasize the high intensity portion of this program while decreased elevation and a small increase in speed mark the recovery segment High in...

Page 31: ...levation Cool Down Warm Up Cool Down Profiles Show Level 10 at 20 Minutes Cardio Custom 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 1 0 3 0 4 0 5 0 2 0 6 0 8 0 9 0 10 0 7 0 12 0 13 0 14 0 11 0 15 0 17...

Page 32: ...Cybex Sport Treadmill Owner s Service Manual This page intentionally left blank Operation Page 3 14...

Page 33: ...lified 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 maintenan...

Page 34: ...e 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...

Page 35: ...bolt equally on each side B Turn the power on and press the Quick Start key C Press the Speed to bring the speed up to 3 5 4 mph 5 6 6 4 kph Allow the treadmill to run for a minute D Observe the belt...

Page 36: ...tighten both rear roller adjustment bolts 1 2 of a turn clockwise Adjust the belt until no further slipping is felt If the running belt continues to slip the drive belt could be loose Checking the Be...

Page 37: ...ed the deck should be replaced In time a worn belt and deck can cause high current draw and ultimately motor failure For instructions on replacing the belt and deck see Running Belt and Deck in the Se...

Page 38: ...eck 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 activiti...

Page 39: ...Service Schedule Cybex Sport Treadmill Owner s Service Manual Preventive Maintenance Page 4 7...

Page 40: ...ers Total Hours Motor Current 3 mph 4 8 kph Motor Voltage 10 mph 16 1 kph without load with 160 lbs load Notes Total Miles Total Hours Motor Current 3 mph 4 8 kph Motor Voltage 10 mph 16 1 kph without...

Page 41: ...should be well lit and well ventilated Locate the treadmill on a structurally sound and level surface do not place in recessed areas or on plush carpet a few feet away from walls and other equipment...

Page 42: ...e the treadmill user s orientation 1 Read and understand all instructions thoroughly before assembling the treadmill NOTE Each step number in the assembly instructions tells you what you will be doing...

Page 43: ...center with decals 6 1 PL 16465 Motor cover right in box 7 1 PL 16464 Motor cover left in box NA 1 AX 16956 Hardware pack in box NA 1 LT 16602 Sport Manual in box NA 1 LT 16314 Assembly Poster NOTE N...

Page 44: ...4 7 1 4 3 2 5 2 2 6 2 4 2 3 8x 1x 2x 8x Figure 2 4 3 2 8x 1x 2x 8x Hardware Actual Size Item Qty Part Number Description 2 8 HS 16929 Screw hex head whiz lock 3 8 16 x 5 8 3 2 HS 16950 Screw button he...

Page 45: ...while pivoting the treadmill See Figure 3 5 Pivot the console and uprights into position A Remove all plastic wrapping except the white wrapping on the uprights B Ensure that the display cable does n...

Page 46: ...gure 4 B Using a 9 16 socket wrench with a 4 extension attach the uprights with six of the 3 8 16 x 5 8 hex head whiz lock screws NOTE Do not securely tighten the screws until step 7C See Figure 5 C T...

Page 47: ...e 9 10 Arrange power cord A Decide whether you will plug the power cord into an outlet near the front of the treadmill or the back of the treadmill Follow the corresponding routing procedure below NOT...

Page 48: ...et on the power cord into the back exit hole with the curved end first d Using a Phillips head screwdriver secure the left end cap See Figure 11 B Wind the excess power cord onto the arms See Figure 1...

Page 49: ...e the screws are catching the motor cover s holes 12 Level your treadmill A Confirm that your treadmill is on a level surface 13 Attach emergency stop key A Confirm that the emergency stop key is in p...

Page 50: ...Cybex Sport Treadmill Owner s Service Manual Figure 13 Setup Assembly Page 5 10 Emergency Stop Key Emergency Stop Button...

Page 51: ...3 2 1 and sounds a tone for each count After it reaches one 1 the treadmill gives a longer tone and then begins accelerating the belt to reach 1 mph 1 6 kph 5 The bottom left display will flash the t...

Page 52: ...ay you will have 3 seconds to toggle the unit of measurement to your preference by pressing the key Choose English or Metric units English is the default NOTE Metric appears as nnE 4 When line appears...

Page 53: ...83 Order parts and find information on the web at www eCybex com or by email at techhelp cybexintl com Serial Number Voltage Your serial number and voltage can be found on the front of your treadmill...

Page 54: ...ir 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 ite...

Page 55: ...ust 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...

Page 56: ...Cybex Sport Treadmill Owner s Service Manual This page intentionally left blank Customer Service Page 6 4...

Page 57: ...n 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...

Page 58: ...f starts log error codes 1 5 Afterward TEST appears on the display To exit Test Mode press Stop Stuck Key List If Test Mode occurs without holding any keys a key may be stuck closed or Error 7 may hav...

Page 59: ...ey LED Blinks on once per speed sensor pulse Heart key LED Blinks on when hand grips are held and contact heart rate is activated Key Functions While in Test Mode press the following keys for desired...

Page 60: ...rection 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 Se...

Page 61: ...er display and the weight of the person NOTE Call Cybex Customer Service to confirm that the load is within acceptable range Loads over 200 are generally unacceptable E Press Stop to exit Test Mode 2...

Page 62: ...6 Attach the motor cover A Lower the motor cover center into position See Figure 2 B Using a Phillips head screwdriver tighten the three screws on each side Speed Sensor Adjustment Tools Required Phil...

Page 63: ...ower left window If it fluctuates in over 0 5 mph increments then your speed sensor gap needs to be readjusted E Press Stop and turn the power switch to the off O position F Enter Test Mode again and...

Page 64: ...ess the Speed Up key once to set the treadmill speed to 1 0 mph 1 6 kph WARNING Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the tread...

Page 65: ...ghten the three screws on each side NOTE Be sure the screws are catching the center motor cover s holes Speed Calibration 1 Calibrate the speed A Stay off the running belt during this procedure CAUTIO...

Page 66: ...ench 9 16 Socket wrench with a 3 extension WARNING Disconnect the power cord before beginning this procedure 1 Disconnect the external power source A Turn the main power switch on the left side to the...

Page 67: ...socket wrench loosen the two rear roller bolts one roller bolt on each side NOTE Loosen each bolt evenly making sure not to loosen either bolt too many turns before moving to the other bolt See Figur...

Page 68: ...not need to remove it for this procedure B Place a 9 16 socket wrench with a 3 extension in the left front roller access hole Remove the left front roller screw See Figure 8 NOTE Leave the front rolle...

Page 69: ...a 1 2 socket wrench loosen but do not remove the two screws on the motor saddle See Figure 9 12 Remove the drive belt A If you are changing the drive belt slip the drive belt around the flywheel pulle...

Page 70: ...in first and then hold the rear roller up while you pivot the group of hardware into the rear roller slot Be sure the bronze bushing is touching the head of the bolt See Figure 11 C Using a 3 4 socket...

Page 71: ...e 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...

Page 72: ...eld It will snap out C Disconnect the motor cable from the lower board and line filter NOTE You will disconnect four wires red black yellow and green See Figure 13 D Carefully remove the drive motor N...

Page 73: ...the flywheel screw washers and motor ansi square key from the old motor See Figure 14 B Place the flywheel in position on the new motor and slide the motor key into the slot on the flywheel See Figur...

Page 74: ...brush covers to remove it from the motor See Figure 15 B Lift off the round brush cover See Figure 15 If necessary carefully pry the cover up using a flathead screwdriver 12 Remove the brushes A Usin...

Page 75: ...s 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...

Page 76: ...e motor cables A Connect the motor cable to the lower board and line filter as shown in Figure 13 red to A1 black to A2 yellow to BW and green to the line filter NOTE For internationally installed tre...

Page 77: ...the screws are catching the center motor cover s holes 21 Perform the appropriate procedures A Follow the Speed Calibration procedure located in this chapter required B If you replaced the motor follo...

Page 78: ...be required to properly lift the treadmill Always use proper lifting methods when moving heavy items A While two people are lifting the front of the treadmill have a third person place a wooden block...

Page 79: ...ower board NOTE The board is labeled P3 at the elevation port The connector can only fit in one direction E Place the lower board shield in position and push the clips down NOTE The clips will snap in...

Page 80: ...ews on each motor cover side left and right See Figure 2 B Lift the motor cover center up and off the treadmill The screws will stay in place See Figure 2 3 Disconnect the cables from the lower contro...

Page 81: ...s head screwdriver secure the four screws that hold the bracket to the base 7 Connect the cables to the lower control board A Connect the cables to the lower control board This includes the elevation...

Page 82: ...sure the screws are catching the center motor cover s holes See Figure 2 12 Calibrate speed A Follow the Speed Calibration procedure located in this chapter Power Cord NOTE This procedure will cover t...

Page 83: ...gure 4 4 Remove the left side panel A Pull the left side panel out and off the treadmill Power Switch 5 Remove the power switch A Using a Phillips head screwdriver remove the two screws that hold the...

Page 84: ...t the black cable to the front left fast on on the line filter and route it through the access hole C Connect the ends of these two cables to the lower board The white connects to the fast on labeled...

Page 85: ...the left side to the off O position B Unplug the treadmill from the power outlet NOTE The display board is susceptible to damage from a discharge of static electricity While handling parts underneath...

Page 86: ...head screws that hold the display board to the console C Gently pull the display board up to disconnect it from the CSAFE board 4 Attach the display board A Place the display board in position and gen...

Page 87: ...will cover the contact heart rate board and the CSAFE board with a jumper Tools Required Phillips head screwdriver ESD Electro Static Discharge grounding strap 1 Disconnect the external power source A...

Page 88: ...t hold the heart rate board in place F Turn the heart rate board over and use a Phillips head screwdriver to remove the screw from the heart rate bracket See Figure 26 5 Attach the heart rate bracket...

Page 89: ...nd heart rate bracket and secure it tightly See Figure 25 C Using a Phillips head screwdriver secure the console front to the handrail with other eight black screws removed during step 4B D While bein...

Page 90: ...se 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 top con...

Page 91: ...See Figure 28 C Push the display cable down through the handrail and out the handrail s bottom hole See Figure 29 NOTE Twisting the cable as you push will help it go through D Push the display cable...

Page 92: ...r tighten the three screws on each side NOTE Be sure the screws are catching the center motor cover s holes Cybex Sport Treadmill Owner s Service Manual Service Page 7 36 Figure 29 Shield Display Cabl...

Page 93: ...e top console back 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 t...

Page 94: ...Standard or or Custom Color 17 DE 16705 Decal Safety walk 18 HS 16875 Screw SEM ext 1 4 20 x 1 2 PNHD Phil 19 EH 10291 Anchor Cable Tie 20 EH 00986 Cable Tie without anchor 21 PL 16737 Plug Power Cor...

Page 95: ...AX 17762 Motor Base Plate Assy 70 HS 16849 Screw 5 16 18 x 2 0LG H x HD GR5 Tap 71 HW 00165 Washer Lock Ex 5 16 Zinc 72 FM 16774 Spacer Motor Base 73 HB 16426 Bushing Flanged 1 0ID x 1 12OD x 75LG 74...

Page 96: ...rew Sems 10 32 x 3 8 PNHD ext BL ZN 122 FS 16990 Plate Switch Power On Off 123 SW 10523 Switch On Off NS AF 16833 Bracket Salutron Ground NS AF 16834 Bracket Salutron Mount NS LT 16602 4 Owner s Servi...

Page 97: ...Cybex Sport Treadmill Owner s Service Manual Page 7 41...

Page 98: ...L 2 SWITCH 5 ROW 1 SWITCH J3 7 5V 5 9v REG REF GND ELEV UP Zero Switch AD 17275 ASSY SPORT DISPLAY BOARD C B A 4 3 2 6 5 ROW 3 SWITCH COL 2 SWITCH COL 1 SWITCH ROW 2 SWITCH ROW 1 SWITCH S N E STOP MAG...

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