CYBEX TREADMILL – CYBEX 525T – HOW TO ENTER TO SERVICE MODE – CYBEX 525 ERROR CODES AND CAUSES – HOW TO ADJUST THE RUNNING BELT - MAINTENANCE TIPS

Cybex treadmill – Cybex 525T – How to enter to service mode – Cybex 525 error codes and causes – How to adjust the running belt - maintenance tips

Cybex 525T:  Service mode

1. Press and the hold the Display option and DOWN keys for 3 seconds. A beep signifies the first screen of the Statistics menu.
2. Press the UP or DOWN keys to scroll up and down in the statistics menu.
The Statistics menu includes: Miles/Km, Hours, Starts, and Error log.
3. The first menu item is Miles/Km.
4. Record Distance.
5. Navigate to menu item Hours.
6. Record Hours.
7. Navigate to menu item Starts.
8. Record Starts.
9. Navigate to menu item Error log.
10.Record Errors.
11. Exit Statistics menu by pressing the STOP key.

Running Belt Maintenance
Belt and Deck

 Wipe the belt surface and the deck area with a clean dry towel to minimize the effect of friction between the deck and the running belt. This should be done often to prevent premature wear of the deck, running belt, and the drive motor system. See the Service Schedule at the end of this chapter.
The running belt may become loose and slip on the drive roller with each foot plant. If it does, follow the Tension and Center the Belt procedure below. 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

Center and tension the running belt
1. Plug the power cord into the power outlet.
2. Turn the main power switch to the on (I) position.
3. Press the Quick Start key.
4. Press the Speed + to bring the speed up to 5 mph (8 kph). Allow the treadmill to run for a minute.
The lateral position of the running belt is correctly centered when the Cybex logo is centered between the inside edges of the two belt tracking slots. If the Cybex logo is not centered between the belt tracking slots, center the running belt with the following procedure.
5. Observe the Cybex logo position relative to the belt tracking slots with the treadmill running at 5 mph (8 kph).

1. Cybex logo

 2. Running belt

3. Belt tracking slots

While centering the running belt choose one bolt to adjust. Do not adjust both bolts.
6. Tighten the rear roller bolt on the side of the treadmill toward which the running belt is moving using a 3/4” socket wrench. For example: If the running belt moves to the right of the belt tracking slots, tighten the bolt on the right side of the frame, tighten about 1/2 of a turn (clockwise) and wait 30 seconds. If the running belt does not move back to the center of the belt tracking slots, make another adjustment to the same bolt. Once the running belt has been adjusted closer to the center of the belt tracking slots, use about 1/4 of a turn until the running belt has been stabilized.

1.Rear roller bolts

7. Check the belt tension after the running belt has been centered. Make sure the running belt tension is tight enough so that the running belt does not slip or hesitate when stepped on.
Walk on the treadmill at 3.5 - 4 mph (5.6 - 6.4 kph) and every 4th to 5th step throw your weight into your step to feel if the running belt is slipping. If slipping is felt, confirm it is the running belt slipping and not the drive belt. With the hood cover removed, observe movement at the drive belt and front roller.
Do not over tighten the running belt. Over tightening the running belt can cause the belt to stretch and require replacement. Continue procedure until running belt stops slipping.
8. Check running belt for centering position. If running belt is not centered, perform steps 5 and 6.
Checking the Running 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. The running belt should be replaced every 15,000 miles (24,140 km). The running deck should be flipped every 15,000 miles (24,140 km) and replaced every 30,000 miles (48,280 km). A service prompt will appear at this interval and the parts will need to be replaced. Inspect the edges of the belt as described below.

Tools Required
Phillips screwdriver
Disconnect the external power source
9. Toggle the on/off (I/O) power switch to the off (0) position.The on/off (I/O) power switch is located under the front end of the unit, or on the front right side panel.
10.Unplug the treadmill from the power outlet.
Check the running belt condition
1. Remove the two screws securing the right end cap using a Phillips screwdriver.

1. Screws (2)

2. Right end cap

2. Repeat step 1 for the left end cap.
3. Inspect the top surface, seam, and edges of the running belt while you roll it by hand. If the belt has any rips or looks excessively worn the belt needs to be replaced.
If the running belt and deck need replacement refer to a qualified service technician.
4. Install the screws securing the end caps removed in steps 1 and 2 using a Phillips screwdriver.

Maintenance Tips

Elevation Motor Lubrication

In time the elevation motor pivot points or tube nut may develop a squeak. Lubricate the upper and lower bolts and the spacers with a small amount of lithium grease. 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 buildup of static electricity on your body and the discharge path of the treadmill. If you experience this type of situation, you may want to increase the humidity to a comfortable level through the use of a humidifier.

Service schedule

First 500 miles (800 km)
Check running belt tension and tracking.
Every 5,000 miles (8,000 km)
# Check running belt tension and tracking.
# Unplug unit.
# Vacuum the fan and heat sink area of the motor controller.
# Plug in unit.
# Raise elevation to 15%, unplug unit, roll the treadmill backwards to clean underneath with a dry cloth and vacuum. Return to normal position when done.
# Plug in unit.
Every 15,000 miles (24,140 km)
# Replace running belt and flip deck.
# Check elevation assembly and replace worn parts.
# Lubricate elevation pivot points.
Every 30,000 miles (48,280 km)
# Replace running belt and deck.

ERROR CODES CUSES AND SOLUTION 

ERROR	DESCRIPTION	PROBABLE CAUSE
1	No speed signal at startup	With or without belt movement? 130 VDC spike? SCR or brushes
2	Excessive current draw	Check amp draw with & without load, Belt & Deck, or motor circuit
3	Loss of speed signal	Check speed sensor, sensor gap and cable
4	No frequency lock	Noisy line voltage, Install dedicated outlet
5	Elevation error	Calibrate, Check voltage to motor, potentiometer and cable
14	Software error	Reseat EPROM, Replace
50	Over speed	Check speed sensor and cable, SCR, cap, brake on XL models
70	Loss of NOVRAM data	Reseat EPROM, Replace, if not display needs repair

CYBEX LCX 425T - TREADMILL - ERROR CODES - SPEED SENSOR ADJUSTMENT

CYBEX LCX 425T - TREADMILL - ERROR CODES - SPEED SENSOR ADJUSTMENT

ERROR CODES

    Error codes notify you of a problem condition and are displayed on the console. These codes can also help to indicate the part of the treadmill most likely to be causing the problem. Errors that present a hazard to the user provide a measure of safety by causing a one second beep,

stopping the treadmill and locking out operation of the treadmill. Reset power by unplugging unit for a few seconds, then plug power cord into outlet.

    A log of errors can be viewed and cleared. Enter Test Mode and press the Pace (min/mi/km) key to display the log. The most recent error is always first 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 Pause/Stop to exit Test Mode.

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.

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).

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.

SVC  Maintenance prompt. Is activated every 9,000 miles (14,484 km). Display shows “SVC” and beeps every 2 minutes. In Test Mode press “Cool Down” and then press up and down arrows to display “RST” for reset. Press Enter to reset service odometer to zero.

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 Reset power by unplugging unit for a few seconds, then plug power cord into outlet.

I Perform speed calibration procedure.

SPEED SENSOR ADJUSTMENT

Unplug the treadmill from the power outlet.

Remove the motor cover.

Using a Phillips head screwdriver, loosen two screws on each motor cover side.

Using a Phillips head screwdriver, loosen two screws on the front motor cover.

Lift the motor cover up and off the treadmill. The screws will stay in place.

Adjust the speed sensor gap (if needed). [Do not over tighten nuts on plastic speed sensor housing]

Using two 1/2” open end wrenches, loosen the nuts that attaches the speed sensor to the frame bracket.

Adjust the gap between the speed sensor and the magnet on the front roller to 1/4” (.635 cm) and tighten the two nuts.

Test for speed errors.

Connect the power cord to a power outlet.

Bring the speed of the treadmill up to maximum speed, 11.0 mph (17.6 kph).

After reaching maximum speed reduce the speed to 1.0 mph (1.6 kph). If a speed error occurs then your speed sensor gap needs to be readjusted.

Press Pause/Stop.

Enter Test Mode again and check the error log for Error 3. If any new errors occurred, readjust the speed sensor and test again. NOTE: If you are unsure whether an error is new you can clear the error log by pressing the scan key twice and then repeat steps 3A through 4E.

Exit Test Mode by pressing Pause/Stop.

Speed Calibration

Stay off the running belt during this procedure.  CAUTION:  During this procedure STAY OFF THE RUNNING BELT! Stand with your feet on the two steps.

In Test Mode press and hold the Heart Rate and Time keys for five seconds. The  display will show “CAL”. The running belt will accelerate to three different speeds and when completed the display will show “SAV”

Press Pause/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 Pause/Stop during this procedure the calibration will not be stored. Exiting Test Mode while the belt is moving may generate an error condition.

CYBEX LCX 425T - TREADMILL HOW TO REPLACE MOTOR BRUSHES

CYBEX LCX 425T - TREADMILL

HOW TO REPLACE MOTOR BRUSHES - 

MOTOR BRUSH REPLACEMENT

Motor Brushes 110 VAC (Product Numbers SK-18553)

Motor brushes are wear items that will periodically need to be replaced.

Both drive motor brushes must be replaced as a pair. This will ensure even commutator contact and brush wear. However, the negative brush will wear 20% faster than the positive brush. Therefore, always measure the negative brush length to determine whether you should replace the pair. The negative brush is located closest to the front of the frame. You should still check the positive brush for cracks or chips.

It is not necessary to remove the drive motor in order to reach the motor brushes.

Tools Required

Phillips head screwdriver

Flat head screwdriver

7/16” open-end wrench

1/2” open-end wrench

[Keep wet items away from inside parts of the treadmill. Electrical shock could occur even if the treadmill is unplugged. A qualified service technician should perform motor brush removal and replacement.]

Verify the kit contents shown.

A. Brush Assembly, 110 VDC, Red (1)

B. Brush Assembly, 110 VDC, Black (1)

C. Brush Retainer, Molded (2)

D. Wire tie, 18”, EH-12260 (1)

E. Wire tie, 9”, EH-00986 (3)

Remove motor cover.

Using a Phillips head screwdriver loosen but do not remove the two screws securing the left motor cover in place. Loosen the two screws securing the right motor cover.

Lift the top motor cover up and off of the treadmill.

Elevate the treadmill.

Without standing on the belt, press the Start key and begin running the treadmill.

Press the up arrow and elevate the treadmill fully.

Disconnect the power.

While the treadmill is still fully elevated and running unplug the power cord from the wall outlet.

Access drive motor.

Carefully lift the rear of the treadmill until the top of the console is resting on the ground. { Drive belt is under tension. Do not pinch fingers while releasing tension.}

Release drive belt tension by placing the Phillips head screwdriver into the square hole located in the bottom of the idler pulley assembly.

While pushing down on the Phillips head screwdriver carefully slide the drive belt off of the drive motor pulley. Slowly release tension on the idler pulley assembly. [WARNING: Motor plate is heavy and will drop down when motor plate bolts are removed.]

Using a 1/2” open-end wrench remove the two motor plate bolts and washers.

Slowly and carefully lower the drive motor plate.

Disconnect the motor cables.

Locate the red and black drive motor cables exiting the drive motor and connected to A1 and A2 on the lower control board.

Disconnect the two motor cables from the lower board. WARNING: Avoid touching lower board components such as resistors and capacitors.

Cut the wire ties securing the drive motor cables to the drive motor housing and other cables on the lower control board.

Remove the ferrite from the two motor cables.

Using the 7/16” open end wrench loosen the nut securing the wire clamp retainer at the end of the motor. Remove drive motor cables from retainer.

Remove the black brush assembly.

Using a large flat head screwdriver pry out the brush retainer on the drive motor that secures the black wire. The brush and spring will pop out.

Examine the brush and commutator.

Inspect the commutator by looking through the top brush holder into the motor. Slowly spin the motor by turning the flywheel. Look for noticeable damage and for signs of wear such as arcing, pitting, burning, or uneven wear. Commutator bars that are ‘dirty penny’ brownish copper are in great condition. Also, 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. Brush dust can be loosened from the motor surfaces where the brush is placed by lightly filing the surfaces. Dirt and brush dust should be vacuumed out of the motor.

Inspect the brushes for signs of excessive wear or cracks. The motor brushes must be replaced if one or both is worn to .375” (9.5 mm) or less in length, is broken or chipped, has a broken spring, or binds in the motor.

Replace the black brush assembly.

Slide the new brush into the motor brush holder. If the new brush does not slide in and out easily, the edges or corners of the brush can be lightly filed down. If cleaning the motor, and filing the brush doesn’t allow the brush to slide easily in the brush holder, the motor should be replaced.

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.

Fully compress the spring by pushing as far into the brush holder as possible.

While compressing the spring, place the new brush retainer into the motor housing until the brush retainer is fully seated into the motor housing.

Repeat steps for the red brush assembly.

Connect the drive motor cables.

Place the new drive motor cables into the wire clamp retainer at the end of the motor.

Using the 7/16” open end wrench tighten the nut securing the drive motor cables in the wire clamp retainer.

Secure the drive motor cables to the drive motor housing with a wire tie

Attach the ferrite removed in step 7D around the two drive motor cables.

Connect the drive motor cables to the lower board. The black wire connects to A2, The red wire connects to A1 WARNING: Avoid touching lower board components such as resistors and capacitors.

Secure the drive motor cables to the other cables in the lower control board with two wire ties.

Secure drive motor plate.

Slowly and carefully raise the drive motor plate.

Using a 1/2” open end wrench secure the two motor plate bolts and washers removed.

Install drive belt.

Place the Phillips head screwdriver into the square hole located in the bottom of the idler pulley assembly.

While pushing down on the Phillips head screwdriver carefully slide the drive belt into the grooves on the drive motor pulley and front roller. Slowly release tension on the idler pulley assembly.

Ensure that the drive belt is aligned properly in the grooves on the drive motor pulley and front roller pulley.

Lower treadmill.

Carefully lower the rear of the treadmill until the back feet are resting on the ground.

Install motor cover

Place the top motor cover into position.

Using a Phillips head screwdriver tighten the two screws securing the left motor cover in place. Tighten the two screws securing the right motor cover.

Test the unit for proper operation.

Connect the treadmill to the power outlet.

The treadmill will lower itself. Wait until the treadmill resets its elevation to 0%

Operate the unit at all levels to verify proper operation.