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Cybex Arc Trainer 610AService ManualCardiovascular SystemsMay 2004Cybex and the Cybex logo are registered trademarks 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 reservethe right to revise this document at any time or to make changes to the product described within it without notice or obligation tonotify any person of such revisions or changes. 2004, Cybex International, Inc. All rights reserved. Printed in United States of America.10 Trotter Drive Medway, MA 02053 800-766-3211 508-533-4300 FAX 508-533-5183www.cybexinternational.com [email protected] [email protected] May 2004

Cybex Arc Trainer 610A Service ManualAbout This ManualThe Service Manual is available in pdf format only. Contact Customer Service at800-766-3211 or 508-533-4300.To contact Cybex with comments about this manual you may send email [email protected] Compliance Information! WARNING: Changes or modifications to this unit not expressly approved by the partyresponsible for compliance could void the user’s authority to operate theequipment.This equipment has been tested and found to comply with the limits for a Class B digitaldevice, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonableprotection 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 withthe instructions, may cause harmful interference to radio communications. However, there isno guarantee that interference will not occur in a particular installation. If this equipment doescause harmful interference to radio or television reception (which can be determined byturning the equipment off and on) the user is encouraged to try to correct the interference byone 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 thereceiver is connected. Consult the dealer or an experienced radio TV technician for help.Page i

Cybex Arc Trainer 610A Service ManualDeclaration of ConformityWe declare that to the best of our knowledge that the fitnessequipment listed below, and manufactured by:Cybex International, Inc.10 Trotter DriveMedway MA, 02053, USAConforms to:Directives: 73/23/EEC, 89/336/EECStandards: EN60335-1, EN55081-1, EN55014-1, EN61000-3-2,EN61000-3-3, EN 957-1Cybex Arc Trainer 610AProduct Name:610AModels:European Contact: Attention: European Sales DirectorFloor 2, 56 Bridge Street,Newport, South Wales, NP20 4BLUnited Kingdom Phone 011-44-1633-251222Page ii

Cybex Arc Trainer 610A Service ManualTable of ContentsFront PagesAbout this Manual . . . . . . . . . . . . . . . . . . iFCC Compliance Information . . . . . . . . . . iTable of Contents . . . . . . . . . . . . . . . . . . iii1 SafetyImportant Voltage InformationGrounding Instructions . . . . .Important Safety InstructionsWarning Decals . . . . . . . . . . .Caution Decals . . . . . . . . . . .1-11-11-21-41-7Warnings/Cautions . . . . . . . . . .Regular Maintenance Activities .Cleaning Your Cybex Arc TrainerDrive Belt Maintenance . . . . . . .Lubrication . . . . . . . . . . . . . . . .Environment of the Arc Trainer .Service Schedule . . . . . . . . . . .2-12-12-22-32-52-52-6Contacting Service . . . . . . . . . . . . .Serial Number & Voltage . . . . . . . . .Return Material Authorization (RMA)Damaged Parts . . . . . . . . . . . . . . . .Ordering Parts . . . . . . . . . . . . . . . . .3-13-13-13-33-32 Preventive Maintenance3 Customer Service4 ServiceWarnings/Cautions . . . . . . . . . . . . . . . 4-1Test Mode . . . . . . . . . . . . . . . . . . . . . . 4-2LED Functions . . . . . . . . . . . . . . . . . . . 4-3Key Functions . . . . . . . . . . . . . . . . . . . 4-3Error Codes . . . . . . . . . . . . . . . . . . . . 4-4Speed Sensor Adjustment . . . . . . . . . . 4-5Drive Belts . . . . . . . . . . . . . . . . . . . . . 4-7Eddy Current Brake . . . . . . . . . . . . . . 4-13Elevation Motor . . . . . . . . . . . . . . . . . 4-16Power Switch . . . . . . . . . . . . . . . . . . 4-20Upper Pillow Blocks . . . . . . . . . . . . . .4-22Lower Pillow Blocks . . . . . . . . . . . . .4-26Arm and Handle Link . . . . . . . . . . . . .4-28Pedal Arm and Foot Plates . . . . . . . .4-30Lower Control Board . . . . . . . . . . . . . 4-31Lower Control Board Fuses . . . . . . . . 4-33Upper Display Board . . . . . . . . . . . . . 4-34Upper Display Cable . . . . . . . . . . . . . 4-36Lower Display Cable . . . . . . . . . . . . . 4-37Display Overlays . . . . . . . . . . . . . . . . 4-41Parts List . . . . . . . . . . . . . . . . . . . . . . 4-43Exploded Views . . . . . . . . . . . . . . . . . 4-45Schematic . . . . . . . . . . . . . . . . . . . . . 4-53Page iii

Cybex Arc Trainer 610A Service Manual1 - SafetyIMPORTANT:Read all instructions and warnings before using the unit.Important Voltage InformationBefore plugging the power cord into an electrical outlet, verify that the voltage requirements for yourarea match the voltage of the unit that you have received. The power requirements for the unit include5%, 50/60 Hz and 15 amps; or 230 VACa grounded circuit, rated for one of the following: 115 VAC 10%, 50/60 HZ and 10 amps. See the voltage requirement decal for the exact voltage requirements ofyour unit.! WARNING: Do not attempt to use this unit with a voltage adapter. Do not attempt to use thisunit with an extension cord.Grounding InstructionsThis unit must be grounded. If it should malfunction or break down, grounding provides a path of leastresistance for electric current to reduce the risk of electric shock. This product is equipped with a cordhaving an equipment-grounding conductor and a grounding plug. The plug must be plugged into anappropriate outlet that is properly installed and grounded in accordance with all local codes andordinances.! DANGER: Improper connection of theequipment grounding conductor can result in arisk of electric shock. Check with a qualifiedelectrician or service provider if you are in doubtas to whether the unit is properly grounded. Seeka qualified electrician to perform anymodifications to the cord or plug. Cybex is notresponsible for injuries or damages as a result ofcord or plug modification.This unit is for use on a nominal 115 VAC 5%,10%, 50/60 Hz50/60 Hz and 15 amps; or 230 VAC and 10 amps and a grounded circuit. Make sure thatthe unit is connected to an outlet having the sameconfiguration as the plug. Do not use a ground plugadapter to adapt the power cord to a non-groundedoutlet.115VNEMA 5-15Euro PlugCEE 7/7SafetyPage 1-1

Cybex Arc Trainer 610A Service ManualImportant Safety Instructions(Save These Instructions)! DANGER: To reduce the risk of electric shock, always unplug this unit from the electrical outletimmediately after using it and before cleaning it.! WARNING: Serious injury could occur if these precautions are not observed. To reduce the riskof burns, fires, electric shock, or injury:User Safety PrecautionsSafetyPage 1-2 Keep children away. Teenagers and disabled must be supervised.Tenez les enfants éloignés. Lesadolescents et les handicapés doivent être surveilles. Obtain instruction before using. Lisez les instructions avant l'utilisation. Wait until foot plates come to a complete stop before dismounting. Attendre l'arret complet desreposes pieds avant de descendre. Obtain a medical exam before beginning any exercise program. Stop exercising if you feel faint, dizzy, or experience pain. Read and understand the Owner's Manual and all warnings posted on the unit before using. DO NOT wear loose or dangling clothing while using. Keep all body parts, towels, and the like free and clear of moving parts. Use the handrails for support and to maintain balance. DO NOT use the unit if you exceed 400 lbs. (180 kg). This is the rated maximum user weight. Replace any warning labels if damaged, worn or illegible. Report any malfunctions, damage or repairs to the facility. Wait until foot plates come to a complete stop before dismounting. All maintenance activities shall be performed by qualified personnel. Failure to do so could result inserious injury. DISCONNECT POWER BEFORE SERVICING. Moving parts. Keep hands away when in use.

Cybex Arc Trainer 610A Service ManualFacility Safety Precautions Make sure all user and safety precautions are observed. Read and understand the Owner's Manual completely before using the unit. Make sure all users are properly trained on how to use the equipment. Make sure that each machine is setup and operated on a solid level surface. Do not installequipment on an uneven surface. Perform regular maintenance checks on the equipment. Also pay close attention to all areas mostsusceptible to wear, including (but not limited to) cables, pulleys, belts and grips. Immediately replace worn or damaged components. If unable to immediately replace worn ordamaged components then remove from service until the repair is made. Do not attempt repairs, electrical or mechanical. Seek qualified repair personnel when servicing. Ifyou live in the USA, contact Cybex Customer Service at 800-766-3211. If you live outside the USA,contact Cybex Customer Service at 508-533-4300. Disconnect all power before servicing the unit. Keep a repair log of all maintenance activities. Use only Cybex supplied components to maintain/repair the equipment. Do not use attachments unless recommended for the unit by Cybex. Do not operate the unit if: (1) the cord is damaged; (2) the unit is not working properly or (3) if theunit has been dropped or damaged. Seek service from a qualified technician. Do not operate electrically powered units in damp or wet locations. Do not operate the unit around or where aerosol (spray) or where oxygen products are being used. Do not use the unit outdoors.NOTE: It is the sole responsibility of the user/owner or facility operator to ensure that regularmaintenance is performed.SafetyPage 1-3

Cybex Arc Trainer 610A Service ManualWarning DecalsCarefully read and understand the following before using the unit:NOTE: To replace any worn or damaged decals do one of the following: Visitwww.cybexinternational.com to shop for parts online, fax your order to 508-533-5183 or contact CybexCustomer Service at 800-766-3211. If you live outside of the USA, call 508-533-4300.Warning decals indicate a potentially hazardous situation, which, if not avoided, could result in death orserious injury. The warning decals are shown below.Warning decal part number610A-349-4WARNINGRead and understand the Owner'sManual and all warnings posted onthe unit before using.DO NOT wear loose or danglingclothing while using.Keep all body parts, towels, and thelike free and clear of moving parts.SERIOUS INJURYCOULD OCCUR IFTHESE PRECAUTIONSARE NOT OBSERVEDUse the handrails for support andto maintain balance.DO NOT use the unit if you exceed400 lbs. (180 kg). This is the ratedmaximum user weight.Replace any warning labels ifdamaged, worn or illegible.Report any malfunctions, damageor repairs to the facility. 610A-349-4SafetyPage 1-4

Cybex Arc Trainer 610A Service ManualUnderneathAccess CoverWarning decal part number - DE-17322-4Warning decal part numberCM000240CM000240SafetyPage 1-5

Cybex Arc Trainer 610A Service ManualSERIOUS INJURY COULD OCCURIF THESE PRECAUTIONSARE NOT OBSERVEDHigh voltage is present underthis shield. This shield shouldonly be removed by a qualifiedservice technician.Keep wet items away frominside parts.High voltage may still be presenteven if the unit is unplugged.Shield part numberPL-17237-4Warning decal part numberDE-17155-4WARNINGHot flywheel! Wait until itcools before servicing.DE-17155-4SafetyPage 1-6

Cybex Arc Trainer 610A Service ManualCaution DecalsCaution decals indicate a potentially hazardous situation, which, if not avoided, may result in minor ormoderate injury. The caution decals are shown below.CAUTIONMoving parts.Keep hands awaywhen in use.DE-17219-4Caution decal part numberDE-17219-4NOTE: This decal is located on both sides of the unit in a total of two locations.SafetyPage 1-7

Cybex Arc Trainer 610A Service ManualThis page intentionally left blankSafetyPage 1-8

Cybex Arc Trainer 610A Service Manual2 - Preventive MaintenanceWarningsAll warnings and cautions listed in this chapter are as follows:! WARNING: All maintenance activities shall be performed by qualified personnel. Failure to doso could result in serious injury.! WARNING: To prevent electrical shock, be sure that the power is shut off and the unit isunplugged from the electrical outlet before performing any cleaning ormaintenance procedures.! WARNING: Keep wet items away from inside parts of the unit. Electrical shock could occureven if the unit is unplugged. Do not touch components on the lower board. Acharge can remain after unplugging the power cord and turning off the unit.! WARNING: Disconnect the power cord before beginning this procedure. Keep wet items awayfrom inside parts of the unit. Electrical shock could occur even if the unit isunplugged.! WARNING: The flywheel may be hot. Wait until it cools before servicing.Regular Maintenance Activities! WARNING: All maintenance activities shall be performed by qualified personnel. Failure to doso could result in serious injury.Preventive maintenance activities must be performed to maintain normal operation of your unit. keepinga log of all maintenance actions will assist you in staying current with all preventive maintenanceactivities. See Service Schedule located at the end of this chapter.NOTE: Worn or damaged components shall be replaced immediately or the unit removed from serviceuntil the repair is made.NOTE: Cybex is not responsible for performing regular inspection and maintenance actions for yourunit. Instruct all personnel in equipment inspection and maintenance actions and also inaccident reporting/recording.PreventiveMaintenancePage 2-1

Cybex Arc Trainer 610A Service ManualCleaning Your Arc Trainer 610A! WARNING: To prevent electrical shock, be sure that power is shut off and the unit is unpluggedfrom the electrical outlet before performing any cleaning or maintenanceprocedures.When cleaning your unit spray a mild cleaning agent, such as a water and dish soap solution, on aclean cloth first and then wipe the unit with the damp cloth.NOTE: Do not spray cleaning solution directly on the unit. Direct spraying could cause damage to theelectronics and may void the warranty.After Each Use - Wipe up any liquid spills immediately. After each workout, use a cloth to wipe up anyremaining perspiration from the handrails and painted surfaces.Be careful not to spill or get excessive moisture on the console and display overlays, as this mightcreate an electrical hazard or cause failure of the electronics.As Needed - Vacuum any dust or dirt that might accumulate under or around the unit. Cleaning thisarea should be done as often as indicated in the Service Schedule.! WARNING: Keep wet items away from inside parts of the unit. Electrical shock could occureven if the unit is unplugged. Do not touch components on the lower board. Acharge can remain after unplugging the power cord and turning off the unit.To clean inside the unit, remove the four Phillips head screws securing the access cover in place. Use avacuum attachment or hand vacuum to clean the exposed elevation assembly and remove dirt anddebris off of internal components.Use a dry cloth to wipe all exposed areas. Replace the access cover and secure it with the screwswhen finished.Lift the rear of the unit and roll it back from its present position so as to vacuum the floor areaunderneath the unit. When finished, return the unit to its normal position.Contact Heart Rate Grips - Contaminants, such as hand lotions, oils or body powder, may come offon the contact heart rate grips. These can reduce sensitivity and interfere with the heart rate signal. It isrecommended that the user have clean hands when using the contact heart rate. Clean the grips usinga cloth dampened with a cleaning solution containing alcohol. The grips are the only part of the unityou should use a cleaning solution containing alcohol.PreventiveMaintenancePage 2-2

Cybex Arc Trainer 610A Service ManualDrive Belt MaintenanceThere are two drive belts that may become loose, worn or cracked. See Figure 1.Primary Belt - This is the wider of the two belts.It has grooves that keep it aligned on the largeupper pulley. Unless the unit has been servicedand not put back together properly, it is unlikelythat the primary belt will need to be re-tensioned.Secondary Belt - This is the narrower of the twobelts. It has grooves that keep it aligned on theflywheel’s drive pulley. It is unlikely that thesecondary belt will become loose because it is astretch-fit belt. Unless the unit has been workedon and not put back together properly, it isunlikely the tension will change.Follow this Drive Belt Maintenance procedure toensure that the belts are tensioned properly and ingood condition. See the Service Schedule in thischapter for a minimum schedule for checking thebelt tension and condition. NOTE: If a belt hascracks or appears worn, it must be replacedimmediately by a qualified service technician.PrimaryDrive BeltSecondaryDrive BeltFigure 1Tools Required Phillips head screwdriver! WARNING: Disconnect the power cord before beginning this procedure. Keep wet items awayfrom inside parts of the unit. Electrical shock could occur even if the unit isunplugged.1. Read and understand this Drive Belt Maintenance section thoroughly before proceeding tostep 2.2. Disconnect the external power source.A. Turn the main power switch above the power inlet to the off (O) position.B. Unplug the power cord from the power outlet.PreventiveMaintenancePage 2-3

Cybex Arc Trainer 610A Service Manual3. Remove the access cover.AccessCoverA. Using a Phillips head screwdriver, remove the fourscrews securing the access cover in place. SeeFigure 2.B. Remove the access cover.! WARNING: The flywheel may be hot. Wait until itcools before servicing.4. Check the condition of each belt.A. Roll each belt by pulling down on it. Examine thecondition of each belt. If a belt has cracks orappears worn, it must be replaced immediatelyby a qualified service technician.5. Check the tension of the primary belt.A. Press on the primary belt with your hand. Youshould not feel any “give” in the primary belt. Ifthe belt “gives”, it must be adjusted immediatelyby a qualified service technician.Screw (4)Figure 26. Check the tension of the secondary belt.A. Press on the secondary belt with your hand. The belt should “give” about 1/4” (0.6 cm). If thebelt “gives”, it must be adjusted immediately a qualified service technician.Lower Pivot ShaftB. Locate the spacers under the lower pivotshaft. Visually check that the spacers arein place and in good condition. If thespacers are visibly cracked or missing, itmust be replaced immediately by aqualified service technician. See Figure 3.SpacersFigure 3PreventiveMaintenancePage 2-4

Cybex Arc Trainer 610A Service ManualLubricationThe Arc Trainer 610A is designed with no-maintenance parts. Although there are grease fittings on thepillow blocks, re-lubrication of the bearings is not required.Elevation Motor Lubrication - In time the elevation motor pivot points may develop a squeak. If asqueak is present, the unit will need to be serviced by a qualified service technician.EnvironmentStatic Electricity - Depending upon where you live, you may experience dry air, causing a commonexperience of static electricity. This may be especially true in the winter time. You may notice a staticbuild-