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CYBEX 600H HIKER, Service Manual

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CYBEX 600H HIKER Service Manual Download Page 14

11

3 / I

NSTALLATION

Installation of the 600H Hiker by Cybex can be unsafe if you don’t
follow directions. The following installation steps are listed in
sequential order assuming that the Hiker has been completely
disassembled.

NOTE:

Safety glasses should be worn while assembling or

disassembling the Linkage System.

STEP 1-Installing the Front Linkage Assembly

(Tools required–One 9/16” deep socket, on 9/16” wrench, safety
glasses.)

1. Select one front linkage assembly: One 3/8-16 x 3.75” long

bolt, one 3/8-16 lock nut.

2. Orient the front linkage in relationship to the unit as shown in

figure 3-1.

3. Align the holes in the bearing with the mounting holes in the

unit.

4. Slide one 3/8-16 x 3.75” bolt in from the top. Make sure the

wide spacing of the linkage assembly is on the bottom. (See
figure 3-2.)

5. Attach on 3/8-16 lock nut and tighten to 22 ft-lb minimum.

STEP 2-Installing the Front Pivot Arm Assembly

(Tools required–Two 1/2” wrenches.)

1. Select the front pivot arm assembly. This is comprised of

four 5/16-18 x .75” long screws, four 5/16-18 lock nuts, four
flangettes, and two 1” ID bearings. (See figure 3-3.)

2. To rotate the pivot arm assembly into position, keep turning

until it slides in. Put one pivot shaft of pivot arm through one
pivot bracket, then twist and rotate the shaft until it fits into
the other pivot bracket. Make sure the bumper attachment
is towards the front of the unit.

3. A bearing set contains two flangettes and one 1” ID bearing.

Slide both bearing sets onto the pivot shaft with the
extended race towards the inside. (See figure 3-4.)

Fig. 3-2

Fig. 3-4

Fig. 3-1

Fig. 3-3

Summary of Contents for 600H HIKER

Page 1: ...Cybex 600H Hiker Service Manual Cardiovascular Systems ...

Page 2: ...The 600H measures monitors and motivates your fitness and health Cybex International Inc 10 Trotter Drive Medway Massachusetts 02053 USA The 600H Service Manual SM 15649 Rev A ...

Page 3: ...rn or illegible DO report any malfunctions damage or repairs to the facility Commercial Equip Only DO NOT use the Hiker if you exceed 350 lbs This is the maximum rated user weight DO NOT install in a commercial setting For consumer use only Consumer Equip Only WARNING Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user s authorit...

Page 4: ...age Rod Assembly 13 Step 5 Installing the Rear Pivot Arm Assembly 14 Step 6 Assembling the Foot Plate Linage Rod 15 Step 7 Attaching a Foot Plate to the Front Pivot Arm Assembly15 Step 8 Installing the Foot Plate Linkage Rod Assembly 16 Step 9 Assembling the Pulley Assembly 17 Step 10 Installing the Pulley Assembly 18 Step 11 Attaching the Drive Belt to the Foot Plate 18 Step 12 Installing the Lon...

Page 5: ...1 INTRODUCING THE 600H HIKER BY CYBEX 600H Hiker by Cybex 2 ...

Page 6: ...fortable for the hips and the foot plates are angled to create a natural hiking motion Users have the option of using the ergonomically designed handles which are linked to the pedals By having all four points the two pedals and two handles linked little coordination is required to accomplish the total body cardio workout The dual action 600H Hiker works the major muscles of both the upper and low...

Page 7: ...WARRANTIES EXPRESS OR IMPLIED WITH REGARD TO GOODS OR SERVICES PROVIDED BY SELLER OTHER THAN THOSE SET FORTH HEREIN ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF BUYER WHICH EXCEEDS THE FOREGOING WARRANTY IS HEREBY DISCLAIMED BY SELLER SELLER WILL NOT BE LIABLE FOR ANY DIRECT OR INDIRECT CONSEQUENTIAL OR INCIDENTAL DAMAGES LOSSES OR EXPENSES INCLUDING BUT NOT LIMIT...

Page 8: ...f the machine Disassembly of the 600H Hiker can be unsafe if you don t follow directions The following disassembly steps are listed in sequential order In some cases you can ignore some steps In those cases we have listed the steps you must follow before further disassembly WARNING It is very important to recognize that with few exceptions the tension from the linkage system must be released befor...

Page 9: ...the foot plate tie rod assembly 4 Remove the retaining ring attaching the foot plate tie rod assembly 5 Remove the foot plate tie rod assembly WARNING Be sure that tension from the linkage system has been released prior or further disassembly STEP 4 Disassembling the Tie Rod Assemblies Must complete at least Steps 1 2 3 Disassembly Tools required One 3 4 wrench one 5 8 wrench NOTE The rod ends and...

Page 10: ...w 4 1 2 13 lock nut 5 1 2 28 nut left hand thread 6 1 2 28 nut right hand thread 7 1 2 rod end with 1 2 28 left hand thread 8 1 2 rod end with 1 2 28 right hand thread 9 Short tie rod 10 Long tie rod 11 Foot plate tie rod 12 1 2 flat washer 13 1 2 ID spacer 14 3 4 ID wear washer x 7 15 Retaining ring foot plate tie rod Fig 2 6 Fig 2 7 Fig 2 8 14 11 9 10 ...

Page 11: ...ley assembly 4 Remove the 1 2 x 625 long shoulder screw 5 Remove the pulley assembly See figure10 WARNING Be sure that tension from the linkage system has been released prior to further disassembly STEP 7 Removing the Foot Plate Must complete at least Step 2 Disassembly Tools required One flat head screwdriver one rubber hammer 1 Remove the two retaining rings on the foot plate which attach the fo...

Page 12: ...sets 5 Rotate pivot arm assembly to remove WARNING Be sure that tension from the linkage system has been released prior to further disassembly STEP 9 Removing the Front Pivot Arm Assembly Must complete Steps 1 2 3 4 Disassembly Tools required Two 1 2 wrenches 1 Remove four 5 16 18 x 75 long screws and four 5 16 18 lock nuts See figure 2 15 2 Slide off both of the bearing sets 3 Rotate the pivot ar...

Page 13: ...one 9 16 wrench 1 Remove one 3 8 16 x 3 75 long bolt and one 3 8 16 lock nut See figure 2 17 2 Slide out the front linkage assembly See figure 2 18 NOTE It is sometimes easier to see if you stand machine on its rear legs WARNING Be sure that tension from the linkage system has been released prior to further disassembly Fig 2 17 Fig 2 18 ...

Page 14: ...bolt in from the top Make sure the wide spacing of the linkage assembly is on the bottom See figure 3 2 5 Attach on 3 8 16 lock nut and tighten to 22 ft lb minimum STEP 2 Installing the Front Pivot Arm Assembly Tools required Two 1 2 wrenches 1 Select the front pivot arm assembly This is comprised of four 5 16 18 x 75 long screws four 5 16 18 lock nuts four flangettes and two 1 ID bearings See fig...

Page 15: ...ad one 1 2 rod end with 1 2 28 left hand thread one 1 2 28 check nut right hand thread and one 1 2 rod end with 1 2 28 right hand thread See figure 3 7 2 Screw the 1 2 28 check nut left hand thread onto the 1 2 28 rod end with 1 2 28 left hand thread 3 Screw the rod end with nut into the 1 2 28 left hand threaded end of the short tie rod 4 Repeat steps 2 and 3 for the right hand rod end and nut 5 ...

Page 16: ... linkage assembly See figure 3 11 4 Slide from the top one 1 2 13 x 1 75 long bolt through the assembly 5 Attach on 1 2 13 lock nut and tighten to 50 ft lb minimum See figure 3 11 6 Position the short linkage rod assembly against the inside surface of the front pivot and in line with lower 1 2 diameter hole See figure 3 12 7 From the inside of the unit slide one 1 2 13 x 1 75 long bolt through the...

Page 17: ... set includes one 1 ID bearing and two flangettes Slide both bearing sets onto the pivot shaft with the extended race facing toward the inside See figure 3 15 4 Slide both plastic cap brackets See figure 3 16 5 Slide the four 5 16 18 x 75 long screws through the holes in the plastic bracket flangette and mounting bracket See figure 3 16 6 Attach the four 5 16 18 lock nuts and leave loose 7 Adjust ...

Page 18: ...ront Pivot Arm Assembly Tools required One flat head screwdriver 1 Select a foot plate along with three 3 4 ID wear washers one belt attachment assembly and two retaining rings 2 Slide one 3 4 ID wear washer A onto the pivot shaft See figure 3 21 3 Slide one foot plate halfway onto the pivot shaft See figure 3 21 4 Slide one 3 4 ID wear washer onto the pivot shaft See figure 3 21 5 Slide one belt ...

Page 19: ... the foot plate linkage rod assembly through the foot plate from the outside of the unit See figure 3 23 3 Slide the five 3 4 ID wear washers onto the shaft See figure 3 23 4 Attach the retainer See figure 3 23 5 Rotate the tie rod into position and install the 1 2 13 x 1 50 bolt See figure 3 24 6 Tighten the 1 2 13 x 1 50 long bolt to a 50 ft lb minimum See figure 3 25 7 Orient the rod end parall...

Page 20: ...3 Slide one 3 8 16 x 2 5 long bolt through the hole in the pulley and bracket it from the side corresponding to the offset space on the bottom of the pulley bracket See figure 3 28 4 Tighten the nut and bolt to a 22 ft lb minimum 5 Slide the pivot bushing into the loop of the extension spring 6 Using one 1 2 x 1 750 long shoulder bolt and one 3 8 16 lock nut assemble into the spring bracket two sp...

Page 21: ...hings See figure 3 30 5 Attach the 3 8 16 lock nut and tighten to a 22 ft lb minimum STEP 11 Attaching the Drive Belt to the Foot Plate Tools required One 1 8 Allen wrench 1 Select one drive belt along with one belt retainer and two 1 4 x 5 16 long set screws into the belt retainer 2 Insert the two 1 4 x 5 16 long set screws into the belt retainer 3 Slide the belt retainer with the set screws on t...

Page 22: ...ley See figure 3 33 5 Twist the drive belt 90 degrees so that the teeth surface of the drive belt will engage the drive pulley 6 Route the drive belt over the drive pulley See figure 3 34 7 Attach the drive belt to the other foot plate following the instruction in Step 11 Installation Attaching the Drive Belt to the Foot Plate STEP 13 Attaching the Extension Spring to the Spring Shaft No tools req...

Page 23: ...ith 1 2 28 right hand thread See figure 3 37 2 Screw the 1 2 28 check nut left hand thread onto the 1 2 28 rod end with 1 2 28 left hand thread 3 Screw the rod end with nut into the 1 2 28 left hand threaded end of the long tie rod 4 Repeat steps 2 and 3 for the right hand rod end and nut 5 Adjust each rod end so that it is 95 from the end of the tie rod to the shoulder onto he rod end See figure ...

Page 24: ...ube See figure 3 41 5 Slide the 1 2 ID spacer onto the 1 2 13 x 2 00 long bolt See figure 3 41 6 Slide the rod end onto the 1 2 13 x 2 00 long bolt See figure 3 41 7 Attach one 1 2 13 lock nut and tighten to a 50 ft lb minimum See figure 3 42 8 Position yourself straddling the side tube as shown in figure 3 43 9 Grasp the long tie rod assembly with one hand and lift it up 10 With your foot push th...

Page 25: ...en 7 50 and 7 75 from the floor go to step 4 3b If the foot plate are level and between 7 50 and 7 75 from the floor go to step 5 4 To adjust the position of the foot plate rotate the long tie rod See figure 3 47 Note that one full revolution 360 degrees of the tie rod is equal to approximately 1 of movement at the foot plate 5 Verify that the idler pulley does not make contact with either the fra...

Page 26: ...p so that it touches the 2 x 2 tube See figure 3 50 3 Tighten the check nut to a 22 ft lb minimum 4 Position the foot plates at full stroke and measure the distance from the end of the foot plate to the end of the foot plate See figure 3 51 5 This dimension should be between 23 and 25 If it is not then the unit is not properly adjusted and the adjustment for the linkage system and the adjustment f...

Page 27: ...ud into position 4 Slide the left shroud down over the left handle and into position 5 Slide the right shroud down over the right handle and into position 6 Attach all 15 metal screws and washers to the shrouds and tighten 7 Attach the left side shroud to the frame using one 1 32 x 50 long screw 8 Attach the right side shroud to the frame using one 10 32 x 50 long screw 9 Attach the shrouds to the...

Page 28: ...the screws aside 3 While holding both the display console front with display board attached and the plastic wire cover lift them both slowly until the plastic wire cover can be removed to expose the console wiring 4 Unplug the console cable and the heart rate cable from the display console circuit board Loosen and remove the two Phillips head screws that fasten the board to the console front Disco...

Page 29: ...NTENSITY window at the same time 3 Press CARDIO 1 and use the right or key to adjust the first smaller number recorded earlier 4 Press START and use the right or key to adjust the second larger number recorded earlier 5 Press START and SAVE will appear in the right window 6 Press the and keys in the INTENSITY window to exit the diagnostic mode Pulley Replacement NOTE It is not necessary to remove ...

Page 30: ...ing upward in the current position of the machine Install the pulley hardware and tighten 9 Using the TFL spray lube supplied with the kit spray the toothed pulleys 2 being sure to cover the entire toothed area all the way around the pulley 10 Grasp the tension spring and stretch and connect the loose end over the shaft it was removed from 11 Return the Hiker to its normal operating position 12 Sl...

Page 31: ...RDIO 1 to enter this test mode NOTE The Hiker cannot execute this calibration manually the calibration numbers need to be entered from current data Refer to the calibration procedure outlined in the Hiker Retro Kit section 4 To get back to the Display LED testing mode press FAT BURN 1 To exit the Calibration testing mode press the and key in the window labeled DURATION DVM Test This test is to che...

Page 32: ...s the Fat Burn 2 Program button to measure display if necessary toggle back to LED test by pressing Fat Burn 1 Program button 2 If left display does not show bat press left switch until it does This voltage typically reads about 0 2 volts lower than a meter directly on the battery 3 Leave this display active for at least 2 minutes voltage may drop slightly during this time Read and record the fina...

Page 33: ...split 312 55 2 HS327600 Washer SAE 312 56 18 HS 00266 Bolt Hex head 5 16 18 x 3 4 57 1 FW 15061 Flywheel 58 1 HX 14597 Extension spring 59 2 PW 11644 Pulley clutch timing aluminum ITEM QTY PART NO DESCRIPTION 60 1 FM 14527 Shaft clutch 61 1 HX 14731 Retaining ring 1 shaft external 62 5 HB 12136 Bearing thrust 1 0 x 1 75 63 1 3900 307 Sprocket driver secondary 64 5 HC700415 Button head socket 375 1...

Page 34: ... 99 56 37 14 57 85 79 80 16 15 80 81 20 65 64 63 75 62 86 59 62 21 21 62 59 62 61 45 44 38 60 66 30 28 31 28 66 30 29 58 20 13 20 13 76 77 37 18 17 84 82 83 56 19 56 74 45 52 49 45 49 50 46 47 53 51 48 49 82 56 8 69 67 71 68 70 34 33 26 25 23 24 73 23 72 28 32 30 3 1 32 30 28 31 29 37 20 41 38 36 38 10 93 93 97 98 65 64 89 7 12 92 94 96 95 22 64 54 35 88 91 87 9 90 87 31 ...

Page 35: ...00 366 CONTACT HEART RATE CONTACT HEART RATE 3900 366 ASSY HIKER DISPLAY 3900 346G2 BLACK RED BLACK RED BATT J3 BATT J4 LEAD ACID 6V 4AH FIELD J5 ALTAC J6 J10 LOAD J1 ALT J2 ALT D C GND BLACK VCC WHITE BIOSIG SIGNAL RED U9 BIOSIG INPUT A B TO TOP SWITCH GND VCC SIGNAL POLAR TO BOTTOM SWITCH INPUT POLAR J6 INTERNALLY BLUE 7 13 14 2 4 3 6 5 11 10 9 12 1 8 WHITE BROWN GREEN GND GND I 13 7 14 1 3 2 LO...

Page 36: ...10 Trotter Drive Medway MA 02053 1 888 GO CYBEX 1 888 462 9239 FAX 508 533 5183 www eCybex com techhelp cybexintl com Copyright 2000 Cybex International Inc All rights reserved SM 15649 March 2000 ...

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