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Cybex Arc Trainer

630A

Service Manual

Cardiovascular Systems

Part Number 630A-901

Cybex

and the Cybex logo are registered trademarks of Cybex International, Inc.

Arc Trainer

and its mark are registered trademarks of Cybex International, Inc.

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
obligation to notify any person of such revisions or changes.

2009

4ROTTER$RIVE-EDWAY-!sss&!8
WWWCYBEXINTERNATIONALCOMsTECHHELP CYBEXINTLCOMs

630A-901 B

December 2009

Summary of Contents for Arc Trainer 630A

Page 1: ...Cybex Arc Trainer 630A Service Manual Cardiovascular Systems Part Number 630A 901 B www cybexinternational com ...

Page 2: ......

Page 3: ...onal 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 obligation to notify any person of such revisions or changes 2009 Cybex International Inc All rights reserved Printed in United States of America 4ROTTER RIVE EDWAY s s s 8 WWW CYBEXINT...

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Page 5: ... PROVIDE REASONABLE PROTECTION AGAINST HARMFUL INTERFERENCE IN A RESIDENTIAL INSTALLATION 4HIS 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 F THIS EQUIPMENT DOES CAUSE ...

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Page 7: ... Trainer 630A 2 2 RIVE ELT AINTENANCE 2 3 Lubrication 2 5 Environment 2 5 Storage 2 5 Service Schedule 2 6 2ECHARGEABLE ATTERY 2 7 3 Customer Service Contacting Service 3 1 3ERIAL UMBER AND 6OLTAGE 3 1 2ETURN ATERIAL UTHORIZATION 2 3 2 Damaged Parts 3 3 Ordering Parts 3 3 4 Service PartList Main Assembly XPLODED 6IEW AIN SSEMBLY Parts List Console Assembly XPLODED 6IEW ONSOLE SSEMBLY 0ARTS IST RON...

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Page 9: ...CORD HAVING AN EQUIPMENT GROUNDING CONDUCTOR AND A GROUNDING PLUG 4HE PLUG MUST BE PLUGGED INTO AN APPROPRIATE OUTLET THAT IS PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ordinances Cybex Arc Trainer 630A Service Manual AW 19522 EW600005 AW 19587 AW 19521 6 6 6 6 DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check w...

Page 10: ...RAM s 3TOP EXERCISING IF YOU FEEL FAINT DIZZY OR EXPERIENCE PAIN s 2EAD AND UNDERSTAND THE WNER S ANUAL AND ALL WARNINGS POSTED ON THE UNIT BEFORE USING s 4 WEAR LOOSE OR DANGLING CLOTHING WHILE USING s EEP ALL BODY PARTS TOWELS AND THE LIKE FREE AND CLEAR OF MOVING PARTS s 5SE THE HANDRAILS FOR SUPPORT AND TO MAINTAIN BALANCE s 4 USE THE UNIT IF YOU EXCEED LBS KG 4HIS IS THE RATED MAXIMUM USER WE...

Page 11: ...LL MAINTENANCE ACTIVITIES s 5SE ONLY YBEX SUPPLIED COMPONENTS TO MAINTAIN REPAIR THE EQUIPMENT s O NOT USE ATTACHMENTS UNLESS RECOMMENDED FOR THE UNIT BY YBEX s O NOT USE THE UNIT IF THE UNIT IS PLUGGED INTO AN OPTIONAL POWER ADAPTER THAT HAS A DAMAGED CORD THE UNIT IS NOT WORKING PROPERLY OR IF THE UNIT HAS BEEN DROPPED OR DAMAGED 3EEK service from a qualified technician s O NOT USE THE OPTIONAL ...

Page 12: ...ES AND ADDITIONAL PROTECTIVE EARTH MAY BE NEEDED TO ASSURE COMPLIANCE WITH s O NOT POWER THE ENTIRE SYSTEM FROM A SINGLE OUTLET OR POWER STRIP F THE UNIT IS USED WITH THE OPTIONAL POWER SUPPLY ENSURE THAT THIS POWER SUPPLY IS PLUGGED IN TO A SEPARATE OUTLET THAN ANY CONNECTED DEVICE TO PREVENT EXCEEDING THE ALLOWABLE LEAKAGE CURRENT OF THE SYSTEM s ND USER OF A SYSTEM SHALL ENSURE THAT INTERRUPTIO...

Page 13: ...8 533 5183 or contact Cybex Customer Service at 888 462 9239 If you live outside of the USA call 508 533 4300 7ARNING DECALS INDICATE A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR serious injury The warning decals are shown below Warning Decals 7ARNING DECAL PART NUMBER Cybex Arc Trainer 630A Service Manual ...

Page 14: ... may still be present even if the unit is unplugged SERIOUS INJURY COULD OCCUR IF THESE PRECAUTIONS ARE NOT OBSERVED WARNING DE 17155 4 Hot flywheel Wait until it cools before servicing 3HIELD PART NUMBER 630A 316 7ARNING DECAL PART NUMBER Warning battery DE 19586 Located on battery bracket Underneath Access Cover 7ARNING DECAL PART NUMBER Cybex Arc Trainer 630A Service Manual ...

Page 15: ... Arm Left Rear 610AK010 Foot Plate Arm Right Rear 610AK011 Foot Plate Right 610AK002 Foot Plate Left 610AK003 Foot Plate Wave Washer 610AK020 Frame Main Frame Assembly 610AK019 4 Linkage Rod Left 600AK006 Linkage Rod Right 600AK007 Linkage Cap 600AK012 Hardware Pack 610AK017 Heart Rate Grip w o Drill Bit 620AK002 Heart Rate Grip with Drill Bit 620AK007 Accessories Handle Bar 620AK005 Personal Ente...

Page 16: ...Service Page 4 18 This page intentionally left blank ...

Page 17: ... unit has three screws then remove crank cover mounting bracket and discard as this is no longer required Figure 3 5 Attach the new crank cover A Place new crank cover B in position B Using a Phillips screwdriver attach the two screws A securing the crank cover in place See Figure 3 6 Secure the linkage arm A Reinstall SHCS flat washer cap and spacer that was removed in step 3A See Figure 2 NOTE S...

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Page 19: ...Remove the two upper screws securing the access cover See Figure 2 C Remove the access cover Figure 1 Figure 2 4 Attach the new access cover A Install the four grommets and screws NOTE Place grommets on the inside of the front cover Install upper two gromments screws first then the two lower gromments washers B Tighten the four screws using a Phillips screwdriver NOTE Do not over tighten screws Se...

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Page 21: ...o install the other screws washers I Turn the main power switch to the on I position J Test the unit to verify proper operation Figure 1 Figure 2 3 Replace the pivot cover A Turn the main power switch above the power inlet to the off 0 position B Using two 7 32 Allen wrenches remove the four BHSCS and pivot shaft retainers securing the pivot cover NOTE Once one of the two screws is removed two in ...

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Page 23: ...isconnect the power cord before continuing this procedure Keep wet items away from inside parts of the unit Electrical shock could occur even if the unit is unplugged Access Cover C D H B 4 Elevate the unit and disconnect the power source A Elevate the unit to a minimum of level 7 incline B While the unit is elevated turn the main power switch to the off 0 position and unplug the power cord from t...

Page 24: ...htened into B Using a 3 16 Allen wrench reinstall the parts removed in step 6A See Figure 3 C Torque to 100 in lbs 13 Reinstall access cover A While being sure not to pinch any cables hold the access cover in place See Figure 2 B Using a Phillips head screwdriver install and tighten the two upper screws first removed in step 5B NOTE Do not over tighten screws C Install and tighten the two lower sc...

Page 25: ...t NOTE Do not press stop 4 Remove the center elevation motor cover A Using a Phillips head screwdriver remove the two screws securing the center cover in place B Remove the center cover WARNING Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the unit 5 Replace the acme tube A Using two 9 16 open end wrenches remove the bottom bolt and ...

Page 26: ... position C Operate the unit at all levels to verify proper operation D Turn main power switch off to verify it is wired properly 10 Trotter Drive Medway MA 02053 508 533 4300 FAX 508 533 5183 www cybexinternational com techhelp cybexintl com techpubs cybexintl com Copyright 2008 Cybex International Inc All rights reserved 600A 307 A March 2008 Cybex and the Cybex logo are registered trademarks of...

Page 27: ...rce A Turn the main power switch to the off 0 position and unplug the power cord from the power outlet WARNING Disconnect the power cord before continuing this procedure Keep wet items away from inside parts of the unit Electrical shock could occur even if the unit is unplugged A 4 Remove the access cover A Using a Phillips head screwdriver remove the four screws and four washers securing the acce...

Page 28: ... straight edge verify that both pulleys are aligned properly See Figure 4 NOTE The straight edge must be no more than 1 16 from pulley edge 10 Trotter Drive Medway MA 02053 508 533 4300 FAX 508 533 5183 www cybexinternational com techhelp cybexintl com techpubs cybexintl com Copyright 2008 Cybex International Inc All rights reserved 600A 317 B March 2008 Figure 4 7 Attach the access cover A While ...

Page 29: ...Screw 4 NOTE This instruction sheet describes how to replace the primary drive 16 rib belt on the Arc Trainer 600A 610A TOOLS REQUIRED Cloth or rag 2 1 2 Socket wrench Phillips screwdriver 1 2 Open end wrench 3 16 Allen wrench 9 16 Socket wrench 7 16 Socket wrench 9 16 Open end wrench 3 Socket wrench extension 600AK012 not supplied with this kit E 5 Detach the linkage arms A Using a 3 16 Allen wre...

Page 30: ...igure 4 B Remove both side covers NOTE The gasket will come off with one of the side covers Figure 4 Washer Screw Side Cover Gasket 7 Remove the crank covers and the crank arm disk supports A Using a Phillips screwdriver remove the three screws securing each crank cover and remove the crank covers See Figure 5 B Using a Phillips screwdriver remove the screw securing each crank arm disk support See...

Page 31: ...HCS two lockwashers two washers and two hex nuts D Turn each HHCS in a couple of turns by hand E Place secondary drive belt on the secondary pulley and then on the lower pulley F Place primary drive belt on the lower pulley and then stretch onto crank shaft pulley G Using a 1 2 socket wrench with a 3 extension tighten one of the HHCS a few turns then tighten the other HHCS a few turns Alternate un...

Page 32: ...tep 5A See Figure 3 20 Attach the access cover A While being sure not to pinch any cables hold the access cover in place See Figure 2 B Using a Phillips head screwdriver tighten the four screws and washers securing the access cover See Figure 2 21 Test unit for proper operation Cybex and the Cybex logo are registered trademarks of Cybex International Inc Arc Trainer and its mark are registered tra...

Page 33: ...access cover See Figure 2 B Remove the access cover WARNING Flywheel may be hot Wait until it cools before servicing 5 Detach the connecting rods A Using a 3 16 Allen wrench remove the SHCS and spacer securing the linkage arm See figure 3 NOTE Figure 3 shows the contents of the linkage cap kit that will be installed in step 23A B Lay the linkage bar down on the frame NOTE Place a cloth in between ...

Page 34: ...securing each crank cover and remove the crank covers See Figure 5 B Using a Phillips screwdriver remove the screw securing each crank arm disk support See Figure 6 Figure 5 Figure 6 Figure 9 Figure 10 Figure 8 WARNING Failure to release the drive belt tension may cause potential injury and may damage the unit 8 Release the drive belt tension A Using a 7 16 socket wrench remove the two screws two ...

Page 35: ...belt is self tensioning 17 Release the tension of the primary drive belt if applicable A Using a 1 2 socket wrench loosen the bottom screw on the idler pulley See Figure 13 B Using a 1 2 socket wrench loosen the top screw on the idler pulley See Figure 13 18 Torque the primary belt if applicable A Using a 3 8 square hole torque wrench pull up until the idler wheel rocks against the brake and is to...

Page 36: ... screws and six washers securing each side cover See Figure 5 22 Secure the connecting rods A Attach each connecting rod to each crank using the 600AK012 Linkage Cap kit Follow the instructions in the kit 23 Attach the access cover A While being sure not to pinch any cables hold the access cover in place See Figure 2 B Using a Phillips head screwdriver tighten the four screws and washers securing ...

Page 37: ... into F Secure the foot plate using the SHCS and washer removed in step 3C to the new foot plate arm Figure 1 A Arm 1 see appropriate kit number listed above B Linkage cap kit 600AK012 NOTE The linkage cap kit is used on the linkage rods only Please retain 600AK012 for future service requirements 3 Remove the proper foot plate arm A Turn the main power switch above the power inlet to the off 0 pos...

Page 38: ...bex logo are registered trademarks of Cybex International Inc Arc Trainer and its mark are registered trademarks of Cybex International Inc 10 Trotter Drive Medway MA 02053 508 533 4300 FAX 508 533 5183 www cybexinternational com techhelp cybexintl com techpubs cybexintl com Copyright 2008 Cybex International Inc All rights reserved 610A 368 A March 2008 ...

Page 39: ...o flat washers B and SHSC C and securely tighten E Repeat steps 4C and 4D for the other washers B and SHCS C Figure 1 right foot assembly Figure 2 right foot assembly A 3 Remove right foot plate assembly A Turn the main power switch above the power inlet to the off 0 position B Using a 3 16 Allen wrench remove the two SHCS securing the right foot plate NOTE The right and left foot plates are not i...

Page 40: ...ot assembly Figure 2 left foot assembly A 3 Remove left foot plate assembly A Turn the main power switch above the power inlet to the off 0 position B Using a 3 16 Allen wrench remove the two SHCS securing the left foot plate NOTE The right and left foot plates are not interchangeable C Remove all hardware securing the old foot plate F Turn the main power switch to the on I position G Test the uni...

Page 41: ... 3 Remove right foot plate assembly A Turn the main power switch above the power inlet to the off 0 position B Using a 3 16 Allen wrench remove the two SHCS securing the right foot plate C Remove flat washers and foot plate NOTE Do not remove spacer D Repeat steps 3B 3C for left foot plate G Turn the main power switch to the on I position H Test the unit to verify proper operation SHCS Flat Washer...

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Page 43: ...off 0 position and unplug the power cord from the power outlet 4 Remove console A Using a 7 32 Allen wrench remove the four 375 16 x 1 50 BHCS Button Head Cap Screw and four washers See Figure 1 B Unplug upper display cable from lower display cable C Set console aside NOTE Console will be attached to the new frame later 5 Remove lower left linkage rod A Using a 3 16 Allen wrench remove each SHCS S...

Page 44: ...re 5 E Raise front footplate arm so that the holes align with holes in frame and pivot cover F Insert pivot pin removed in step 7A See Figure 5 G Repeat steps 11C 11D Rear foot plate arm Foot plate arm assembly F Repeat steps 6A 6E to remove other handle linkage rod and arm handle 7 Remove left front foot plate arm A Using two 7 32 Allen wrenches remove the inside BHSCS and retainer While holding ...

Page 45: ...0 and 11 See Figure 5 15 Remove the left and right crank covers A Using a Phillips screwdriver remove the screws securing the crank covers and remove See Figure 7 Screws 16 Remove the left shroud A Using a long phillips head screwdriver remove the ten screws and two washers securing left shroud cover in place See Figure 8 Screws 17 Remove the right shroud A Using a long phillips screwdriver remove...

Page 46: ...ttach HHCS sleeve and locknut removed in step 20A and tighten securing elevation motor to frame See Figure 12 22 Attach display cable to control board A Route display cable through holes in drive frame assembly following existing wires to control board B Plug display cable in to display jack on control board See Figure 11 23 Attach controller cover A Place cover in position and secure by pushing t...

Page 47: ...rt pivot pin removed in step 6D See Figure 4 NOTE You may need a rubber mallet to install the pivot pin C Place a drop of loctite 242 on the BHSCS removed in step 6D Place another drop of loctite 242 inside pivot pin shaft where the BHSCS will be tightened into D Using two 7 32 Allen wrenches install the two BHSCS and washers removed in Step 6D See Figure 4 E Repeat steps 28A 28D for right arm han...

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Page 49: ... black zinc 1 HS 17084 C SHCS 250 20 x 75 1 HS 17055 D Flat Washer 281 ID x 50 OD x 062 1 HS307601 E Spacer 1 600A311 F Spacer 1 PL 17281 G Cap 1 63 OD 1 PL 17188 H Cap 2 00 OD 1 PL 16535 I Loctite not shown NOTE B F G used on Arc Trainer 600A only 3 Replace the appropriate linkage rod assembly A Turn the main power switch above the power inlet to the off 0 position B Confirm you have the proper r...

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Page 51: ...Linkage Arm NOTE SHCS must be tightened to a minimum of 90 inch pounds NOTE This instruction sheet decribes how to replace the linkage cap in the Arc Trainer 600A 610A TOOLS REQUIRED 3 16 Allen wrench 1 Read and understand all instructions thoroughly before installing this kit 2 Verify kit contents See Figure 1 Figure 1 A SHCS 250 20 UNC 3A SS 2 HX622815 B Flat Washer 2 HS307601 C Spacer 2 600A 31...

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Page 53: ... 10 will be tightened into Allen wrench 3 16 BK030201 1 Allen wrench 7 32 BK030204 2 Linkage Rod Cap PL 16535 2 Washer 281 x 50 HS307601 2 SHCSC 250 20 x 75 HX622815 2 Flange Spacer 600A 311 2 BHSCS 375 16 x 1 50 JC700422 4 Internal Tooth Lockwasher JS347400 4 Pan HD Phil HD Self Tapping 8 16 x 75 Type WB Black HT552515 2 1 3 4 5 6 7 8 9 6 Water Bottle Holder 1 3 2 5 7 7 6 5 4 4 2 10 Loctite 242 Y...

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Page 55: ...contain any screws that are visible B New style grips contain two screws that are visible on the finger side 4 Remove old style grips and sensor B Using a Phillips screwdriver remove the two screws and two nuts securing the grip in place See Figure 2 5 Remove new style grips A Using a Phillips screwdriver remove the two screws securing the grips in place See Figure 3 A With a flat head screwdriver...

Page 56: ...NOTE If no heart rate reading is showing verify that the black and the brown or red wire location is correct and that the cable labeled left is on the left side Figure 4 Handle Assembly Figure 5 Heart Rate Cable Connectors Console Assembly BHSCS Plastic Insert BHSCS 4 Washer 4 Console Assembly Frame B Using a flat head screwdriver pry off the plastic insert from the hand assembly See Figure 5 C Us...

Page 57: ...D BHSCS 375 16 X1 00 SS 2 HX 700417 E Loctite 1 YA000201 B C D 3 Remove handle assembly A Using a 7 32 Allen wrench remove the Button Head Socket Cap Screw BHSCS D and pivot shaft retainer B from each side of the handle assembly See Figure 2 B D Loctite Figure 2 A A Figure 3 Heart Rate Cable Connectors Console Assembly C B Using a 7 32 Allen wrench remove the two BHSCS C securing the handle assemb...

Page 58: ...e D and pivot shaft retainer to each side of the handle assembly See Figure 2 5 Test the unit for proper operation Cybex and the Cybex logo are registered trademarks of Cybex International Inc Arc Trainer and its mark are registered trademarks of Cybex International Inc 10 Trotter Drive Medway MA 02053 508 533 4300 FAX 508 533 5183 www cybexinternational com techhelp cybexintl com techpubs cybexin...

Page 59: ...llen wrench 3 mm 1 BK030210 H Adapter 1 4 plug to 1 8 stereo jack 1 ES000001 I Self tapping screw 8 16 x 31 2 HT552509 J Self tapping screw 8 16 x 75 2 HT552515 K Strain relief bushing 1 PP740000 L A V bottom membrane 1 SW 19295 4 NOTE for English Console only M Cybex monitor kit 1 EE000005 or EE000007 N Poster 1 620A 387 not shown O Warranty sheet 1 LT 20219 not shown P Cable Tie 2 EW000028 Figur...

Page 60: ... BHSCS Screw 4 Lock Washer 4 Figure 6 Figure 7 Access Hole Block Wheel Bolt Nut 5 Remove left wheel A Place a block under the unit as shown in Figure 7 B Using a 7 16 wrench and a 5 32 Allen wrench remove the bolt and nut securing the left wheel in place and remove the wheel See Figure 7 Figure 8 Coax Cable and Power Cable with male connector Cables Access Hole Feed cable down to the bottom then b...

Page 61: ...e 10 C Unplug the bottom membrane ribbon cable from the the main display PC board See Figure 11 D Using a utility knife pry off bottom membrane from the front console cover See Figure 12 Figure 11 Ribbon Cable E Peel off backing from new A V membrane and place on the front console cover See Figure 12 F Plug the A V membrane ribbon cable into the main display PC board See Figure 11 G Using a Philli...

Page 62: ... and audio cables A Attach the RJ 45 C and audio cables B to the main display pc board See Figure 14 B Insert the RJ 45 cable up through the monitor mount and exit the top See Figure 17 C Using a 5 32 Allen wrench reattach the four BHSCS and four lock washers securing the console to the new console mount See Figure 6 13 Installing coax and power cables in console mount A Lay the console mount on t...

Page 63: ...assembly to the heart rate connector from the handle assembly See Figure 5 NOTE Ensure cable connectors are securely fastened C With 8 of coax and power cables exiting the top of the console assembly pull the extra coax and power cables out of the bottom of the main frame NOTE Exactly 8 20 cm of cable must exit the top of the monitor mount D Using a 7 32 Allen wrench attach the two BHSCS securing ...

Page 64: ...base of the Arc 17 Set up monitor for first time use A Locate the Personal Entertainment Monitor Manual LT 20191 and follow the set up procedure in Chapter 5 B Plug the power cord X into a wall outlet C Plug headphones not supplied into headphone jack located at base of console D Refer to Chapter 3 of the Personal Entertainment Monitor Manual LT 20191 regarding use of the channel and volume keys l...

Page 65: ...ws one screw on each side securing the access cover See Figure 2 B Remove the two upper screws one screw on each side securing the access cover C Remove the Access cover A Voltage Assembly Kit 1 630AK0XX B Cable Tie 1 EW000028 C Disconnect Power 7 Languages Decal 1 CM000240 D Medical Inlet Decal 1 DE 19547 4 E Power Cord 1 250V 3A AW 19521 110V 60Hz AW 19522 110V 50Hz AW 19587 220V 50Hz EW600005 A...

Page 66: ... screws 11 Reinstall access cover A While being sure not pinch any cables hold the access cover in place See Figure 2 B Using a Phillips screwdriver install and tighten the two upper screws ﬁrst removed in step 5B NOTE Do not over tighten screws C Install and tighten the two lower screws removed in step 5A NOTE Do not over tighten screws 12 Install warning decals A Peel off backing and install the...

Page 67: ...O SEND 7 RTS REQUEST TO SEND 6 DSR DATA SET READY 4 DTR READY 3 TD TRANSMIT DATA 2 RD RECEIVE DATA 1 CD CARRIER DETECT ELEV UP POT HIGH POT WIPER DISPLAY CHASSIS GND LOGIC GND PWM GND BATTERY ON AW 18440 P3 TXD RXD AW 18439 BRAKE 9V RPM 9V ELEV DOWN NC AW 18447 2 5A 250V FB BATTERY PWR 15A 125V FB INCLINE MOTOR CABLE SPA 12V BATTERY VDD TO DISPLAY 0 75A 24V PTC RESETTABLE BATTERY 12V 7AHR EC 18267...

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Page 70: ...10 Trotter Drive Medway MA 02053 508 533 4300 FAX 508 533 5183 www cybexinternational com Techhelp cybexintl com techpubs cybexintl com ...

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