CYBEX 610A, Service Manual

Page 1: ...away from inside parts of the unit Electrical shock could occur even if the unit is unplugged WARNING Flywheel may be hot Wait until it cools before servicing CAUTION Do not pinch your fingers between the belt and pulley during this procedure WARNING Failure to release the drive belt tension may cause personal injury and may damage the unit WARNING Do not touch components on the lower board A char...

Page 2: ...e 1 Test Mode To enter Test Mode press and hold down the Pause end key on the display while turning the power switch to the on I position When all keys are released ARC and the software revision x xx are shown on the display To exit Test Mode press Pause end Stuck Key List It Test Mode occurs without holding any keys a key may be stuck closed or Error 7 may have occurred You may need to replace th...

Page 3: ...ed sensor Key Functions While in Test Mode press the following keys for desired information Hill Interval key Lights all of the LEDs for a short period of time Weight Loss key Lights only the columns Strength key Lights only the rows Incline Run elevation motor up Incline Run elevation motor down Resistance plus Run resistance up Resistance minus Run resistance down Distance Press once for odomete...

Page 4: ...he next stored error To clear the Error Log Press the Scan key twice To exit Test Mode Press the Stop key NOTE A processor upset can cause a bAd See F then G Error Description bAd0 Bad check sum See F then E bAd2 Internal RAM error See F then E bAd3 Watchdog timeout See F then E Err3 Speed sense lost See A and B Err5 No index switch sense within timed limits This is declared when the timed elevati...

Page 5: ...lips head screwdriver remove the four screws securing the access cover See Figure 2 B Remove the access cover 3 Visually inspect the target disk on the lower pulley A Turn the lower pulley slowly and look for dirt scratches or other damage on the target disk See Figure 3 NOTE If the target disk or speed sensor is dusty use a soft dry cloth to wipe off the dust A dirty scratched or damaged disk may...

Page 6: ...dure C Slowly move the flywheel with your hand and check the speed LED on the lower board It should blink as the target disk passes the sensor D Mount the unit and begin striding at a steady pace E While striding take note of the speed that is displayed in the strides per minute display This number should increase as you stride faster If the number fluctuates greatly then your speed sensor gap may...

Page 7: ...nnect the power source A Plug the power cord into the power outlet B Enter Test Mode C Elevate the unit to a minimum of level 7 incline D While the unit is elevated turn the main power switch to the off O position and unplug the power cord from the power outlet 2 Remove the access cover A Using a Phillips head screwdriver remove the four screws securing the access cover See Figure 2 B Remove the a...

Page 8: ...wrench remove the two screws two lock washers and two flat washers from the lower pivot shaft See Figure 7 NOTE The tension is now released The primary belt can be replaced without loosening the idler pulley NOTE If you are not replacing the secondary belt leave the lower pivot assembly loose in its place skip steps 6B 8E and continue with step 9 B Remove the lower pivot assembly out of the second...

Page 9: ...he lower board See Figure 10 D Using a Phillips head screwdriver remove the top two screws from the lower board assembly and loosen the bottom two screws See Figure 11 E Slide the lower board assembly to the left and off the two screws then gently let it suspend by the cables 9 Remove the crank shaft assembly if applicable A Using a 9 16 socket wrench and a 9 16 open end wrench remove the two bolt...

Page 10: ...le A Confirm that a pin removed in step 9B protrudes about 1 4 out of the back of each pillow block NOTE The pins will slide into the frame in the next step See Figures 12 and 13 B Lift the assembly and slide the pins into the holes on the frame NOTE The pins should be flush with the front of the pillow blocks You may need to tap them in C Using a 9 16 socket wrench and a 9 16 open end wrench secu...

Page 11: ...ry drive belt into place on the frame 15 Secure the lower pivot assembly A Slide the lower pivot assembly through both drive belts and into place on the frame B Confirm that the secondary drive belt is straight and centered on the lower pulley See Figure 12 C Confirm that the two spacers are still in place under the lower pivot shaft D Using a 7 16 socket wrench tighten the two screws two lock was...

Page 12: ... attach the three screws securing each crank cover in place See Figure 6 20 Attach the side covers A Place each side cover in position in the rubber gasket B Using a Phillips head screwdriver tighten the six screws and six washers securing each side cover See Figure 5 21 Secure the connecting rods A Using a 3 16 Allen wrench attach the screw securing each connecting rod to each crank See Figure 4 ...

Page 13: ... elevated turn the main power switch to the off O position and unplug the power cord from the power outlet 2 Remove the access cover A Using a Phillips head screwdriver remove the four screws securing the access cover See Figure 2 B Remove the access cover WARNING Flywheel may be hot Wait until it cools before servicing 3 Detach the connecting rods A Using a 3 16 Allen wrench remove the screw secu...

Page 14: ...d A charge can remain after unplugging the power cord and turning off the unit 7 Disconnect the brake cables A Pull out on the lower board shield See Figure 9 NOTE It will snap out B Locate the two brake cables on the lower board that are labeled J1 and J2 C Disconnect the two brake cables from the lower board CAUTION Pulley on eddy current brake is sharp Wear work gloves to protect your hands 8 R...

Page 15: ... into the secondary drive belt E Place the two pins in any of the non threaded holes on the bracket NOTE Do not place the pins in threaded holes F Confirm that the brake is flat against the bracket and that the drive belt is straight on the pulley NOTE Continue to support the brake during the next step G Using a 3 16 Allen wrench first tighten the two top screws securing the eddy current brake See...

Page 16: ...gure 4 15 Attach the access cover A While being sure not to pinch any cables place the access cover in position B Using a Phillips head screwdriver attach the four screws removed in step 2A See Figure 2 16 Test the unit for proper operation A Connect the power cord into the power outlet B Turn the main power switch above the power inlet to the on I position C Operate the unit to verify proper oper...

Page 17: ... NOTE Detach only the ends where the rods connect to the crank B Place a cloth on the frame where each connecting rod will rest C Rest each rod on a cloth to prevent scratches See Figure 4 4 Remove the side covers A Using a Phillips head screwdriver remove the six screws and six washers securing each side cover in place See Figure 5 B Remove both side covers NOTE The gasket will come off with one ...

Page 18: ...er board and temporarily connect the power NOTE The switch should automatically adjust to the level 3 position starting level before adjusting the tube nut B Turn the tube with your fingers until it measures 11 37 28 9 cm from the center of the top hole to the center of the bottom hole See Figure 17 C Turn the main power switch above the power inlet to the off O position and disconnect the power c...

Page 19: ...ewdriver attach each side cover with the six screws and six washers removed in step 4A NOTE You will have to elevate the unit to level 7 to attach the bottom two screws as discussed in step 1 13 Attach the connecting rods A Place each connecting rod in position B Using a 3 16 Allen wrench attach each connecting rod with a screw removed in step 3A See Figure 4 14 Attach the access cover A While bei...

Page 20: ...wires from the Filtered Power Input Module middle one E Connect the three wires removed from step 5D to the new Filtered Power Input Module See Figure 4 F Remove the three wires from power outlet module and remove this module from the old switch plate G Place the existing power outlet module into the new switch plate H Connect the wires as shown in Figure 4 I With two pieces of tape mark the top t...

Page 21: ... cables place the access cover in position B Using a Phillips head screwdriver attach the four screws removed in step 3A 6 Test the unit for proper operation A Connect the power cord into the power inlet and the power outlet B Turn the main power switch to the on I position C Operate the unit at all levels to verify proper operation D Turn main power switch off to verify it is wired properly Figur...

Page 22: ... turn the main power switch to the off O position and unplug the power cord from the power outlet 2 Remove the access cover A Using a Phillips head screwdriver remove the four screws securing the access cover See Figure 2 B Remove the access cover WARNING Flywheel may be hot Wait until it cools before servicing 3 Detach the connecting rods A Using a 3 16 Allen wrench remove the screw securing each...

Page 23: ...h crank arm disk support in place See Figure 20 WARNING Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the unit 8 Remove the lower board assembly A Pull out on the lower board shield NOTE It will snap out B Disconnect the elevation cable from the lower board C Using a 3 8 nutdriver remove the nut washer and ground wire from the stud a...

Page 24: ... pillow block on each end of the shaft See Figure 21 NOTE Orientation of pillow block sleeve and set screws must go toward the inside Do not tighten the set screws until step 13F 13 Attach the crank shaft assembly A Confirm that a pin protrudes about 1 4 out of the back of each pillow block and flush with the front NOTE The pins will slide into the frame in the next step B Place the assembly into ...

Page 25: ... into its slot on the frame D Place the washer first and the ground terminal next onto the stud and tighten with the nut removed during step 8C E Place the lower board shield in position and snap it in 16 Attach the crank arm disk supports A Using a Phillips head screwdriver attach each crank arm disk support with one screw removed during step 7A See Figure 20 17 Tension the drive belt A Using a 7...

Page 26: ... Phillips head screwdriver 3 16 Allen wrench 1 8 Allen wrench 2 5 6 3 cm Wooden block 9 16 Socket wrench 9 16 Open end wrench WARNING Disconnect the power cord before beginning this procedure Keep wet items away from inside parts of the unit Electrical shock could occur even if the unit is unplugged 1 Elevate the unit and disconnect the power source A Plug the power cord into the power outlet B En...

Page 27: ...2 C Pull each pillow block and pin off the frame See Figure 22 NOTE You may need to tilt the pillow block up or pry it up off the frame There is a pin in each pillow block D Discard the pillow blocks and pins if applicable 6 Attach the new lower pillow blocks A Confirm that a pin protrudes out of the back of each pillow block about 1 4 and flush with the front B Slide each pillow block on the shaf...

Page 28: ...nd Handle Link NOTE The arms and handle links are removed in the same way This procedure can be used for both Tools Required Phillips head screwdriver 3 16 Allen wrench 7 32 Allen wrench 1 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 2 Disconnect the contact heart rate cable A Unplug the ...

Page 29: ...opriate arm into the frame B Using a 7 32 Allen wrench secure the arm to the frame using the screws and washers removed in step 4A C Using a Phillips head screwdriver or 3 16 Allen wrench attach handle link with the appropriate screw securing the cap See Figure 24 Figure 23 Figure 24 Contact Heart Rate Cable Heart Rate Cable Plug Linkage Rod Handle Link Foot Plate Arm Rear Foot Plate Arm Front Cap...

Page 30: ...3 Attach the new foot plate and pedal arm A Slide the appropriate arm on the shaft or shafts B Slide the foot plate on the foot plate shafts if applicable C Place a drop of threadlocker on one of the SHCS Place another drop of threadlocker in the shaft where the SHCS will be tightened into D Using a Phillips head screwdriver or 3 16 Allen wrench attach cap with the appropriate SHCS securing the ca...

Page 31: ...de parts of the unit Electrical shock could occur even if the unit is unplugged 1 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 2 Remove the access cover A Using a Phillips head screwdriver remove the four screws securing the access cover See Figure 2 B Remove the access cover Figure 25 Fo...

Page 32: ...s B Slide the lower board assembly left and off the bottom screws NOTE Cybex may want the old parts for evaluation Call Cybex Customer Service to get an RMA number 5 Attach the lower board assembly A Place the lower board assembly over the two bottom screws and slide it to the right B Using a Phillips head screwdriver attach the top two screws removed in step 4A and tighten the bottom two screws 6...

Page 33: ...cover WARNING Flywheel may be hot Wait until it cools before servicing WARNING Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the unit 3 Replace the fuses A Locate the lower board B Pull out on the lower board shield it will snap out See Figure 26 C Locate the fuses in the upper left hand corner of the control board See Figure 26 D Re...

Page 34: ... heart rate cables ground wire and the polar heartrate cable See Figure 28 3 Remove the display board A Using a Philips head screwdriver remove the five display board mounting screws B Lift and rotate the display board to the right and unplug the three overlay ribbon cables from the display board Set the display board aside NOTE Cybex may want the old parts for evaluation Call Cybex Customer Servi...

Page 35: ...t to the console back B Using a Phillips head screwdriver secure the access cover to the console back with the screw removed in step 2A CSAFE Connector Upper Display Board Mounting Screws 5 Contact Heart Rate Ports Lower Switch Membrane Connector on front side Upper Switch Membrane Connectors on front side Polar Heart Rate Board Polar connector Display Cable Ports Figure 28 RJ 45 Port Ground wire ...

Page 36: ...tly pull the console front forward and disconnect these cables from the display board the display cable the contact heart rate cable ground wire and the polar heartrate cable See Figure 28 3 Remove the console mount A Using a 7 32 Allen wrench remove the four screws and four lock washers securing the console mount in place See Figure 29 B Remove the console mount by lifting upward 4 Remove the upp...

Page 37: ...e being sure not to pinch any cables use a Phillips head screwdriver to tighten four screws securing the console front to the console back removed in step 2B B Using a Phillips head screwdriver secure the access cover to the console back with the screw removed in step 2A Figure 29 Upper Display Cable Lower Display Cable Contact Heart Rate Cables Console Assembly Washers 4 Screws 4 Lower Display Ca...

Page 38: ...ce See Figure 30 5 Detach the lower display cable WARNING Do not touch components on the lower board A charge can remain after unplugging the power cord and turning off the unit A Pull out on the lower board shield NOTE It will snap out B Disconnect the display cable from the lower board See Figure 31 C Remove the lower display cable from the wire holder bracket See Figure 31 6 Attach the new lowe...

Page 39: ... I Confirm that the cable is routed through the access holes see Figure 30 and through the wire holder bracket see Figure 35 J Connect the display cable to the lower control board K Connect the contact heart rate cables to the cable plugs removed in step 6F L Plug the two contact heart rate cable sockets into the frame 7 Attach the console A Place the console assembly in position and connect the u...

Page 40: ...wooden block from under the unit 11 Test the unit for proper operation A Connect the power cord into the power outlet B Turn the main power switch above the power inlet to the on I position C Operate the unit at all levels to verify proper operation Figure 34 NOTE Frame only shown for cable routing Lower Display Cable To Lower Board Right Contact Heart Rate Cable Left Contact Heart Rate Cable Figu...

Page 41: ...y pull the console front forward and disconnect these cables from the display board the display cables the contact heart rate cables ground wire and the polar heartrate cable See Figure 28 D Using a Philips head screwdriver remove the five display board mounting screws E Lift and rotate the display board to the right and unplug the three overlay ribbon cables from the display board Set the display...

Page 42: ...te cable See Figure 28 6 Attach the console front A While being sure not to pinch any cables secure the console front to the console back with the four Phillips head screws removed in step 2B 7 Attach the access cover A Using a Phillips head screwdriver secure the access cover to the console back with the screw removed in step 2A See Figure 27 8 Test the new display overlay A Turn the main power s...