CYBEX Arc Trainer 425A User manual

Cybex Arc Trainer®425A
Service Manual
Cardiovascular Systems
Part Number 425A-901 A
www.cybexinternational.com

Cybex Arc Trainer®425A
Service Manual
Cardiovascular Systems
Part Number 425A-901 A
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.
© 2008 Cybex International, Inc. All rights reserved. Printed in United States of America.
10 Trotter Drive Medway, MA 02053 • 888-426-9239 • 508-533-4300 • FAX [phone]
www.cybexinternational.com • [email protected] • [email protected] • 425A-901 A • August 2008

Page i
About This Manual
To purchase additional copies of this manual or any other Cybex manual, please do one of
the following:
• contact Cybex Customer Service at 888-462-9239
• or contact Cybex Customer Service at 508-533-4300
To contact Cybex with comments about this manual send email to [email protected].
Cybex Arc Trainer 425A Service Manual
FCC Compliance Information
! WARNING: Changes or modifications to this unit not expressly approved by the party
responsible for compliance could void the user’s authority to operate the
equipment.
This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection 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 with
the instructions, may cause harmful interference to radio communications. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception (which can be determined by
turning the equipment off and on) the user is encouraged to try to correct the interference by
one 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 the
receiver is connected.
• Consult the dealer or an experienced radio TV technician for help.

Front Pages
About this Manual .................. i
FCC Compliance Information ......... i
Table of Contents .................. iii
1 Safety
Important Voltage Information......... 1-1
Grounding Instructions............... 1-1
Important Safety Instructions ......... 1-2
Warning Decals .................... 1-4
2 Preventive Maintenance
Warnings ......................... 2-1
Regular Maintenance Activities ........ 2-1
Cleaning Your Arc Trainer 425A ....... 2-2
Drive Belt Maintenance .............. 2-3
Lubrication ........................ 2-4
Environment ....................... 2-4
Storage ........................... 2-4
3 Customer Service
Contacting Service ................. 3-1
Serial Number and Voltage ........... 3-1
Return Material Authorization (RMA).... 3-2
Damaged Parts .................... 3-3
Ordering Parts ..................... 3-3
4 Service
Parts List - Main Assembly . .......... 4-2
Exploded View - Main Assembly . ..... 4-3
Exploded View - Main Assembly . ..... 4-4
Exploded View - Main Assembly . . . . . . 4-5
Parts List - Console Assembly . . . . . . 4-6
Exploded View - Console Assembly .... 4-7
Parts List - Drive Frame Assembly ..... 4-8
Exploded View - Drive Frame Assembly 4-9
Schematic . . . . . . . . . . . . . . . . . . . . . . . 4-11
Arc Trainer 425A Kits . . . . . . . . . . . . . . . 4-13
Table of Contents
Page v
Cybex Arc Trainer 425A Service Manual

Safety
Page 1-1
1 - Safety
Important Voltage Information
IMPORTANT: Read all instructions and warnings before using the unit.
Before plugging the power cord into an electrical outlet, verify that the voltage requirements for your
area match the voltage of the unit that you have received. The power requirements for the unit include
a grounded circuit, rated for one of the following: 115 VAC 5%, 50/60 Hz and 15 amps; or 230 VAC
10%, 50/60 HZ and 10 amps. See the voltage requirement decal for the exact voltage requirements of
your unit.
! WARNING: Do not attempt to use this unit with a voltage adapter. Do not attempt to use this
unit with an extension cord.
+
_
+
_
Grounding Instructions
This unit must be grounded. If it should malfunction or break down, grounding provides a path of least
resistance for electric current to reduce the risk of electric shock. This product is equipped with a cord
having an equipment-grounding conductor and a grounding plug. The plug must be plugged into an
appropriate outlet that is properly installed and grounded in accordance with all local codes and
ordinances.
AW-19624 AW-19625 AW-19626
115 VAC 230 VAC 230 VAC
AW-19627
100 VAC
! DANGER: Improper connection of the
equipment grounding conductor can
result in a risk of electric shock. Check
with a qualified electrician or service
provider if you are in doubt as to whether
the unit is properly grounded. Seek a
qualified electrician to perform any
modifications to the cord or plug. Cybex is
not responsible for injuries or damages as
a result of cord or plug modification.
This unit is for use on a nominal 115 VAC
5%, 50/60 Hz and 15 amps; or 230 VAC
10%, 50/60 Hz and 10 amps and a grounded
circuit. Make sure that the unit is connected
to an outlet having the same configuration as
the plug. Do not use a ground plug adapter
to adapt the power cord to a non-grounded
outlet.
+
_
+
_

(Save These Instructions)
! DANGER: To reduce the risk of electric shock, always unplug this unit from the electrical outlet
immediately after using it and before cleaning it.
! WARNING: Serious injury could occur if these precautions are not observed. To reduce the risk
of burns, fires, electric shock, or injury:
User Safety Precautions
• Keep children away. Teenagers and disabled must be supervised.Tenez les enfants éloignés. Les
adolescents 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 des
reposes 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 handles for support and to maintain balance.
• DO NOT use the unit if you exceed 350 lbs. (160 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.
Facility 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 set up and operated on a solid level surface. Do not install
equipment on an uneven surface.
Safety
Page 1-2
Important Safety Instructions

Safety
Page 1-3
• Make sure there is enough room for safe access and operation of the equipment.
• Perform regular maintenance checks on the equipment. Also pay close attention to all areas most
susceptible to wear, including (but not limited to) cables, pulleys, belts and grips.
• Immediately replace worn or damaged components. If unable to immediately replace worn or
damaged components then remove from service until the repair is made.
• Do not attempt repairs, electrical or mechanical. Seek qualified repair personnel when servicing. If
you live in the USA, contact Cybex Customer Service at 888-462-9239. 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 the
unit 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 regular
maintenance is performed.

425A-495-4 A
SERIOUS INJURY
COULD OCCUR IF
THESE PRECAUTIONS
ARE NOT OBSERVED
Keep children away. Teenagers and
disabled must be supervised.Tenez
les enfants éloignés. Les
adolescents 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 des
reposes pieds avant de descendre.
Obtain a medical exam before
beginning any exercise program.
Stop exercising if feeling faint,
dizzy, or experiencing pain.
Keep foot plate surface clean and dry.
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 handles for support and to
maintain balance.
DO NOT use unit if user exceeds
350 lbs. (160 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.
WARNING
Safety
Page 1-4
Carefully read and understand the following before using the unit:
NOTE: To replace any worn or damaged decals, do one of the following: Fax your orders to
508-533-5183 or contact Cybex Customer Service at 888-462-9239. 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 or
serious injury. The warning decals are shown below.
Warning Decals
Warning decal part number
425A-495-4

Safety
Page 1-5
CM000240 E
ОТКЛЮЧИТЕ
ПИТАНИЕ,
ПРЕЖДЕ ЧЕМ
ПРИСТУПАТЬ
КОБСЛУЖИВАНИЮ.
ПРЕДУПРЕЖДЕНИЕ
Warning decal part number
CM000240
Warning decal part number
DE-17219-4 (Both Sides)
DE-17219-4 A
CAUTION
Moving parts.
Keep hands away
when in use.

Safety
Page 1-6
Warning decal part number
425A-479

Preventive
Maintenance
Page 2-1
2 - Preventive Maintenance
Warnings
Cybex Arc Trainer 425A Service Manual
All warnings and cautions listed in this chapter are as follows:
! WARNING: All maintenance activities shall be performed by qualified personnel. Failure to do
so could result in serious injury.
! WARNING: To prevent electrical shock, be sure the unit is unplugged from the electrical outlet
before performing any cleaning or maintenance procedures.
! WARNING: Keep wet items away from inside parts of the unit. Electrical shock could occur
even if the unit is unplugged. Do not touch components on the lower board. A
charge can remain after unplugging the power cord.
! 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.
! 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 do
so could result in serious injury.
Preventive maintenance activities must be performed to maintain normal operation of your unit. keeping
a log of all maintenance actions will assist you in staying current with all preventive maintenance
activities. See Service Schedule located at the end of this chapter.
NOTE: Worn or damaged components shall be replaced immediately or the unit removed from service
until the repair is made.
NOTE: Cybex is not responsible for performing regular inspection and maintenance actions for your
unit. Instruct all personnel in equipment inspection and maintenance actions and also in
accident reporting/recording.

Cybex Arc Trainer 425A Service Manual
! WARNING: To prevent electrical shock, be sure the unit is unplugged from the electrical outlet
before performing any cleaning or maintenance procedures.
When cleaning your unit spray a mild cleaning agent, such as a water and dish soap solution, on a
clean 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 the
electronics and may void the warranty.
After Each Use - Wipe up any liquid spills immediately. After each workout, use a cloth to wipe up any
remaining perspiration from the handles and painted surfaces.
Be careful not to spill or get excessive moisture on the console and display overlays, as this might
create 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 this
area 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 occur
even if the unit is unplugged. Do not touch components on the lower board. A
charge can remain after unplugging the power cord.
To clean inside the unit, remove the four Phillips head screws securing the access cover in place. Use
a vacuum attachment or hand vacuum to clean the exposed elevation assembly and remove dirt and
debris off of internal components.
Use a dry cloth to wipe all exposed areas. Replace the access cover and secure it with the screws
when finished.
Lift the rear of the unit and roll it back from its present position so as to vacuum the floor area
underneath 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 off
on the contact heart rate grips. These can reduce sensitivity and interfere with the heart rate signal. It is
recommended that the user have clean hands when using the contact heart rate. Clean the grips using
a cloth dampened with a cleaning solution containing alcohol. The grips are the only part of the unit
you should use a cleaning solution containing alcohol.
Preventive
Maintenance
Page 2-2
Cleaning Your Arc Trainer 425A

Preventive
Maintenance
Page 2-3
Drive Belt Maintenance
There 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 large upper pulley. It is
unlikely that the primary belt will become loose because it is
a stretch-fit belt.
Secondary Belt - This is the narrower of the two belts. It
has grooves that keep it aligned on the flywheel’s drive
pulley. It is unlikely that the secondary belt will become loose
because it is a stretch-fit belt.
NOTE: If a belt has cracks or appears worn, it must be
replaced immediately by a qualified service technician.
Tools Required
• Phillips head screwdriver
Cybex Arc Trainer 425A Service Manual
Primary
Drive Belt
Secondary
Drive Belt
Screw (4)
Access
Cover
Figure 1
! WARNING: Disconnect the power cord from the wall outlet 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. Read and understand this Drive Belt Maintenance section thoroughly before proceeding to
step 2.
2. Disconnect the external power source.
A. Unplug the power cord from the power outlet.
Figure 2
3. Remove the access cover.
A. Using a Philips screwdrivew, remove the four screws
securing the access cover.
B. Remove the access cover.
! WARNING: the flywheel may be hot. Wait until it cools
before servicing.
4. Check the condition of each belt.
A. Roll each belt by to examine it condition. If a belt has
cracks or appears worn, it must be replaced
immediately by a qualified service technician.
5. Attach the access cover.
A. Using a Philips head screwdriver, tighten the screws
first (removed in step 3A). NOTE: Do not over tighten
screws.
6. Test unit for proper operation.

Preventive
Maintenance
Page 2-4
The Arc Trainer 425A is designed with no-maintenance parts. Although there are grease fittings on the
pillow blocks, re-lubrication of the bearings is not required.
Elevation Motor Lubrication - In time the elevation motor pivot points may develop a squeak. If a
squeak is present, the unit will need to be serviced by a qualified service technician.
Lubrication
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 unit. You may experience a shock due to the build-up of static electricity on
your body and the discharge path of the unit. If you experience this type of situation, you may want to
increase the humidity to a comfortable level through the use of a humidifier.
Humidity - The unit is designed to function normally in an environment with a relative humidity range
of 30% to 75%.
NOTE: Do not install or use the unit in an area of high humidity, such as in the vicinity of a steam room,
sauna, indoor pool or outdoors. Exposure to extensive water vapor, chlorine and/or bromine
could adversely affect the electronics as well as other parts of the machine.
Temperature - The unit is designed to function normally in an environment with an ambient
temperature range of 50o F (10o C) to 104o F (40o C) degrees.
Environment
Storage
Humidity - The unit can be shipped and stored in an environment with a relative humidity range of
10% to 90%.
NOTE: Do not store the unit in an area of high humidity, such as in the vicinity of a steam room, sauna,
indoor pool or outdoors. Exposure to extensive water vapor, chlorine and/or bromine could
adversely affect the electronics as well as other parts of the machine.
Temperature - The unit can be shipped and stored in an environment with an ambient temperature
range of 32o F (0o C) and 140o F (60o C) degrees.
Cybex Arc Trainer 425A Service Manual

Cybex Arc Trainer 425A Service Manual
Customer
Service
Page 3-1
3 - Customer Service
Contacting Service
Hours of phone service are Monday through Friday from 8:30 a.m. to 6:00 p.m. Eastern Standard Time.
For Cybex customers living in the USA, contact Cybex Customer Service at 888-462-9239.
For Cybex customers living outside the USA, contact Cybex Customer Service at 508-533-4300 or fax
508-533-5183.
Find information on the web at www.cybexinternational.com or by e-mail at [email protected].
Serial Number and Voltage
Your serial number and voltage can be found on the front of the unit. See Figure 1.
For your convenience record your serial number and voltage below so that you will have it ready if you
call Cybex Customer Service.
Serial Number Voltage
Figure 1
Serial Number

Cybex Arc Trainer 425A Service Manual
Return Material Authorization (RMA)
The Return Material Authorization (RMA) system outlines the procedures to follow when returning
material for replacement, repair, or credit. The system assures that returned materials are properly
handled and analyzed. Follow the following procedures carefully.
Contact your authorized Cybex dealer on all warranty-related matters. Your local Cybex dealer will
request an RMA from Cybex, if applicable. Under no circumstances will defective parts or equipment
be accepted by Cybex without proper RMA and an Automated Return Service (ARS) label.
1. Call the Customer Service hotline listed on Page 6-1 for the return of any item that is defective.
2. Provide the technician with a detailed description of the problem you are having or the defect in the
item you wish to return.
3. Provide the model and serial number. The serial number is located on the front of the unit as shown
in Figure 1. The serial number begins with a letter, for example: R09-101331100.
4. At Cybex’s discretion, the technician may request that you return the problem part(s) to Cybex for
evaluation and repair or replacement. The technician will assign you an RMA number and will send
you an ARS label. The ARS label and RMA number must be clearly displayed on the outside of the
package that contains the item(s) to be returned. Include a description of the problem, the serial
number of the unit and the name and address of the owner in the package along with the part(s).
5. Forward the package through UPS to Cybex.
Attn: Customer Service Department
Cybex International, Inc.
1975 24th Ave SW
Owatonna MN 55060, USA
NOTE: Merchandise returned without an RMA number on the outside of the package or shipments sent
C.O.D. will not be accepted by the Cybex receiving department.
Customer
Service
Page 3-2

Cybex Arc Trainer 425A Service Manual
Customer
Service
Page 3-3
Damaged Parts
Materials damaged in shipment should not be returned for credit. Shipping damages are the
responsibility of the carrier (UPS, Federal Express, trucking companies, etc.).
Apparent Damage - Upon receipt of your shipment, check all boxes carefully. Any damage seen with
a visual check must be noted on the freight bill and signed by the carrier’s agent. Failure to do so will
result in the carrier’s refusal to honor your damage claim. The carrier will provide you with the required
forms for filing such claims.
Concealed Damage - Damage not seen with a visual check upon receipt of a shipment but noticed
later must be reported to the carrier as soon as possible. Upon discovery of the damage, a written or
phone request to the carrier asking them to perform an inspection of the materials must be made
within ten days of the date of delivery. Keep all shipping containers and packing materials: they will be
needed as part of the inspection process. The carrier will provide you with an inspection report and the
necessary forms for filing a concealed damage claim. Concealed damage is the carrier’s responsibility.
Ordering Parts
Fax orders to 508-533-5183. To speak with a customer service representative, call 888-462-9239
(for customers living within the USA) or 508-533-4300 (for customers outside the USA).
Cybex will void warranty if
non-Cybex
replacement parts are used.