CYBEX 610A User manual

Service
Page 4-1
4 - Service
Warnings/Cautions
Cybex Arc Trainer 610A 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: 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: 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 charge can remain after
unplugging the power cord and turning off the unit.
! CAUTION: Pulley on eddy current brake is sharp. Wear work gloves to protect your hands.

time
level
resistance
strides
minute
scan
Cybex International, Inc. Medway, MA USA [phone] www.Cybexinternational.com
manual hill
interval
weight
loss
enter
weight
Cybex Arc Trainer 610A Service Manual
! WARNING: All maintenance activities shall be performed by qualified personnel.
Failure to do so could result in serious injury.
For any service related concerns, call Cybex
Customer Service at 800-766-3211 (for Cybex
customers living within the USA). For customers
living outside the USA, call 508-533-4300 or fax
508-533-5183.
NOTE: Read and understand each procedure
thoroughly before servicing. Unless otherwise noted
“right” and “left” denote user orientation for all
procedures.
Service
Page 4-2
Upper
Overlay
Lower
Overlay
Figure 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 the upper and/or lower display overlay. See Figure 1. If “KEY#” is
displayed you can determine which key is stuck closed by referring to the number list below.
1 Mets 9 Incline Down 17 Incline Up 25 Pause/End
2 Auxiliary 10 Resistance Down 18 Resistance Up 26 Quick Start
3 Channel Up 11 Channel Down 19 Volume Down 27 Volume Up
4 Scan 12 Strength 20 Center Up 28 Hill Interval
5 Watts 13 Cal/Hr 21 Cal 29 Dist
6 Cardio 14 Interval 22 Weight Loss 30 Manual
7 Level 15 Time 23 Weight 32 Strides/Minute
8 Enter 16 Center Down 24 Heart

Cybex Arc Trainer 610A Service Manual
Service
Page 4-3
LED Functions
LEDs are used to indicate the status of many of the unit inputs. After entering Test Mode refer to the
following list to check that these LEDs are functioning properly:
Heart LED - Blinks on blue with every signal from the contact heart rate receiver and red for wireless
signals (Polar).
Weight LED - Blinks on when CSAFE data is being received.
Level LED - Blinks on when CSAFE data is being transmitted.
Lower Left Window - The numbers indicate actual elevation. The decimal point before the numbers
shows the activation of the level 3 position switch in the elevation motor (on above level 3). If dashes
are shown in the display, the unit is either above or below the level 3 position switch, requiring it to be
manually run through the switch to begin indicating actual elevation.
Lower Right Window - The numbers indicate resistance (0-100). The right most decimal point
indicates the pulses from the speed 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 odometer information (DST) to appear in the speed window.
Press again for hour meter information (HRS) to appear in the speed window.
Press three times for number of starts information (USES) to appear in the speed window.
Press four times for number of positions the elevation (ELV) has ever moved. Example: if a user runs
the elevation from 2 to 3, 1 position is added to this number.
Strides Per Minute - Displays and cycles through error log. Up to 10 errors can be stored.
Scan - Clears error log when pressed twice while in error log mode.
Mets - Displays the torque in ft-lbs, (relative to LOAD).
Calories - Displays brake pulse width (PWM) value (the value of brake load in A/D counts). The number
range is relative to brake current and goes from 0-200.
Enter - Required to save setup values.

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Service
Page 4-4
Error Codes
Error codes notify you of a problem condition and are displayed on the center of the console. These
codes can also help to indicate the part of the unit most likely to be causing the problem. Errors that
present a hazard to the user provide a measure of safety by causing a one second beep, stopping the
unit and locking out operation of the unit.
A log of errors can be viewed and cleared. Up to 10 errors can be stored.
To enter Test Mode: Press and hold down any key on the display while turning the power switch to
the on (I) position.
To view the Error Log: Press the Strides Per Minute key to display and cycle through error log; Press
again to cycle to the 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 elevation
reaches 0% without tripping the index. See D and A.
Err7 EEPROM error (memory lost, loads new defaults, enters Test Mode). See E.
ErrE Index switch always on (or switch disconnected or wired backwards). This means that timed
elevation has gone up 3 positions and the index is still sensed. See D.
Action
A Check the lower board
B Check the brake
C Check the speed sensor and speed sensor disc
D Check the elevation motor
E Replace the display board is problem persists
F Turn the power switch to the off (O) position and back on (I)

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Service
Page 4-5
Speed Sensor Adjustment
Tools Required
• Phillips head screwdriver
! 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. 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.
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 cause Error 3 to occur.
4. Measure the speed sensor gap.
A. Measure the gap between the speed sensor
and the lower pulley. It should measure 3/16”
(.48 cm) and should be parallel to the lower
pulley. See Figure 3.
Figure 2
Screws (4)
Access
Cover
Figure 3
Gap Speed
Sensor
Screw
Target Disk
on Lower
Pulley

5. Adjust the speed sensor gap (if needed).
A. Using a Phillips head screwdriver, loosen the screw securing the speed sensor in place. See
Figure 3. NOTE: Gently bend the side cover to get at the speed sensor screw.
B. Adjust the gap between the speed sensor and the lower pulley to 3/16” (.48 cm) and tighten
the screw. See Figure 3.
6. Test for speed errors.
A. Connect the power cord to a power outlet.
B. Enter Test Mode.
! 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.
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 need to be readjusted or replaced.
F. Press Stop and turn the power switch to the off (O) position.
7. 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 securing the access cover.
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Service
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Cybex Arc Trainer 610A Service Manual
Service
Page 4-7
Drive Belts
NOTE: This procedure will cover the primary and secondary drive belts.
Tools Required
• Phillips head screwdriver
• 3/16” Allen wrench
• 2 Cloths
• 3/8” Nutdriver or socket wrench
• 7/16” Socket wrench
• 1/2” Socket wrench (only if belt tension needs to be reset)
• 1/2” Open end wrench (only if belt tension needs to be reset)
• 3/8” Square-hole torque wrench (only if belt tension needs to be reset)
! 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. 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 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 Cap, SHCS
and spacer securing the linkage rod. See Figure 4.
NOTE: Detach only the ends where the rods connect
to the crank.
B. Lay the linkage rod down on the frame.
NOTE: Place a cloth in between the
linkage rod and the frame to prevent
scratches.
Figure 4
SHCS
Cloth on
the Frame
Connecting
Rod
Washer
Cap

4. Remove the side covers.
A. 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 of the side
covers. See Figure 5.
5. Remove the crank covers.
A. Using a Phillips head screwdriver, remove
the three screws securing each crank
cover in place. See Figure 6.
B. Remove both crank covers.
! WARNING: Failure to release the drive belt
tension may cause personal injury
and may damage the unit.
6. Remove the lower pivot assembly.
A. Using a 7/16” socket 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 secondary belt and from the frame.
See Figure 8.
7. Remove the secondary belt (if applicable).
A. Slide the secondary drive belt off the unit
and discard it.
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Service
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Figure 5
Figure 6
Screw (6)
Side Cover
Crank Cover
Screw (3)
Figure 7
Screw
Lock
Washer
Flat
Washer
Lower Pivot
Shaft
Gasket
Washer (6)

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Service
Page 4-9
NOTE: If you are not replacing the primary belt skip to
step 14.
! 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 (if applicable).
A. Pull out on the lower board shield. See Figure 9.
NOTE: It will snap out.
B. Disconnect the elevation motor cable from the
lower board. See Figure 10.
C. Using a 3/8” nutdriver, remove the nut, washer
and ground wire from the stud above the
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 bolts,
four flat washers and two nuts from each
of the top pillow blocks. See Figure 12. Figure 9
Lower Board
Shield
Figure 10
Nut
Elevation
Cable
Washer Stud
Ground
Wire
Figure 11
Remove Top Screws
Loosen Bottom
Screws
Figure 8
Lower Pivot Assembly
Lower
Pulley
Secondary Drive Belt
(Removed in Step 7)
Lower Board
Assembly
Spacer (2)

B. Remove the crank shaft assembly
along with the primary belt, pillow blocks
and crank arms out of the unit. NOTE:
You may need to wiggle the assembly out.
There is a pin in each pillow block. Be
sure not to lose them. See Figure 13.
10. Remove the primary belt (if applicable).
A. Slide the primary drive belt off the
upper pulley and discard it. See
Figure 13.
11. Attach the primary belt (if applicable).
A. Slide the new primary drive belt on
the upper pulley. See Figure 13.
B. Confirm that the primary drive belt is
straight and centered on the upper
pulley.
12. Attach the crank shaft assembly (if applicable).
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, secure the two bolts, four flat
washers and two nuts (removed in step 9A) to each pillow block. See Figure 12.
Cybex Arc Trainer 610A Service Manual
Service
Page 4-10
Figure 13
Crank Shaft Assembly
Figure 12
Pin
Pillow Block (2)
NOTE: Nuts (4) and
flat washers (4) are
behind the pillow
blocks. Flat Washer (8)
Bolt (4)
Primary
Drive Belt
Upper
Pulley
Crank
Arm (2)
Pillow
Block (2)
Pin
Washer (8)
Screw (4)
Pin (2) Nut (4)

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! CAUTION: Do not pinch your fingers between the belt and pulley during this procedure.
13. Attach the lower board assembly.
A. Slide the lower board assembly over the two bottom screws and to the right.
B. Using a Phillips head screwdriver, attach the top two screws and tighten the two bottom
screws securing the lower board assembly in place.
C. Place the washer on the stud then follow it with the ground wire terminal. Use a 3/8”
nutdriver to secure the nut over the terminal. See Figure 10.
D. Connect the elevation motor cable into the lower board.
E. Place the shield into position and push in (the shield will snap in). See Figure 9.
14. Position the secondary drive belt.
A. Slide the new secondary 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 washers and two flat washers
securing the lower pivot assembly in place.
16. Check the tension of the primary drive belt.
A. Press on the primary belt with your hand. You should not feel any “give” in the primary belt. If
the belt “gives”, follow step 17 through 18. Otherwise, skip to step 19. NOTE: The secondary
belt is self-tensioning.
17. Release the tension of the primary drive belt.
A. Using a 1/2” socket wrench, loosen the bottom screw on the idler pulley. See Figure 14.
B. Using a 1/2” socket wrench, loosen the top screw on the idler pulley See Figure 14.

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 torqued to 75 ft-lbs. NOTE: Continue holding the torque wrench at 75 ft-lbs during the
next step.
B. While holding the torque wrench at 75 ft-lbs, use a 1/2” socket wrench to tighten the top screw
on the idler pulley. See Figure 14.
C. Using a 1/2” socket wrench, tighten the bottom screw on the idler pulley. See Figure 14.
19. Attach the crank covers.
A. Place each crank cover in position.
B. Using a Phillips head screwdriver, 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.
22. Attach the access cover.
A. While being sure not to pinch any cables, hold the access cover in place. See Figure 2.
Cybex Arc Trainer 610A Service Manual
Service
Page 4-12
This Side of
Bracket This Side of
Bracket
Top Screw
Bottom Screw
Figure 14
NOTE: Do not adjust
the idler pulley unless
it is obvious that your
belt is not tensioned
properly.
Idler
Pulley

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Page 4-13
B. Using a Phillips head screwdriver, tighten the four screws securing the access cover.
See Figure 2.
Eddy Current Brake
Tools Required
• Phillips head screwdriver
• 3/16” Allen wrench
• 7/16” Socket wrench
• Work Gloves
! 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. 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 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 connecting rod to each crank.
See Figure 4.
B. Place a cloth on the frame where the connecting rod will rest.
C. Rest the rod on the cloth to prevent scratches. See Figure 4.
4. Loosen the left side cover
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 of the side covers.
See Figure 5.

5. Remove the left crank cover.
A. Using a Phillips head screwdriver, remove the
three screws securing the left crank cover in
place. See Figure 6.
B. Remove the left crank cover.
! WARNING: Failure to release the drive belt tension
may cause personal injury and may
damage the unit.
6. Release the drive belt tension.
A. Using a 7/16” socket wrench, loosen the two
screws on the lower pivot shaft until the screws
are raised 1/2” (1.25 cm) above the screws on the lower pivot shaft. See Figure 15. NOTE: The
drive belt tension is now released.
! WARNING: Do not touch components on the lower board. 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. Remove the eddy current brake.
A. Wear work gloves whenever handling the eddy current brake. The pulley is sharp.
See Figure 16.
Cybex Arc Trainer 610A Service Manual
Service
Page 4-14
Figure 15
Loosen Screws
Lower Pivot
Shaft
Figure 16
Pins on
Brake
Mount
Bracket
Orientation of
the Cable
Secondary Drive
Belt
Flywheel
Threaded Hole (4)
Screw (4)
Non-Threaded Hole (4)
Pulley
Screw (4)

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Service
Page 4-15
B. When the flywheel is cool, remove the secondary belt from the eddy current brake.
C. Using a 3/16” Allen wrench, first remove the two bottom screws securing the eddy current
brake in place. See Figure 16.
D. Support the brake with your hand while removing the two top screws so that it does not fall.
E. Remove the eddy current brake from the unit. NOTE: Cybex may want the old parts for
evaluation. Call Cybex Customer Service to get an RMA number.
9. Attach the new eddy current brake.
A. Locate the holes on the eddy current brake. Notice that there are four threaded holes and four
non-threaded holes. See Figure 16.
B. Locate the two pins on the brake mount bracket. See Figure 16.
C. Orient the brake with the cable away from the unit. See Figure 16.
D. Slide the brake pulley 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 Figure 16.
H. Tighten the two bottom screws securing the eddy current brake.
10. Connect the brake cables.
A. Locate the J1 and J2 fast-ons on the lower board.
B. Connect the brake cables to the lower board at J1 and J2. NOTE: It does not matter which
brake cable connects to J1 and J2.
C. Place the lower board shield in position and snap it in.
11. Tension the drive belt.
A. Confirm that the secondary drive belt is straight and centered on the lower pulley. See
Figure 12.
B. Confirm that the two spacers are still in place under the lower pivot shaft.
C. Using a 7/16” socket wrench, tighten the two screws on the lower pivot shaft.

! CAUTION: Do not pinch your fingers between the belt and pulley during this procedure.
D. Use your hand to slowly turn the flywheel and ensure that the belt is on straight.
12. Attach the left crank cover.
A. Place the crank cover in position.
B. Using a Phillips head screwdriver, attach the three screws removed in step 5A. See Figure 6.
13. Secure the left side cover.
A. Using a Phillips head screwdriver, attach the six screws and six washers removed in step 4A.
14. Attach the left connecting rod.
A. Place the left connecting rod in position.
B. Using a 3/16” Allen wrench, attach the screw removed in step 3A. See Figure 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 operation.
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Elevation Motor
Tools Required
• Phillips head screwdriver
• 3/16” Allen wrench
• 7/16” Socket wrench
• 3/8” Nutdriver or socket wrench
• 9/16” Open end wrench
• 9/16” Socket 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.

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Page 4-17
1. Elevate the unit and disconnect 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 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 connecting rod to each crank.
See Figure 4. 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 of the side covers.
See Figure 5.
5. Remove the center 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.
6. Disconnect the elevation cable.
A. Pull out on the lower board shield. NOTE: It will snap out.
B. Disconnect the elevation cable from the lower board and slide it out of its slot on the frame.

7. Remove the elevation motor.
A. Place your body next to the front
end assembly to prevent it from
pivoting and falling to the floor
during the next step.
B. Using a 9/16” open end wrench
and a 9/16” socket wrench,
remove the top bolt and nut
securing the elevation motor in
place. See Figure 17. NOTE: Do
not lose the spacer between the
bolt and nut.
C. Pivot the front end assembly back
and lean it against the frame
(not the floor).
D. Using a 9/16” open end wrench
and a 9/16” socket wrench,
remove the bottom bolt and nut
securing the elevation motor in
place. NOTE: Do not lose the
spacer between the bolt and nut.
E. Remove the elevation motor.
NOTE: Cybex may want the old
parts for evaluation. Call Cybex
Customer Service to get an RMA number.
8. Calibrate the elevation motor.
A. Connect the elevation motor to the lower 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 cord.
D. Disconnect the elevation motor cable from the lower board and set the motor aside until step
10A.
9. Attach the elevation motor.
A. Confirm that the two spacers (from step 7B and 7D) are in place.
B. Pivot the front end assembly back into the position it was before step 7C.
C. Place the new elevation motor in position and slide both bolts into the slots before tightening.
See Figure 17. NOTE: The top bolt goes from the left to the right, but the bottom bolt can go
either way.
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Page 4-18
Figure 17
Nut
11.37”
(28.9 cm)
Tube
Top
Bolt
Nut
Bottom
Bolt
Spacer
Spacer

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Page 4-19
D. Using a 9/16” open end wrench and a 9/16” socket wrench, tighten a nut on each bolt.
10. Connect the elevation cable.
A. Connect the elevation cable to the lower board and place it in the slot mentioned in step 6B.
B. Place the lower board shield in position and snap it in.
11. Secure the center cover.
A. Place the center cover in position.
B. Using a Phillips head screwdriver, attach the two screws removed in step 5A.
12. Secure the side covers.
A. Place the two side covers and the gasket in position.
B. Using a Phillips head screwdriver, 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 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.
15. 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.

Cybex Arc Trainer 610A Service Manual
Service
Page 4-20
Power Switch
Tools Required
• Phillips head screwdriver
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 and from the power inlet.
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.
3. Remove the power switch assembly.
A. Using a Phillips head screwdriver, remove the two
screws on each side of the power switch. See
Figure 18.
B. Reach inside the unit and pull the power switch
assembly up and out of the slot.
C. Make note of which fast-ons are connected to the
connectors.
D. Disconnect the three 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 two wires to the on/off switch. NOTE: The purpose for
marking the top two wires is so that you do not accidentally bypass the on/off switch when
reconnecting the wires.
J. Remove the four wires from the on/off switch and remove the switch from the old switch plate.
K. Place the existing on/off switch into the new switch plate (positioned exactly as removed from
the old switch plate).
L. Connect the four wires as shown in Figure 4. Make sure the taped wires are connected to the
same connectors from step 5I. Remove the tape from the two wires.
Figure 18
Screw (2)