CYBEX 600H HIKER Service Manual

Cybex 600H Hiker Service Manual

Cardiovascular Systems

The 600H measures, monitors, and
motivates your fitness and health.

Cybex International, Inc.
10 Trotter Drive, Medway, Massachusetts 02053 USA

The 600H

Service Manual

SM-15649 Rev A

Read all instructions before using. Save These Instructions.

! WARNING: SERIOUS INJURY COULD OCCUR IF THESE PRECAUTIONS ARE NOT OBSERVED

DO obtain a medical exam before beginning any exercise program.
DO keep children away from the Hiker. Teenagers and disabled persons must be supervised while using.
DO set up and operate the Hiker on a solid, level surface. DO NOT operate in recessed areas or on plush carpet.
DO provide adequate clearance to the side, front, and back of Hiker. This should be a few feet from walls

and furniture and allow for safe access and passage around the machine.
DO NOT operate in damp or wet locations.
DO NOT use the Hiker outdoors.
DO NOT operate the Hiker around or where aerosol (spray) or where oxygen products are being used.
DO read the Owner's Manual completely before using the Hiker.
DO read all warnings posted on the Hiker.
DO inspect all belts and connections before each use. DO NOT use until worn or damaged parts are replaced.
DO NOT wear loose or dangling clothing while using the Hiker.
DO keep all body parts, towels, water bottles, and the like free and clear of moving parts.
DO use support devices at all times. These include the front, hand and side rails.
DO stop exercising if you feel faint, dizzy, or experience pain at any time while exercising and consult

your physician.
DO maintain and replace parts regularly. Refer to the Owner's Manual for detail.
DO use Cybex factory parts when repairing the Hiker.
DO call Cybex for technical support before attempting to perform any procedure that you are unsure about.
DO follow instructions in Service Manual for disassembly and assembly, when required.
DO NOT modify the Hiker in any way.
DO NOT use attachments not recommended for the Hiker.
DO replace any warning label if damaged, worn or illegible.
DO report any malfunctions, damage or repairs to the facility. (Commercial Equip.Only)
DO NOT use the Hiker if you exceed 350 lbs. This is the maximum rated user weight.
DO NOT install in a commercial setting. For consumer use only. (Consumer Equip.Only)

WARNING: Changes or modifications to this unit not expressly approved by the party responsible
for compliance could void the user’s authority to operate the equipment.

NOTE: 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.

Cybex and Cybex logo 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.

© 2000 Cybex International, Inc. All rights reserved.
Printed in United States of America.

PREFACE

TABLE OF CONTENTS

1 INTRODUCING THE 600H HIKER BY CYBEX

Ergonomic Design 3
Warranty 3
Customer Service Hotline 4

2 DISASSEMBLY

Setup and Assembly 5
Choosing and Preparing a Site 5
Step 1 Removing the Shrouds 5
Step 2 Releasing Tension from the Linkage System 5
Step 3 Removing the Linkage System 6
Step 4 Disassembling the Tie Rod Assemblies 6
Component Parts of the Linkage System 7
Step 6 Removing the Pulley Assembly and Drive Belt 8
Step 7 Removing the Foot Plate 8
Step 8 Removing the Rear Pivot Arm Assembly 9
Step 9 Removing the Front Pivot Arm Assembly 9
Step 10 Removing the Front Linkage Assembly 10

3 INSTALLATION

Step 1 Installing the Front Linkage Assembly 11
Step 2 Installing the Front Pivot Arm Assembly 11
Step 3 Assembling the Short Linkage Rod Assembly 12
Step 4 Installing the Short Linkage Rod Assembly 13
Step 5 Installing the Rear Pivot Arm Assembly 14
Step 6 Assembling the Foot Plate Linage Rod 15
Step 7 Attaching a Foot Plate to the Front Pivot Arm Assembly 15
Step 8 Installing the Foot Plate Linkage Rod Assembly 16
Step 9 Assembling the Pulley Assembly 17
Step 10 Installing the Pulley Assembly 18
Step 11 Attaching the Drive Belt to the Foot Plate 18
Step 12 Installing the Long Linkage Rod Assembly 19
Step 13 Attaching the Drive Belt 19
Step 14 Attaching the Long Linkage Rod Assembly 20
Step 15 Installing the Long Linkage Rod Assembly 21
Step 16 Adjusting the Linkage System 22
Step 17 Adjusting the End of the Stroke 23
Step 18 Attaching the Shrouds 24

4 RETRO KIT INSTALLATION

Extract Calibration Settings 25
Display Panel Replacement 25
Replace Calibration Settings 26
Pulley Replacement 26
Error 3 27

5 DIAGNOSTICS

Display LED Test 28
Battery Test 28
Production Calibration Test 28
DVM Test 28
Static Diagnostic Check 29

6 DIAGRAMS

Parts List 30
Exploded View 31
Schematic 32

1

1 / INTRODUCING THE 600H HIKER BY CYBEX

600H Hiker™ by Cybex®

2

3

1 / INTRODUCING THE 600H HIKER BY CYBEX

The 600H Hiker by Cybex is a revolutionary new product which
defines a new exercise category. It is designed to provide the
commercial fitness facility and personal user with an effective tool for
total body conditioning. It utilizes a natural movement and provides
training variety with its intuitive display control and feedback. It is the
first and only product of its kind.

Ergonomic Design

The 600H Hiker provides an upper and lower body workout in a
natural pattern that moves the way the body does. It combines the
advantages of a climber and an elliptical machine without any of the
disadvantages. Unlike most climbers’ pattern of movement which
moves the leg backward before it goes down, the 600H Hiker’s
pattern of movement moves the leg down as it goes backward. The
effect is to have a less acute angle at the knee during the exercise
and subsequently less stress in the joint than seen in current climbers
and steppers. In addition, unlike current climbers and elliptical pattern
products, the 600H Hiker’s pattern of movement works the gluteus
muscles harder and through a more complete range.

Unlike elliptical machines which have a fixed stride length, the 600H
Hiker has a user determined stride length. The user determines the stride
length and speed, and selects a resistance level which can simulate the
feel of an incline much like one would feel when hiking up a mountain.
The user can vary their stepping pattern throughout the workout without
having to make any adjustments to the machine. The width between the
pedals puts the user’s body in a position that is comfortable for the hips,
and the foot plates are angled to create a natural hiking motion.

Users have the option of using the ergonomically designed handles,
which are linked to the pedals. By having all four points- the two
pedals and two handles-linked, little coordination is required to
accomplish the total-body cardio workout.

The dual action 600H Hiker works the major muscles of both the
upper and lower body for an effective cardiovascular and fat-burning
workout. It spreads the workload over the body to help the user avoid
premature fatigue and discomfort. Users can choose the stride length
that fits as well as their relative upper and lower body involvement,
and can change it at any time. By varying movement pattern and
body position, users can tailor their workouts to emphasize particular
muscle groups or concentrate on sports-specific training.

The 600H Hiker has a belt drive for smooth, quiet operation, and a
cordless system with no power supply or plugs to worry about. The
center handles have built-in, hand-held heart rate sensors. The 600H
Hiker offers four motivational programs plus a manual mode.

Warranty

LIMITED WARRANTY TO NON-CONSUMER BUYERS: Seller warrants, to the

original Buyer only, that any product manufactured by it, herein listed under
"'EXPIRATION OF LIMITED WARRANTIES FOR NON-CONSUMER BUYERS,"
will be free from defects in material and workmanship, under normal use and
service according to the specified warranty duration listed, beginning from the
date of installation. Seller's obligation under this warranty shall be strictly and
exclusively limited to repairing or replacing parts and materials, free of charge,

If you improve your health, you
reduce the risk of certain chronic
degenerative diseases.

If you improve your
fitness, you can perform
moderate to vigorous
activity without undue
fatigue.

4

1 / INTRODUCING THE 600H HIKER BY CYBEX

F.O.B. origin, which, in Seller's judgment are defective. Seller cannot control the
environment nor manner in which this is used, therefore this warranty does not
cover corrosion of product during use, or deterioration caused by conditions of
use, or that the application of finishes and/or cleaners are sufficient, or the
finishes and/or cleaners applied are suitable for Buyer's environment. Seller
does not warrant normal maintenance repairs such as identified within Seller's
Owner's Manual. Seller assumes no responsibility for repair or replacement
expenses incurred without it's prior written authorization. Buyer shall be
responsible for all labor costs incurred in connection with such repair or
replacement at the installation site unless agreed upon by Seller or covered
herein. All costs of removing, packing and shipping defective product and parts
shall be paid by the Buyer unless otherwise stated by the Seller. Seller's
authorized representative determines, in sole and final discretion that the nature
of the defect precludes remedy by repair or replacement of parts, Seller reserves
the right to satisfy its warranty obligation in full by refunding the full purchase
price upon return of all products to it, freight prepaid. The products or services
of other manufacturers which are furnished by Seller are covered only by such
warranties as are given by sold manufacturer to Seller. In the regard, Seller
agrees to certify to Buyer the identity of the supplier of items claimed to be
defective so that the Buyer may pursue warranty claims against that party.

EXPIRATION OF LIMITED WARRANTIES FOR NON-CONSUMER BUYERS:

Cybex Cardiovascular Products: Seller will warrant labor and parts for three
years. Refer to the "LIMITED WARRANTY FOR NON-CONSUMER BUYERS"
paragraph above for transportation cost responsibility and further explanation
of warranty coverage limitations and exclusions.

DISCLAIMER OF WARRANTIES AND LIMITATION OF REMEDIES:

SELLER MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, WITH
REGARD TO GOODS OR SERVICES PROVIDED BY SELLER OTHER THAN
THOSE SET FORTH HEREIN. ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF BUYER
WHICH EXCEEDS THE FOREGOING WARRANTY IS HEREBY DISCLAIMED BY
SELLER. SELLER WILL NOT BE LIABLE FOR ANY DIRECT OR INDIRECT
CONSEQUENTIAL OR INCIDENTAL DAMAGES, LOSSES, OR EXPENSES,
INCLUDING, BUT NOT LIMITED TO COMMERCIAL LOSSES, BUSINESS
INTERRUPTION, OR DAMAGES RESULTING TO PROPERTY OTHER THAN
THAT WHICH IS THE SUBJECT OF THE SALES TRANSACTION.

ALTERNATIVE DISPUTE RESOLUTION FOR NON-CONSUMER BUYERS ONLY:

SELLER RESERVES THE RIGHT TO MANDATE INFORMAL DISPUTE
RESOLUTION TO SETTLE ANY OR ALL CLAIMS RESULTING FROM THIS
SALES TRANSACTION. ALTERNATIVE DISPUTE RESOLUTION PROCEEDINGS
WILL BE CONDUCTED IN THE STATE OF MASSACHUSETTS ACCORDING TO
THE COMMERCIAL RULES OF THE AMERICAN ARBITRATION ASSOCIATION.

It is understood between the parties that damage to product, ineffectiveness
of product, or other unintended consequences may result because of many
factors including the manner of use or application of the product, all of
which are beyond the control of the Seller. All such risks shall be assumed
by the Buyer.

PROCEDURE FOR OBTAINING WARRANTY PERFORMANCE:

To secure your warranty in event of a defect, contact the Cybex Customer
Service Department with questions regarding your warranty by mail or
telephone for instructions or a Return Authorization Number as provided below:

Cybex International, Inc., Attn: Customer Service Department
10 Trotter Drive
Medway, MA 02053 Tel: [phone]

600H features include:

• Balanced total body involvement for a
better cardiovascular workout.

• “Free-stride” motion lets users
determine the most comfortable stride
length.

• Contact heart-rate monitor lets users
gauge the overall intensity of their
workout.

• Natural path of motion provides
balanced conditioning to the lower
body.

• Fluid motion of handles helps upper
body work efficiently.

• Self-powered unit can be placed
anywhere with no wires to trip over.

• Large worldwide dealer, sales, and
service network.

• Customer Service Hotline number:
Call 888-462-9239 in most areas.
Dial 508-533-4300 or
Fax [phone] in all other areas.

5

2 / DISASSEMBLY

Set up and Assembly

Setting up the 600H Hiker by Cybex is straightforward. Before you
unpack the machine, however, be sure to select a suitable site.

Choosing and Preparing a Site

The area that you select for your 600H Hiker should be well-lit and
well-ventilated. Locate the 600H Hiker on a structurally sound and
level surface (do not place in recessed areas or on plush carpet) a
few feet from walls and other equipment. Allow for safe access and
passage during use of the machine. If the 600H Hiker is located
above the first floor, place it near or above major support beams. If
the area has a heavy plush carpet, the airflow around the base of the
unit may be restricted or the carpeting may interfere with the moving
parts. To protect the carpeting and the machinery, you can place a
3/4” (1.9 cm) thick wood or rigid plastic base under the 600H Hiker.

Do not install the 600H Hiker in an area of high humidity, such as
the vicinity of a steam room, sauna, or indoor pool. Exposure to
intensive water vapor and/or chlorine could adversely affect the
electronics, as well as other parts of the machine.

Disassembly of the 600H Hiker can be unsafe if you don’t follow
directions. The following disassembly steps are listed in sequential
order. In some cases, you can ignore some steps. In those cases we
have listed the steps you must follow before further disassembly.

WARNING: It is very important to recognize that with few
exceptions the tension from the linkage system must be released
before continuation of disassembly. Safety glasses should be
worn while assembling or disassembling the linkage system.

STEP 1-Removing the Shrouds

(Tools required–One Phillips head screwdriver.)

1. Locate and remove all 15 metal screws and washers.

2. Locate and remove two 10-32 x .50” long screws, one on
each side of the unit.

3. Locate and remove one 10-32 x .75” long screw, on the front
of the unit.

4. Slide the right side shroud up and over the handle.

5. Slide the left side shroud up and over the handle.

6. Push one pedal to the bottom of the stroke. Remove the
center shroud.

7. The Hiker should now look like figure 2-1.

STEP 2-Releasing Tension from the Linkage System

(Tools required–One 5/16” Allen wrench, safety glasses.)

1. Position yourself straddling the side tube as shown in figure
2-2.

2. Grasp the long tie rod assembly with one hand and try to
rotate. You should feel resistance.

Fig. 2-1

Fig. 2-2

Fig. 2-3

6

2 / DISASSEMBLY

3. Push the foot pedal backward with your foot (see figure 2-3)
until you can rotate the long tie rod assembly freely with
your hand.

4. Hold the foot pedal in this position and remove the 1/2-13 x

1.50” long screw. (See figure 2-2.)

5. Lay the long tie rod on the assembly floor.

6. Slowly and carefully, let the foot pedal come forward until
there is no force on the pedal.

STEP 3—Removing the Linkage System

Must complete at least Step 2-Disassembly.

(Tools required–Two 3/4” wrenches, one 5/16” Allen wrench, one
flat head screwdriver and safety glasses.)

1. Remove the 1/2-13 x 2.00” long bolt and 1/2-13 lock nut on
the lower end of the long tie rod assembly.

2. Remove the 1/2-13 x 1.75” long bolts and two 1/2-13 lock
nuts on the short tie rod assembly.

3. Remove the 1/2-13 x 1.5” long screw on the foot plate tie
rod assembly.

4. Remove the retaining ring attaching the foot plate tie rod
assembly.

5. Remove the foot plate tie rod assembly.

WARNING: Be sure that tension from the linkage system has
been released prior or further disassembly.

STEP 4-Disassembling the Tie Rod Assemblies

Must complete at least Steps 1,2,3-Disassembly.

(Tools required–One 3/4” wrench, one 5/8” wrench.)

NOTE: The rod ends and check nuts on the front ends of the tie
rod assemblies are all left hand thread while the rod ends and
check nuts on the back ends are right hand thread.

1. While holding the tie rod, loosened the 1/2-28 check nut.

2. Screw out the rod end.

Fig. 2-4

Fig. 2-5

CAUTION

Do not use any lubricant on
tie rod ends. Using lubricant
on tie rod ends can destroy
bearings and will void
warranty.

CAUTION

Use only Cybex replacement
parts when servicing. Failure to do
so could result in personal injury.
Cybex will void warranty if non­Cybex replacement parts are used
or when unauthorized modifications
are made.

7

2 / DISASSEMBLY

Component Parts of the Linkage System

1. 1/2-13 x 1.75” long hex head bolt

2. 1/2-13 x 2.00” long hex head screw

3. 1/2-13 x 1.50” long BHC screw

4. 1/2-13 lock nut

5. 1/2-28 nut, left hand thread

6. 1/2-28 nut, right hand thread

7. 1/2” rod end with 1/2-28 left hand thread

8. 1/2” rod end with 1/2-28 right hand thread

9. Short tie rod

10. Long tie rod

11. Foot plate tie rod

12. 1/2” flat washer

13. 1/2” ID spacer

14. 3/4” ID wear washer x 7

15. Retaining ring, foot plate tie rod

Fig. 2-6

Fig. 2-7

Fig. 2-8

14

11

9

10

8

2 / DISASSEMBLY

WARNING: Be sure that tension from the linkage system has
been released prior to further disassembly.

STEP 6-Removing the Pulley Assembly and Drive
Belt

Must complete at least Steps 1,2-Disassembly.

(Tools required–One 1/8” Allen wrench, one 1/4” Allen wrench, one
9/16” wrench.)

1. Grasp the tension spring and pull down. (See figures 2-8
and 2-9.) Then slip the loop off of the spring shaft.

2. Remove two 1/4” set screws from each of the belt retainers
at foot plate.

3. Slide the drive belt out through the pulley assembly.

4. Remove the 1/2 x .625” long shoulder screw.

5. Remove the pulley assembly. (See figure10.)

WARNING: Be sure that tension from the linkage system has
been released prior to further disassembly.

STEP 7-Removing the Foot Plate

Must complete at least Step 2-Disassembly.

(Tools required–One flat head screwdriver, one rubber hammer.)

1. Remove the two retaining rings on the foot plate which
attach the foot plate to the rear pivot arm assembly. (See
figure 2-11.)

2. Remove the retainer from the foot plate tie rod found in rear
of pedal.

3. Slide the seven wear washers (not shown in figure), foot
plate and the belt attachment assembly off. This may require
a tapping with a rubber hammer.

Fig. 2-11

Fig. 2-12

Fig. 2-10

Fig. 2-9