Precor RBK 815, Service Manual

Page 1: ...nt procedures required to repair and maintain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures troubleshooting procedures replacement procedures and electrical block and wiring diagrams To move directly to a procedure click the appropriate procedure in the bookmark ...

Page 2: ...RBK 815 Recumbent Cycle Page 2 2010 Precor Incorporated Unauthorized Reproduction and Distribution Prohibited By Law ...

Page 3: ...inery and high voltage components When you perform maintenance procedures with the covers removed remove jewelry especially from ears and neck tie up long hair remove neck ties and do not wear loose clothing Exercise caution when touching any wire or electrical component during operation Caution statements are intended to prevent damage to the bicycle as a result of the current activity Caution st...

Page 4: ...s such as the power cord and power adapters away from water and other liquids Do not use accessory attachments that are not recommended by the manufacturer such attachments might cause injuries or damage to the unit General Information For the latest exploded view diagram part number and part pricing information visit the Precor dealer website at www precor com connection ...

Page 5: ...lat head screwdrivers Standard and metric allen wrench set Open end wrench set 1 1 8 inch thin open end wrench Socket wrench set Rubber mallet Snap ring pliers Torque wrench 20030 119 secondary sheave tool Park Tool CCP 22 crankarm puller or equivalent available at bicycle shops Kent Moore BT 33 73Fdrive belt tension gauge or equivalent Equipment Anti static kit Digital multimeter Supplies Cable t...

Page 6: ... adapter if equipped from the bicycle Wipe down the covers handlebars seat and pedals with a damp cloth Daily Maintenance Clean the bicycle s frame covers seat and pedals using a water damped cloth Wipe the surface of the electronic console with a damp sponge or soft cloth Dry with a clean towel Weekly Maintenance Clean underneath the bicycle following these steps 1 Turn off the bicycle with the o...

Page 7: ...eplace both covers On Site Preventive Maintenance Service Technician When you are called to service a RBK 815 perform these preventive maintenance activities Perform the software diagnostics Check LED and keypad function Record the odometer reading See Procedure 3 1 Visually inspect the drive belts for cracks fraying or excessive wear Visually examine all wires and check connectors and wire connec...

Page 8: ...following modes Display Test Keyboard Test Heart Rate Test Machine Test Procedure 1 Using the RESET key and the numeric keypad press keys RESET 5 1 7 6 5 7 6 1 sequentially 2 Hardware Validation will scroll across the display followed by DISPLAY TEST Diagram 3 1 RBK 815 Display Reset Key OK Key Numeric Keypad Clear key ...

Page 9: ... q key HEART RATE will be displayed 8 Grasp both of the heart rate grips on the handlebar after a couple of seconds the heart rate will be displayed in the heart rate and smart rate displays 9 Use chest strap transmitter or a test transmitter to test the wireless heart rate function after a couple of seconds the heart rate will be displayed in the heart rate and smart rate displays 10 Press the CL...

Page 10: ...MATION DISPLAY will scroll across the display 4 Use the p q keys to move to the desired display shown in the list above 5 ODOMETER display Press the OK key 6 The odometer will be displayed as XXX miles Note The odometer data is stored in non volatile memory on the upper PCA If the upper PCA is replaced the odometer data will be lost 7 Press the CLEAR key to exit the odometer display 8 HOUR METER d...

Page 11: ...Press the CLEAR key to exit the serial number display 23 USAGE LOG display Press the OK key 24 Use the p q keys to move through the list of programs A message will scroll describing the program the number of times and the number of minutes the program was used 25 Press the CLEAR key to exit the usage log display 26 ERROR LOG display Press the OK key the quantity of errors in the log will be displa...

Page 12: ...ss the OK key 6 Use the p q keys to toggle between the available languages 7 Press the CLEAR key to exit the select language display 8 SELECT UNITS display Press the OK key 9 Use the p q keys to toggle between U S and METRIC measurements 10 Press the CLEAR key to exit the set units display 11 SET MAX WORKOUT TIME display Press the OK key 12 Use the p q keys to select the maximum time a user can re...

Page 13: ...e set cool down time display 20 SET RESISTANCE RANGE display Press the OK key 21 Use the p q keys to select to HIGH MEDIUM or LOW resistance range 22 Press the CLEAR key to exit the set resistance range display 23 Press the RESET key to exit the Club Settings Program ...

Page 14: ...n you ship it to Precor When a problem occurs record the following information Model and serial number Software version number Note A label on the PCA indicates the software version number User and program number running when the problem occurred A description of a What happened or failed to happen b The action taken by the user just before the problem occurred c Problem related information such a...

Page 15: ...ge appropriately troubleshoot per Procedure 6 3 6 Press the RESISTANCE s key until you reach Resistance Level 10 Operate the C846 for another 2 3 minutes 7 If the resistance does not change or the operation of the bike feels inconsistent compared with Resistance Level 1 troubleshoot per Procedure 6 2 8 Press the RESISTANCE s key until you reach Resistance Level 20 Operate the bike for another 2 3 ...

Page 16: ...djusted to accommodate the twisting of the belt See Diagram 5 1 Diagram 5 1 Primary Belt Tensioning 3 The correct belt tension is 90 pounds 5 pounds If the belt tension range is correct skip to step 7 4 If the belt tension is incorrect slightly loosen the idler pulley mounting nut The idler pulley mounting nut also fastens the belt adjustment bracket The belt tension can not be adjusted if the idl...

Page 17: ...RBK 815 Recumbent Cycle Page 17 Diagram 5 2 Primary Belt Adjustment Adjustment Bolt Adjustment Idler Pulley Mounting Nut Bracket ...

Page 18: ...ot pounds 6 You may find depending on how much the idler pulley mounting nut was loosened that the belt tension increases when the idler pulley mounting nut is tightened If so slightly loosen the idler pulley mounting bolt Then return to step 5 and set the belt tension on the low side so that the belt tension is correct when the idler pulley mounting bolt is torqued to 120 inch pounds 7 Replace th...

Page 19: ...the twisting of the belt See Diagram 5 3 Diagram 5 3 Secondary Belt Tensioning 3 The belt tension should be in the range of 75 pounds 5 pounds If the belt tension is correct skip to step 6 4 If the belt tension is incorrect loosen the 4 bolts that secure generator to the frame then turn the adjustment bolt clockwise or counterclockwise as required until the belt tension is in the range of 75 pound...

Page 20: ...RBK 815 Recumbent Cycle Page 20 Diagram 5 4 Secondary Belt Adjustment 6 Replace the covers per Procedure 7 1 Adjustment Bolt ...

Page 21: ...ounterclockwise to loosen or clockwise to tighten the seat Perform half of the adjustment using the right hand adjustment plate and half of the adjustment using the left hand adjustment plate 4 Apply a minimum of pressure to the adjustment wrench when tightening the seat adjustment Apply only enough pressure to rotate the adjustment plate fully clockwise 5 When the seat is properly adjusted the an...

Page 22: ... generator windings for AC zero cross The monitoring system notes every time the generator AC voltage passes through zero volts By counting the zero cross rate the system knows how fast the generator is turning The system calculates the user RPM from the generator speed If the system does not see a zero cross rate it assumes the bike is not being used and the display will not illuminate when the b...

Page 23: ...RBK 815 Recumbent Cycle Page 23 Diagram 6 1 Lower PCA RBK 815 TP19 TP20 J2 M6 M7 J4 M1 M2 M3 M4 M5 ...

Page 24: ...kip to step 9 8 Remove the upper display panel and disconnect the interconnect cable from the upper PCA With the unit powered up check the voltage between the outer two pins of the interconnect cable for DC volts It should read approximately 8 5 Vdc If the voltage is absent or significantly low troubleshoot the interconnect cable 9 If the voltage measurement in step 4 is correct replace the upper ...

Page 25: ...ding should be approximately 11 Vdc If the reading is significantly low or significantly high skip to step 5 4 If the reading in step 3 was correct the pedalling resistance should be correct skip back to step 2 5 Disconnect the eddy current magnet wires from terminals M1 and M2 of the lower PCA Measure between the eddy current magnet wires with an ohmmeter It should read approximately 10 W Diagram...

Page 26: ...strap to your arm then connect the ground wire of the wrist strap to the units frame 2 If the bicycle powers up and functions normally until a particular key s is pressed skip to step 10 3 If a stuck key message is immediately displayed when the bicycle is powered up continue with the next step 4 This condition may be caused by either the keypad or upper PCA 5 Remove the four screws that attach th...

Page 27: ...RBK 815 Recumbent Cycle Page 27 Diagram 6 3 Upper PCA Keypad Upper PCA Metrics PCA D Pad Assembly Keypad Cable D Pad Cable Metrics Cable D Pad Clip ...

Page 28: ... the key s necessary to access the diagnostic program is not functioning skip to step 14 11 Test the keypad per Procedure 3 1 12 If all of the keys test good the problem may be user error or a key function that is normally disabled during a particular user program 13 If one or more keys do not function correctly either the keypad display front panel or upper PCA could be defective Replace the disp...

Page 29: ...p reading no hand held reading chest strap normal no hand held or chest strap reading or constant or intermittent readings when neither hand held or chest strap are in use Diagram 6 4 Heart Rate Printed Circuit Board Normal hand held reading No chest strap reading 1 Access the diagnostic program Procedure 3 1 Advance to the heart rate display portion of the diagnostic program Verify that a chest s...

Page 30: ...ndlebar contacts and left hand on the right handlebar contacts Cover as much of the contact surface area with your hands as possible you should receive a heart rate reading within ten seconds If a hand held signal is still not being accepted skip to step 10 9 If a hand held signal was accepted in step 8 the hand held contact wiring is reversed The end of the wire harness that connects to the hand ...

Page 31: ...RBK 815 Recumbent Cycle Page 31 replace the heart rate PCA to handlebar wire harness ...

Page 32: ... rate PCA Measure between the ground and 5 Vdc pins of the connector just removed from the heart rate PCA for 5 Vdc If 5 Vdc is present replace the heart rate PCA If the 5 Vdc is not present measure between the corresponding pins of J4 on the upper PCA red and black wires If 5 Vdc is not present replace the upper PCA If 5 Vdc is present replace the upper PCA to heart rate PCA cable Constant or int...

Page 33: ...ree screws from the right side cover remove the left side cover 3 Remove three screws from the left side cover remove the right side cover 4 Remove three screws one each side and one in the rear from the rear cover Remove the rear cover 5 Remove three screws from the seat frame cover Remove the seat frame cover See Diagram 7 2 Diagram 7 2 RBK 815 Covers Top Cover Left Side Cover Rear Cover Seat Fr...

Page 34: ...tep 4 torque to 20 inch pounds 10 Set the right frame cover in its mounting position and fasten it with the screws removed in step 2 torque to 20 inch pounds 11 Slide the connector assembly into the slot in the lower front portion of the right side cover See Diagram 7 3 Diagram 7 3 CAT5 Coax Connector Assembly 12 Set the left side cover in its mounting position with the connector assembly in its s...

Page 35: ...emove and discard the primary belt Diagram 7 4 Primary Belt 5 Place the replacement primary belt in its mounting position around the input pulley under the idler pulley and around the secondary sheave 6 Tension the primary belt per Procedure 5 1 When the belt tension is correct torque the idler pulley mounting nut to 120 inch pounds 10 foot pounds 7 Replace the covers per procedure 7 1 Idler Pulle...

Page 36: ...ve the generator s weight from the secondary belt then remove and discard the secondary belt 5 Lift the generator and place the replacement secondary belt in its mounting position around the generator and secondary pulleys 6 Tension the secondary belt per Procedure 5 2 7 Torque the four generator mounting bolts to 100 inch pounds Recheck the belt tension if it is no longer correct slightly loosen ...

Page 37: ...ly threaded into the crankarms the crankarm s threads may be destroyed when the crankarm is removed 5 Thread the crankarm puller into the nut removed from the crankarm puller See Diagram 7 7 When the crankarm puller tightens in the crankarm continue rotating the crankarm tool clockwise until the crankarm is removed Diagram 7 7 Crankarm with Crankarm Puller 6 The right hand crankarm has a pin on th...

Page 38: ...unds 9 The right hand pedal threads onto the crankarm in a normal clockwise direction the left hand crankarm is reverse counter clockwise threaded 10 Install the pedal removed in step 1 on the replacement crankarm and torque it to 800 inch pounds 67 foot pounds 11 Pedal the bike for 1 minute and then re torque left and right crankarms to the specification indicated in steps 8 and 9 ...

Page 39: ...ch turning clockwise See Diagram 7 8 Diagram 7 8 Input Pulley 7 Remove the input pulley and discard 8 Slide the replacement input pulley onto the input axle ensuring that the spacer is still in place behind the input pulley 9 Thread the retaining nut removed in step 6 onto to the input axle finger tight only at this time 10 Place the primary belt in its mounting position around the input pulley un...

Page 40: ...RBK 815 Recumbent Cycle Page 40 14 Replace the covers per Procedure 7 1 ...

Page 41: ...e input axle assembly See Diagram 7 9 Diagram 7 9 Input Axle Assembly 9 Slide the input axle assembly out of the frame and discard 10 Slide the replacement input axle assembly into its mounting position in the frame 11 Slide spacer onto axle assembly 12 Fasten the input axle assembly with the screws and washers remove in step 8 13 Slide the input pulley removed in step 7 onto the input axle assemb...

Page 42: ...umbent Cycle Page 42 tighten counter clockwise the input pulley s retaining nut 17 Tension the primary belt per Procedure 5 1 18 Replace the left crankarm per procedure 7 4 19 Replace the covers per Procedure 7 1 ...

Page 43: ...lt counter clockwise See Diagram 7 4 4 Remove the primary belt 5 Remove the idler pulley by removing the idler pulley mounting nut Discard the idler pulley 6 Mount the replacement idler pulley using the nut removed in step 5 The idler pulley mounting nut should only be finger tight at this time 7 Replace the primary belt and tension the primary belt per Procedure 5 1 8 Torque the idler pulley moun...

Page 44: ...om turning and allow the secondary sheave to be removed 6 While holding the secondary axle with a 3 8 inch allen wrench use the 20030 119 sheave removal tool and a 1 2 inch drive socket wrench to remove the secondary sheave See Diagram 7 10 Diagram 7 10 Secondary Sheave Removal 7 Thread the replacement sheave onto the secondary axle assembly Using the allen wrench 20030 119 sheave tool and socket ...

Page 45: ...3 3 Remove the retaining clip from the secondary axle See Diagram 7 11 Diagram 7 11 Secondary Pulley 4 Remove the plastic washer and the secondary pulley Discard the secondary pulley 5 Slide the replacement secondary pulley onto the secondary axle Slide the plastic washer removed in step 4 onto the secondary axle fasten the secondary pulley with the retaining clip removed in step 4 6 Replace the s...

Page 46: ...ondary pulley side of the secondary axle 8 Remove a retaining clip and from the secondary sheave side of the secondary axle 9 Remove a large retaining clip from the secondary pulley side of the secondary axle 10 Remove the secondary axle from the frame and discard 11 Slide the replacement secondary axle into its mounting position in the frame Fasten the secondary axle with the large retaining clip...

Page 47: ... the secondary belt then remove the secondary belt Diagram 7 13 Generator Tension Adjustment Hardware 6 Remove three generator mounting bolts one front and two rear 7 Remove and discard the generator 8 Set the replacement generator in its mounting position Hand start and hand tighten the three generator mounting bolts removed in step 6 9 Place the tension adjustment bolt and washer in its mounting...

Page 48: ...ower PCA Connect the two red magnet wires to terminals M1 M2 the order does not matter Connect the red generator wire to M3 the white generator wire to M4 and the black generator wire to M5 Check cable routing to insure cables will not rub on generator See Diagram 7 14 15 Replace the covers per Procedure 7 1 ...

Page 49: ... not have a wire clip on the left side positive side of the battery add one at this time 7 Connect the black wire to the battery s negative terminal and the red wire to the battery s positive red dot terminal 8 Route the cables to left side and run them through the wire clip Ensure cable is not run near the primary pulley 9 Slide the battery in into the battery pocket in the right hand cover the b...

Page 50: ...ts mounting position and fasten it with the four screws removed in step 3 5 Reconnect the wiring to the lower PCA as follows two red generator magnet wires to M1 M2 red generator wire to M3 white generator wire to M4 black generator wire to M5 red battery wire to M6 Black battery wire to M7 the data cable to connector J2 See Diagram 7 14 Diagram 7 14 Lower PCA 6 Replace the covers per Procedure 7 ...

Page 51: ... and Caution statements listed in Section One Things You Should Know 2 Attach the anti static wrist strap to your arm then connect the ground wire of the wrist strap to the units frame 3 Remove the four screws that secure the display s rear cover 4 Disconnect the interconnect cable and heart rate cable from the upper PCA Diagram 7 15 Display with Rear Cover Removed 5 Starting from the top and work...

Page 52: ... cable and metrics PCA cable to the upper PCA See Diagram 6 3 12 Skip to step 33 Replacing a Metrics PCA 13 Disconnect the metrics cable from the metrics PCA See Diagram 6 3 14 Unsnap the metrics PCA from the display front panel and discard 15 Place the replacement metrics PCA in its mounting position on the display front panel and snap it into place 16 Reconnect the metrics cable to the metrics P...

Page 53: ...e display front panel as described in the above procedures 30 Snap the upper PCA metrics PCA and D pad assembly onto the replacement display front panel 31 Reconnect the keypad cable to the upper PCA Reconnect the metrics cable to the upper PCA and metrics PCA Reconnect the D pad cable to the upper PCA and the D pad assembly 32 Starting from the bottom and working upward snap the display front pan...

Page 54: ...eat carriage to avoid damaging the heart rate cables 2 Move the seat carriage to its most forward position Carefully unsnap the water bottle holder from the rear of the seat carriage 3 Remove the two screws that fasten the end cap in the seat rail remove the end cap Slide the seat stop out of the seat rail See Diagram 7 16 Diagram 7 16 Seat Rail End Cap and Seat Stop 4 Remove the cable cover and d...

Page 55: ...ft the grips from the handlebar and disconnect the wire from both grips Repeat this procedure on the right handlebar 7 Remove the heart rate cable from the seat carriage 8 Feed the replacement heart rate cable into the access hole on the underside of the seat carriage so that the portion with the blue shrink tubing is in the right handlebar and the portion with the black shrink tubing is in the le...

Page 56: ...90 inch pounds Replacing a Release Handle Assembly 14 Remove the nut from the right hand side of the release lever Remove the release handle pivot and spring See Diagram 7 19 Diagram 7 19 Release Handle Assembly 15 Remove the bolt from the left hand side of the release handle and remove the release handle from the seat carriage 16 Set the release handle in its mounting position and fasten the left...

Page 57: ...all the way forward Set seat stop in its mounting position Replace the end cap and fasten it to the seat stop with the hardware removed in step 3 See Diagram 7 16 Torque the screws to 20 inch pounds 21 Connect the flat ribbon cable to the heart rate cable in the seat rail and replace the cable clamp Torque to 10 inch pounds See Diagram 7 17 22 Snap the water bottle holder onto the seat carriage ...

Page 58: ...RBK 815 Recumbent Cycle Page 58 Wiring Diagram 8 1 RBK 815 J1 J9A J4 J7 J4 M1 M2 M3 M4 M5 M6 M7 J2 HHHR Grips HHHR Grips Optional A C Adapter ...

Page 59: ...RBK 815 Recumbent Cycle Page 59 Block Diagram 8 2 RBK 815 ...