Monark 828E User manual

INSTRUCTION MANUAL
Monark model 828E
Monark Exercise AB

3
CONTENTS
Page
Assembly instructions 6-9
Brake surface - brake belt 19
Calibration 16-17
Chain 20-21
Crank bearing 24
Elektronic meter 12-14
Flywheel bearing 24
General 4
General about exercise 25-27
Freewheel lubrication 22-23
Operation instruction 10-11
Replacement - adjustment brake belt 18
Replacement of batteries 14
Replacement of freewheel sprocket 22-23
Service checklist 24
Warrenty 4
Zero adjustment scale 15

4
CONGRATULATIONS ON YOUR NEW EXERCISE BIKE
designed by Monark Exercise AB, Sweden. Monark has been the worlds leading manufacturer of high
quality ergometers and exercise cycles for more than 40 years.
GENERAL
It is important that you keep your ergometer clean and properly lubricated. Most important is to protect
the chromed and zinced parts but also painted parts benefit from the same protection.
When cleaning and lubricating be sure to check that all screws and nuts are properly tightened.
Be sure that all moving parts as crank and flywheel is working normal and that no unnormal play or
sound excists. I. e. play in bearings causes fast waring and with that follows a highly reduced lifetime.
PLEASE NOTE: The production number of your exercise cycle is placed according to fig 1 page 6.
WARRANTY
As on any quality product there may be an exceptional fault due to material or manufacture. If such a
fault should arise on your exercise cycle, please return to the place of purchase for necessary repair.
Monark products and parts are guaranteed against defects in materials and workmanship for a period of
one year from the initial date of purchase of the unit.
Parts found to need replacement due to normal wear and tear, such as brake belts, are not covered. This
guarantee covers parts only, not labor costs associated with the repair.
This guarantee does not apply to cases of abuse or vandalism, nor does it extend to any injury or loss to
person or property caused directly or indirectly by any Monark products.
In the event of a defect in material or workmanship during the warranty period, Monark Exercise will
repair or replace (at its option) the product. Monark Exercise will do so at its expense for the cost of
materials but not for labour or shipping

5
PARTS BELOW ARE NOT ASSEMBLED.
ASSEMBLY INSTRUCTION:
See pages 6-9.
HANDLEBAR/HANDLEBAR STEM
PEDAL, LEFT HAND
PEDAL, RIGHT HAND
SUPPORTING TUBE, FRONT
SUPPORTING TUBE, REAR

Fig. 1 Fig. 2
6
Serial number
Tip the cycle forward. Assemble the rear
supporting tube with two bolts and two
nuts.
NOTE: Use the accompanying spanner.
See fig 1.
Tip the cycle backwards. Assemble the front
supporting tube with two nuts onto the two
fixed bolts.
NOTE: Use the accompanying spanner.
See fig 2.

Fig. 3
7
Check that the inclination of the saddle is
comfortable and that the sadle post bracket is firmly
tightened. In order to change the inclination of the
saddle, loosen the saddle bracket and tighten firmly
again.
Adjust to desired height position of saddle/saddle
post by loosening the saddle post bolt.
NOTE: Tighten firmly. See fig 3.
Saddle bracket

Fig 4
Before the handlebar stem is assembled be sure the
expanding wedge is loose. Insert the handlebar stem
into the frame tube and tighten the expanding bolt
firmly by means of the lever.
NOTE: The handlebar stem should be inserted
into the frame tube at least 7.5 cm (about 3
inches). See fig. 4.
Usually this measure is marked out.
To change the height of the handlebar, loosen the
expanding bolt about 5 mm. Give the bolt a light push
to release the expanding wedge. Adjust the handlebar
to the desired position and tighten the expanding bolt
again by means of the lever.
In order to change the inclination of the handlebar,
loosen the expanding bolt one turn. Adjust to desired
angle of handlebar and tighten the expanding bolt/
lever firmly again.
8
7.5 cm

Fig. 5
R right
L left
9
Pedal marked R (Right) is to be assembled on the right hand
side of the cycle (the chain wheel side). The pedal axle has a
right hand thread and must be threaded onto the crank
clockwise. Tighten firmly. See fig 6.
Pedal marked L (Left) is to be assembled on the left hand
side of the cycle. The pedal axle has a left hand thread and
must be threaded onto the crank counter clockwise. Tighten
firmly.See fig 5.
NOTE! Check now and then that both pedals are still firmly
tightened. If not the threading in the pedal arms will be
damaged.
Also check that the pedal arms are firmly tightened on
the crank axle. If nessecary tighten.

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OPERATION INSTRUCTION
The Monark Exercise Ergometer Model 828E is a test cycle which has an adjustable brake
system where the brake force can be set/read in kilopond (kp) and Newton (N). The
actual brake power is showed in Watts on the electronic meter.
The cycle is equipped with an electronic meter showing pedal revulotions per
minute (RPM), heart rate in bpm (HR), exercise time in minutes and seconds (TIME), an
imagined cycling speed in km per hour or miles per hour (SPEED), covered distance in km
or mile (DISTANCE), burned Calories (CAL) and the power on the cycle(WATT).
The watt reading is depending on the pedalling speed which means that the watt figure can
be fine tuned by means of increasing or decreasing the speed or pedal rpm.
When pedalling the subject supplies the flywheel with a kinetic energy.This is braked by
means of a brake belt which runs around the bigger part of the brake surface of the
flywheel. The brake power is changed either by using other pedalling speed or by
increasing or decreasing the tension of the brake belt against the flywheel by means of the
load tension device. The harder the load is adjusted the larger figure, in kp or N, the
pendelum will show on the force scale and the watt figure can be read in the watt display
on the electronic meter. The kp figure can also be read in the kp window beside the
electronic meter. See fig. 6.

11
Fig. 6
The height of the saddle should be adjusted so
that, when sitting comfortably with the middle
of the foot above the pedal axle and with the
pedal in its lowest position, the knee should
only be slightly bent.
The adjustment of the handlebar should give a
comfortable ride. When cycling for a long
time, it may be suitable some time during the
exercise to change the position of the
handlebar.
NOTE! At transport the tension device
should be somewhat tightened to prevent
the brake belt from falling off the fltwheel.

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ELECTRONIC METER
SPECIFICATIONS:
RPM: 0 - 199 pedalrev./min
HR: 50 - 240 bpm
TIME: 0:00 - 99.59 min:sek
SPEED: 0 - 99 km/h or mph
DISTANCE: 0.0 - 99.9 km or mile
FORCE 0.0 - 7.0 kp
CALORIES 0 - 999 kcal
WATT 0 - 7 x rpm watt
Batteries: 1.5 V x 2 AA(R6)
Storing temp.: -10ºC - +60ºC
Operating temp.: 0ºC - 50ºC
Fig. 7

13
ELECTRONIC METER
Press any button or move the pedal to turn on the meter.
At the display for heart rate (HR) a ©is lit which means that the meter is trying to find a pulse signal
from an external source (chestbelt with electrodes, not included. Our part.no 9339-91).
If the meter can not find such a signal this HR function is automatically turned off after 30 seconds.
When the function is turned off the © symbol is not lit any more.
The heart rate function can be turned on again by preessing a button.
Timer starts automatically when pedals are moved. Meter values for Time, Distance and Calories can be set to
zero by pressing the RESET button for more than 2 seconds.
To get correct raedings for calories and watts the kp value on the electronic meter has to be set to the same
value as the pendelum or the kp window to the left of the meter is showing. The watt reading in the display is
then depending on the pedalling speed. The watt reading can be fine tuned through increase or decrease the
pedalling speed.
Calories are calculated all the time.
Do not expose the electronic meter to direct sunlight or extremely high temperature. Do not use any
dissolvents when cleaning. Use only dry cloth.
NOTE: The batteries are at delivery in a separat package.
If the batteries have been stored for a long time, the battery power can be too low to show all functions
on the meter. If so, batteries must be replaced.
See REPLACEMENT of BATTERIES page 13.

Fig. 8
14
REPLACEMENT OF BATTERIES
Take the meter out of the housing by bending up in the
lower end with something sharp.
The batteries, 2 x 1.5V size AA(R6), which are placed
in the holder on the backside of the meter, can then
easily be changed.
See fig.8.
After the batteries has been replaced all segments in
the display are visible and a buzzer will sound for two
seconds.
After 2 seconds the meter turns to main display again
and normal function.
Put the meter into the housing again.
Note: On the backside of the meter is a switch to
change meter function from km to mile or mile to
km.See fig. 9.
Batteries
km/mile

15
ZEROADJUSTMENT OF METER BOARD
Remove the transport tape for the pendulum. Loosen
tension device so the brake belt feels loos. Check that
the pendulum will hang in vertical position. The index on
the pendelum weigh shall now be aligned with the index
at the 0-position on the board.
If adjustment is necessary, first loosen the lock nut and
then change the position of the board, so that it will have
its 0-index in line with the index of the weight. Tighten the
lock nut after the adjustment. See fig 9.
Check at the same time that the scale for kiloponds to
the left of the electronoic meter will have its 0-index in
line with the index in window.
If needed the position of the scale can be adjusted after
the adjusting screw has been loosened.
Tighten the screw firmly after the adjustment.
Lock nut
Adjustm.
weight
Fig. 9

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CALIBRATION OF PENDULUM SCALE
1. Loosen the tension device so the brake belt feels loose.
2. Check 0-adjustment.
See ZEROADJUSTMENT page 15.
3. Detatch the front screw in the frame covers.
4. Fasten a known weight, e.g. 4 kg (our ref No. 9000-211) at the
balancing spring. Note: The weight should not be less than 3 kg,
due to the possibility of inferior accuracy. Take the left cover a little
to the side so the weight cord hangs between the covers. See fig.
5. When correctly set, it should be possible to read this weight from
the corresponding place on the meter board. See fig 10.
6. Should there be a deviation, adjust the pendulum to the correct
weight on the scale by means of the adjusting weight inside the
pendelum. See fig 9.
To change the position of the adjusting weight, loosen the lock
screw of the weight.
Should the index of the pendulum weight be too low, move the
adjusting weight upwards in the weight and if the index should be
too high the adjusting weight is moved somewhat downwards and
locked in the new position. Repeat until the correct reading is
achieved.
Check the calibration of the pendulum weight once a year or when
needed.

17
Fig. 10

Fig. 11
Tension lever
Lock washer
Clip
18
REPLACEMENT OF BRAKE BELT
Remove the tension lever.
Dismantle the front cover over the pendelum weigh by
detatching the 4 screws underneath.
Remove the left or the right frame cover by undoing the
mounting screws (5pcs). Put the crank in a backward posi-
tion. Move the cover somewhat out in the front end and then
take it backwards to remove it.
Loosen the brake belt from the pendelum at the screw and
lock washer.Take it apart at the spring and clip and remove
it from the bike. See fig 11.
Attach the new brake belt and assamble the bike in reverse
order.
NOTE: When replaceing the brake belt it is
recommended to clean the brake surface. See Brake Belt
Contact Surface.
ADJUSTMENT BRAKE BELT
Loosen the tension device to min. load.Adjust the brake belt
so that resistance increases as soon as a the tension device is
turned a little. See fig. 10.

Fig.12
19
Brake surface
Sand paper
BRAKE BELT CONTACT SURFACE - BRAKE BELT
The brake belt should be regularly checked to ensure that it has not suffered
execessive wear. If it looks worn it should be replaced.
Deposits of dirt on the brake belt and on the contact surface may cause the
unit to operate unevenly and will also wear down the brake belt. The brake
belt contact of the flywheel surface should then be ground off with a fine
sand paper and any dust removed with a clean dry cloth.
Dismantle cover see REPLACEMENT BRAKE
BELT.
Set the tension device to min load.
Loosen the brake belt somewhat at the adjustment bolt
and take off the brake belt to the side. Grind with a fine
sand paper. See fig. 12.
Grinding is easier to perform if a second individual
cautiously and carefull pedals the cycle.
Irregularities on the brake belt contact surface are
removed by means of a fine sand paper or an abrasive
cloth. Otherwise unnecessary wear on the brake belt
may occur and the unit can become noisy.
Always keep the brake belt contact surface clean and dry.
No lubricant is allowed to be used.
We recommend to replace the brake belt when cleaning the contact surface.
As regards assembly and adjustment of the brake belt, see previous page.

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CHAIN ½ x 1/8
It is strongly recommended that a cahin solvent be used to keep the chain clean. Excess dirt built up on the
chain will cause excess wear.A chain lubricant and solvent for normal road bikes may be uaed.
Check the lubrication and tension of the chain at regular intervals. In the middle of its free length the chain
should have a minimum play of 5 mm. See fig 12. When the play in the chain is about 20 mm (<1 inch) the
chain must be tightened otherwise it will cause unnormal wear of the chin and chainwheels. Because of this it is
always recommende to keep the chain play as little as possible. When the chain has become so long that it can
no longer be tightened with the chain adjusters it is worn out and shall be replaced with a new one.
ADJUSTING CHAIN
Remove left and right frame cover. See RRPLACEMENT of BRAKE BELT.
To adjust the chain the hub nuts should be loosened. Loosening or tightening the nuts on the chain adjusters
will then move the hub and axle forward or backward. Adjust according to above recommendation. Then
tighten the nuts on the hub axle again. See fig 12.
CHAIN REPLACEMENT
Loosen the chain adjusteras much as possible. Dismantle the cahinlock and remove the chain. Put on a new
chain and assemble the chain lock.The spring of the chain lock should be assembled with the closed end in the
movement direction of the chain. Use a pair of tongs for dismantling and assembling the spring. See fig 13.
Adjust chain adjusters to chainplay according to above. Tighten axle nuts firmly.
Put on frame covers again.
NOTE: At assembly the flywheel has to be parallell with the center line of the frame. Otherwise the
chain and chainwheels makes a lot of noise and wears out very rapidly.