Precor RBK 815 User manual

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RBK 815 Bicycle
Warning: This service manual is for use by Precor trained service providers only
If you are not a Precor Trained Servicer, you must not attempt to service any Precor
Product; Call your dealer for service
This document contains information required to perform the majority of
troubleshooting, and replacement 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
section to the left of this page You may “drag” the separator bar between this page
and the bookmark section to change the size of the page being viewed

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© 2010 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law

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Section One - Things You Should Know
Right, Left, Front, and Back Conventions
In this manual, right, left, front, and back are from the perspective of a user sitting on
the RBK 815 facing the display enclosure
Warning and Caution Statements and General Safety Guidelines
Warning statements indicate a particularly dangerous activity Warning statements
you will find in this manual include:
• To remove power from the RBK 815 the optional power adapter must be
disconnected from the cycle Always ensure that the optional power adapter is
disconnected from the cycle when you inspect or adjust the RBK 815 or when you
isolate, remove, or replace a component
• Removing the covers exposes high voltage components and potentially dangerous
moving parts Exercise extreme caution when you perform maintenance
procedures with the hood removed
• During service operations you will be very close to moving machinery 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 statements included in this manual are listed below:
Safety guidelines you should know and follow include:
• Read the owner’s manual and follow all operating instructions
• Visually check the bicycle before beginning service or maintenance operations If it
is not completely assembled or is damaged in any way, exercise extreme caution
while operating and checking the bicycle
• When operating the bicycle, do not wear loose clothing Do not wear shoes with
heels or leather soles Check the soles of your shoes and remove any embedded
stones Tie long hair back
• Do not rock the unit Do not stand or climb on the handlebars, display enclosure, or
cover
• Do not set anything on the handlebars, display enclosure, or cover While servicing,

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never place liquids on any part of the bicycle The water bottle holder must be
empty
• To prevent electrical shock, keep all electrical components, 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”

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Required Tools and Equipment
The following is a summary of the tools and equipment that may be required when
you service a Precor RBK 815 Upright Cycle
Tools
Phillip and flat-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 ties

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Section Two - Preventive Maintenance
Preventive maintenance measures are either scheduled or unscheduled Scheduled
preventive maintenance activities are included here so that you are aware of
preventive measures performed on a regular basis
Regular Preventive Maintenance (Owner)
Cleanliness of the cycle and its operating environment will keep maintenance
problems and service calls to a minimum Precor recommends that you perform the
following preventive maintenance schedule
After Each Use
• Turn off and, unplug the power 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 on/off switch, then unplug it from the power
adapter (if equipped)
2 Place the bicycle on its side
Note:
Place a drop cloth under the bicycle to protect the flooring and to ensure that the
cycle handrail is not scratched or damaged
3 Vacuum the rug or damp mop the floor
4 Make sure that the floor is dry before returning the bicycle to an upright
position

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Quarterly Maintenance
1 Remove the cover
2 Thoroughly clean inside the bicycle Use a vacuum cleaner and damp rag to
remove all the dust belt particles, etc
3 Check the belt tension of both belts per Procedures 5 1 and 5 2
4 Replace 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 connections Secure
connections and replace wiring as necessary

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Procedure 3 1 - Accessing the Diagnostic Software
The diagnostic software consists of the 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

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3 Press the OK key, the upper most group of LED’s will illuminate on the display
Check the display to ensure that all LED segments are illuminated
4 Press the OK key four more times to display the remaining LED groups Check
each display group to ensure that all LED segments are illuminated
5 Press the CLEAR key then the q key, KEYBOARD TEST will scroll across the
display
6 Press the OK key, a representation of all of the keys on the console will be
displayed Pressing a key on the console will cause the representation of that key
to go off Press all of the keys on the console to ensure that all of the keys are
functioning
7 Press and hold the CLEAR key then the 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 CLEAR key then the q key, MACHINE TEST will scroll across the display
11 Press the OK key, BRAKE test will be displayed
12 Press the q key, PWRB will be displayed with the current power bit setting
13 Press the CLEAR key, BRAKE test will be displayed
14 Press the q key, RPM will be displayed with the current pedaling speed
15 Press the q key, BATTERY test will be displayed
16 Press the OK key, the battery voltage will be displayed as XX X VDC
17 Press the RESET key to exit the hardware validation test

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Procedure 3 2 - Information Display
Software version numbers are invaluable for tracking and identifying problems and
staying aware of changes to the operation and features of the product
Procedure
The information display will access the following data;
• Odometer
• Hour Meter
• U-Boot Software
• U-Base Software
• Lower Software
• Serial Number
• Usage log
• Error Log
Procedure
1 Pedal the bicycle or install an optional external power supply
2 With the PRECOR banner scrolling, press the keys RESET,6,5, sequentially
3 DIAGS-INFORMATION 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 display Press the OK key
9 The operating time of the unit will be displayed as 12345 HOURS The operating
time is defined as total amount of time that the unit has operated in program
modes with the drive motor running The hour meter is also used to provide the
“time stamp” for the error code log
10 Press the CLEAR key to exit the hour meter display

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11 U-BOOT SW display This display the installed version of upper boot software
The boot software is used to upload new software into the upper display PCA
12 Press the OK key The software part number will be displayed as XXXXX-XXX
13 Press the CLEAR key to exit the U-Boot SW display
14 U-BASE SW display This display the installed version of upper PCA software
15 Press the OK key The software part number will be displayed as XXXXX-XXX
16 Press the CLEAR key to exit the U-Base SW display
17 LOWER SW display This display the installed version of lower PCA software
18 Press the OK key The software part number will be displayed as XXXXX-XXX
19 Press the CLEAR key to exit the lower SW display
20 SER NUMBER display Press the OK key
21 The bicycle’s serial number will be displayed The serial number may be incorrect
or not displayed if the upper PCA has been replaced
22 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
displayed
27 Press the OK key, the most recent error will be displayed first
28 Use the p,q keys to move through the list of errors The error messages will list the
error name, the odometer reading when the error occurred, the hour meter when
the error occurred
29 If you wish to clear the error log, press and hold the QUICK START key The
message HOLD TO CLEAR ERRORS will be displayed The error log will be
cleared when the message NO ERRORS is displayed
30 Press the RESET key to exit the information display
31 Please note that the ERROR LOG may also be accessed at any time by pressing
and holding the RESET key for four seconds If the error log does not contain any
errors, the message STUCK KEY will be displayed

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Procedure 3 3 - Selecting Club Settings
Procedure
This procedure allows you to change the following club settings:
• Select Language
• Select Units
• Set Max Workout Time
• Set Max Pause Time
• Set Cool Down Time
• Set Resistance Range
Procedure
1 Pedal the bicycle or install an optional external power supply
2 With the banner scrolling, press keys RESET,5,6,5,1,5,6,5, sequentially
3 Use the p,q keys to move to the desired display shown in the list above
4 DIAGS-SET CLUB PARAMETERS will scroll across the display
5 When SELECT LANGUAGE is displayed Press 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 remain in a program
13 Press the CLEAR key to exit the set max workout time display
14 SET MAX PAUSE TIME display Press the OK key
15 Use the p,q keys to select the maximum time a program will remain in the pause
mode
16 Press the CLEAR key to exit the set max pause time display
17 SET COOL DOWN TIME display Press the OK key
18 Use the p,q keys to select the cool down time

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19 Press the CLEAR key to exit the 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

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Procedure 3 4 - Documenting Software Problems
When a problem is found with either the software or upper or lower PCA’s, record the
information listed below If you isolated the problem to either the PROM, upper PCA,
or lower PCA, include the information you recorded with the malfunctioning PROM or
PCA when 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 as how far into the program the problem
occurred, the work level being used when the problem occurred, etc )
d The frequency of occurrence

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Section Four - Checking Operation
This section provides you with a quick method of checking operation
Procedure
1 Start pedaling
2 With the banner displayed, press QUICK START
3 Select Resistance Level 1 and press ENTER
4 Operate the RBK 815 for 4–5 minutes As you operate the bike, concentrate on
the operating sounds made by the unit Be on the alert for unusual rubbing,
hitting, grinding, or squeaking noises
5 If the electronic display does not change 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 minutes
9 If the resistance of the bike does not change or operation feels inconsistent with
Resistance Levels 1 and 20, troubleshoot per Procedure 6 2
10 Check the LED’s mounted on the upper PCA and the function keys displayed on
the electronic console by performing Procedure 3 1

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Procedure 5 1 - Primary Belt Tension Adjustment
1 Remove the covers per Procedure 71
2 Place the belt tension gauge on the primary belt The belt will twist when the
tension gauge is engaged The belt tensions have been adjusted 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 idler pulley mounting nut is tightened See
Diagram 5 2

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Diagram 5 2 - Primary Belt Adjustment
Adjustment Bolt
Adjustment
Idler Pulley
Mounting Nut
Bracket

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5 Turn the adjustment bolt clockwise or counter clockwise, as required, until the
belt gauge is in the range of 90 pounds ± 5 pounds Torque the idler pulley
adjustment nut to 120 inch poinds (10 foot 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 the covers per Procedure 7 1

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Procedure 5 2 - Secondary Belt Tension Adjustment
1 Remove the covers per Procedure 71
2 Place the belt tension gauge on the secondary belt The belt will twist when the
tension gauge is engaged The belt tensions have been adjusted to accommodate
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 pounds ± 5 pounds See Diagram 5 4
5 Tighten the generator bolts to 100 ± 10 inch pounds

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Diagram 5 4 - Secondary Belt Adjustment
6 Replace the covers per Procedure 7 1
Adjustment Bolt