Ergomedic 828 E Manual 2008

Congratulations on your new Ergometer. The Monark 828 E is the world’s most commonly used exercise ergometer. The adjustable brake system and the force can be set and read Kiloponds (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), 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 level depends on pedaling speed, it can be fine tuned by increasing or decreasing the speed or pedal rpm.

All 828 E Ergometers are calibrated at the factory. This means that you can begin to use the ergometer directly after assembly. However , if the user wishes to verify the scale please read the instruction for “Calibration” in this manual. NOTE! The use of Ergomedic 828 E can be physically strenuous. Always consult a doctor before beginning an exercise program and stop immediately if feeling faint or dizzy.

Features • • • • • • • •

Large, well-balanced flywheel 22kg (48 lbs) Pendulum scale, easy to calibrate Adjustable seat height Adjustable handlebar with quick release lever Stable frame, solid steel tube Powder painted Wheels for easy transport Electronic display with heart rate

Width 530 mm (21”) at handlebar 640 mm (25”) at support tubes Length 1120 mm (44”) Height 890-1130 mm (35-44,5”) at handlebar 800-1120 mm (31,5-44”) at seat Weight 52 kg (114,5 lbs) Included Chestbelt, PC software Monark Ergomedic 828 E

5

Product Information

Product Information

Operating Instruction

Operating Instruction Workload device The 828 E uses a brake belt system to control the resistance. The brake power can be changed by increasing or decreasing the tension of the brake belt against the tension knob(1). See fig: Workload device.

1

Fig: Workload device (1)

Cycle adjustments Seat height should be adjusted to a comfortable position. A suitable height is when your knee is slightly bent and the middle of the foot is straight above the pedal axle with the pedal is in its lowest position. To adjust the seat height loosen the lever on the seat tube. See fig: Adjustments. The handlebar setting shall give a comfortable position when cycling. During longer exercise sessions it is recommended to occasionally change the handlebar position. To adjust the handlebar loosen the quick release lever. See fig: Adjustments.

2

1

Fig: Adjustments 1) Lever, seat post 2) Lever, handlebar 3) Inserted min. 3”

min. 3” 3

6

NOTE! The handlebar stem should be inserted into the frame tube at least 3 inches (about 8 cm). this measure is marked out on the stem(3).

Monark Ergomedic 828 E

Display RPM HR TIME SPEED DISTANCE FORCE CALORIES WATT Batteries: Storing temp.: Operating temp.:

0 - 250 50 - 240 0:00-99:59 0 - 99 0.0 - 99.9 0.0 - 7.0 0 - 999 0 - 7 x rpm

Operating Instruction

Computer specifications rev./min bpm min:sec km/h or mph km or mile kp kcal watt

1.5 V x 2 R6 (AA) -10ºC - +60ºC 0ºC - 50ºC

Computer Instruction 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 (chest belt with electrodes, our part.no 9339-91). If the meter can not find the heart rate signal the 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. The timerer starts automatically when the 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 readings for calories and watts the kp value on the electronic meter has to be set to the same value as the pendulum or the kp window, shown to the left of the electronic meter.

Example: The pendulum and the kp-window is showing 2 kp. Press the kp button to the left on the meter. The lower display window is now showing figures in kp. Increase or decrease in steps of 0.1 kp by pressing the kp button() or the Reset button() until the reading corresponds with the actual or desired kp values on the pendulum scale or in the kp window. After that press the CAL/ WATT button to either show the CAL or WATT figures. The watt reading in the display is depending on the pedaling speed. The watt reading can then be fine tuned through increase or decrease of the pedaling speed. Calories are calculated all the time. Do not expose the electronic meter to direct sunlight or extremely high temperature. Do not use any dissolvent when cleaning. Use only dry cloth.

Monark Ergomedic 828 E

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Service

Service 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 Ergometer, contact your place of purchase to inquire about 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 labor or shipping.

Service check & maintenance

• • • • • •

Check now and then that both pedals are firmly tightened. If not the threading in the pedal arms will be damaged. Also check that pedal arms are firmly tightened on the crank axle, tighten if necessary. When the Ergometer is new it is important to tighten the pedals after 5 hours of pedaling. Check that the chain is snug and there is no play in the pedal crank Be sure that the pedals are moving smoothly, and that pedal axle is clear of dirt and fibers Check that the pedal crank is secure to the crank axle Check that pedals, chain and freewheel sprocket are lubricated Check that the handlebars and seat adjustment screws are lubricated Be sure that the brake belt does not show significant signs of wear

Transport At transport the tension device should be somewhat tightened to prevent the brake belt from falling off of the fltwheel. Please note: The production number of your Ergometer is placed according to fig: Serial number.

To keep your Ergometer in good shape you should make a regular service. • •

• •

8

Keep your Ergometer clean and properly lubricated. Periodically wipe the surface with a rust preventative, especially when it has been cleaned and the surface is dry. This is done to protect the chrome and zinc parts as well as the painted parts. 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 are working normal and that no abnormal play or sound excsists. I.e. play in bearings causes fast wearing and with that follows a highly reduced lifetime.

1

Fig: Serial number (1)

Monark Ergomedic 828 E

Replacement of brake belt

The batteries are in a separate package at delivery. The batteries may need to be replaced upon assembly. To replace the batteries at any time, take the meter out of the housing by bending up in the lower end with a coin or similar. 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: Batteries.

Remove the tension lever(1). Dismantle the front cover over the pendulum weight by detaching the 4 screws underneath. Remove the left or the right frame cover by undoing the mounting screws (5pcs). Put the crank in a backward position. Move the cover somewhat out in the front end and then pull it backwards to remove it. Loosen the brake belt from the pendulum at the screw and lock washer(2). See fig: Brake belt.

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(2).

Take it apart at the spring and clip(3) and remove it from the bike. Attach the new brake belt and assemble the bike in reverse order. Adjust the brake belt so that the resistance increases as soon as the tension device is turned a little. When replacing the brake belt it is recommended to clean the brake surface. See section ”Brake belt contact surface”.

1 2

1 2

Fig: Batteries 1) Batteries 2) km/mile

Fig: Brake belt 1) Tension lever 2) Lock washer 3) Clip

Monark Ergomedic 828 E

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9

Service

Batteries

Service

Brake belt contact surface

Crank bearing

The brake belt should be regularly checked to ensure that it has not suffered excessive 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 fine sand paper and any dust removed with a clean dry cloth.

The crank bearing is long term greased and needs normally no supplementary lubrication. If problem arises, please contact your Monark dealer.

Flywheel bearing The bearings in the flywheel are lifetime greased and require normally no maintenance. If problem arises, please contact your Monark dealer.

Remove left cover. Set the tension device to minimum load/tension. Take off the brake belt to the side. Grind with a fine sand paper. See fig: Brake belt contact surface. Grinding is easier to perform if a second individual cautiously and carefully 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 should be used. We recommend to replacing the brake belt when cleaning the contact surface. In regard to assembly and adjustment of the brake belt, see ”Replacement of brake belt”.

Fig: Brake belt contact surface

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Monark Ergomedic 828 E

It is strongly recommended to keep the chain clean. Dirt build-up on the chain will cause excess wear. A chain lubricant and solvent for normal road bikes may be used. Check the lubrication and tension of the chain in regular intervals. In the middle of its free length the chain should have a minimum play of 10 mm (1/4in). See fig: Chain adjustments. When the play in the chain is about 20 mm (3/4 inch) the chain must be tightened otherwise it will cause abnormal wear of the chin and chainwheels. Because of this it is always recommended 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.

Loosen the chain adjuster as much as possible. Dismantle the chain lock 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: Chain replacement. Adjust chain adjusters to allow chain play according to above. Tighten axle nuts firmly. Put on frame covers again. NOTE: At assembly the flywheel has to be parallel with the centerline of the frame otherwise the chain and chain wheels makes a lot of noise and wears out rapidly.

To replace the chain remove left and right frame cover. 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: Chain adjustments.

5

6

4

Fig: Chain replacement 4) Lock spring 5) Movement direction 6) Chain lock

3 Fig: Chain adjustments 1) Chain adjuster 2) Axel nut 3) Chain play

2

1

Monark Ergomedic 828 E

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Service

Chain 1/2“ x 1/8“

Service

Scale - zero adjustment

Calibration

Loosen tension device so that the brake belt feels loose. Check that the pendulum will hang in vertical position.

Although all Ergometers are calibrated at the factory the user may wish to verify this by performing a mechanical scale calibration. If so please do the following.

Scale board: Check that the index on the pendulum(2) weigh is aligned with the index at the 0-position on the scale board. If adjustment is necessary, first loosen the lock nut(1) and then change the position of the board. Tighten the lock nut after the adjustment. See fig: Scale adjustments. Kp-scale: At the same time, check that the kilopond scale(5) to the left of the meter, shows 0 in line with the index. To adjust the kp-scale lossen the lock screw for scale indicator(9). Tighten the screw firmly after the adjustment. See fig: Calibration, Adjustment kp-scale window.

1 2

Remove the brake belt from the spring. Lean the bike forward so that the calibration weight, 4kg(4) (our part no: 9000-211) is hanging independently from the frame cover. Be sure that the scale board is set to zero before the weight is put on, see section ”Scale - zero adjustment”. Put the weight on on the spring(6). When correctly set, it should be possible to read this weight from the corresponding place on the scale board(7). See fig: Calibration. Should there be a deviation, adjust the pendulum to the correct weight on the scale by means of the adjusting weight inside the pendelum(3). See fig: Scale adjustment. To change the position of the adjusting weight, loosen the lock screw(8) on the back of the pendelum 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. 5

3 Fig: Scale adjustment 1) Locking nut 2) 0-index 3) Adjustment weight, pendulum

7

6

8

E rg

9 Fig: Adjustment kp-scale window 9) Lock screw f. scale indicator

12

Fig: Calibration 4) Calibration weight, 4kg 5) kp-scale 6) Attachment of calibration weight 7) Pendulum at 4kp 8) Screw to adjustment weight

Monark Ergomedic 828 E

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edi

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Service

Freewheel sprocket When replacing the freewheel sprocket remove left and right frame cover. Dismantle the chain as described in part ”Chain 1/2” x 1/8” ”. Loosen the axle nuts and lift off the flywheel. Remove the axle nut, washer, chain adjuster and spacer on the freewheel side. Place the special remover (part No. 9100-14) in the adapter and place the spacer and axle nut outside. See fig: Special remover. NOTE: Do not tighten the axle nut completely. It must be possible to loosen the adapter-sprocket half a turn. The sprocket should be lubricated with a few drops of oil once a year. Tolt the cycle somewhat to make it easier for the oil to reach the ball bearing. See fig: Lubrication.

Fig: Special remover (part no: 9100-14)

Fig: Hub assembly Fig: Lubrication

Monark Ergomedic 828 E

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Spare parts

Spare parts 24 20

23

21

22 25

19

26

18 17 16 15 14 13 12 11 10 9

27

8

7 2 6

3

30

4

28

1

29

5 3

Pos.

Qty.

Art.No.

Description

Pos.

33 32

6

Qty.

Art.No.

34

35

37

36

31

Description

1

1

9301-15

Support tube, front

20

1

9300-115

Bushing f. saddle post

2

1

9301-16

Support tube, rear

21

1

9300-123

Top cover Handlebar complete

3

4

9328-51

Plastic cap, blue

22

1

9300-280

4

4

9328-26

Rubber foot

23

1

9100-180

5

1

9328-37

Transport wheel compl. (pair)

24

1

9126-72

-Handgrip (pair)

6

4

5845

Locking nut M8

25

1

9300-291

Expander wedge

7

2

9300-12

Screw MVBF M8x16 mm

26

1

9300-61

Frame cover, left

8

1

9300-55

Chain 1/2 x 1/8”, 116 l

27

1

9300-60

Frame cover, right

Magnet

28

4

5673-9

Mounting screw LKT-TT 5x12mm

Dust cover

29

10

9306-12

Plastic plug

-Lever M8

9

1

9326-164

10

2

8523-2

11

2

8523-115

Screw M6S 8.8 M8 x 20 FZB

30

1

9301-5

Frame

12

1

9300-430

Steel crank set, complete

31

1

9300-24

Wheel suspension complete set

13

1

9300-220

Pedal, (pair)

32

1

9000-12

-Chain adjuster (pair)

14

1

9300-207

Pedal strap, (pair)

33

1

9106-13

-Sprocket

15

1

8966-175

BB cartridge bearing, complete

34

1

9106-14

-Connection

16

1

9300-138

Saddle post

35

3

91001-6

-Bearing 6001 - 2z

17

1

9300-122

Locking screw

36

1

9300-118

-Axle

18

1

9300-134

Pressure washer

37

19

1

4994-5

1

9300-114

14

1

9322-117

Saddle

1

9339-98

Chest belt

-Saddle bracket

1

9300-365

PC program

Monark Ergomedic 828 E

-Bush, 23 mm

17

6 25 26 20 18 37

16

Spare parts

3 10 8

11

7 4 5 9 3

14

13

15

2

31

1

28 29

12

24

30 32 31

34 22

35

21

33

36 19 37 18 18 27 20 24

23

Pos.

Qty.

Art.No.

Description

Pos.

Qty.

Art.No.

Description

1

1

9300-30

Frame for equipment

18

2

4

9300-21

Screw MVBF 6x16 mm

3

5866

Washer

1

9300-36

Meter panel, complete

4

5863

Washer

19

1

9339-100

-Meter panel

3

5

5843-9

Nut M6

20

2

9000-17

-Spacer

4

1

9300-22

Tension lever

21

1

9300-93

-Meter reader 7kp

5

1

14333-9

Screw M6x45 mm

22

1

9000-103

-Screw

6

1

9300-25

Tension screw M8, complete

23

1

9300-88

-Weight lever

7

1

9100-20

Spring

24

2

19001-6

-Ball bearing 6001-2Z

8

1

9100-26

Tension cylinder complete

25

1

9300-86

-Axle

9

1

14358

Screw M8x40 mm

26

1

9300-87

10

1

5844

Locking nut M8

27

1

9339-21

Screw

11

1

9300-170

Digitalmeter

28

1

5862

Washer

2

2142

Battery 14 x 50 mm

29

1

9000-102

Wing nut

1

9326-162

Crank sensor with cable

30

1

9300-94

Stop

2

9103-40

Screw for crank sensor

31

2

9300-99

Plastic stop

12

-Lock ring SgA 12

13

1

9126-75

Screw RXS B8 x 9.5 FZB

32

1

5671-9

Screw M5 x 10 mm

14

1

9326-166

Sensor holder

33

1

9103-62

Brake belt, complete

15

1

9326-263

Cable 620 mm

34

1

9300-92

Washer

5

9300-66

Holder for cable

35

1

5675-9

Mounting screw

16

1

9300-142

Instrument cover

36

1

9300-3

Brake wheel

17

4

5768

Mounting screw for cover

37

2

5799

Nut

Monark Ergomedic 828 E

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