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Precor Bicycle-mounted Child Seat C842, Service Manual

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Precor Bicycle-mounted Child Seat C842 Service Manual Download Page 77

C842, C842i, C846, C846i Upright and Recumbent Cycle

Page 77

Procedure 7.18 - Replacing the Idler Pulley

1. For C842, C842i, C846i and C846 version 2 units, skip to step 8. For C846 version 1 units, 

continue with step 2.

2. Remove the primary drive belt per Procedure 7.14, steps 1-3.

3. Remove the retaining clip from the idler pulley

Diagram 7.29 - Idler Pulley, C846 version 1

4. Slide the idler pulley off of the idler pulley shaft.

5. Slide the replacement idler pulley onto the idler pulley shaft.

6. Replace the retaining clip.

7. Replace the primary drive belt per procedure 7.14, steps 4-6. This procedure is complete.

8. Remove the right hand cover.

9. Loosen the idler pulley locknut to remove tension from the primary belt. Then remove the 

idler pulley locknut. Remove the idler pulley from its mounting bolt.

10. Slide the replacement idler pulley onto its mounting bolt and hand start the idler pulley 

locknut.

11. Tension the primary belt per Procedure 5.1.

12. Replace the right hand cover.

Retaining Clip

Idler Pulley

Summary of Contents for Bicycle-mounted Child Seat C842

Page 1: ...repair and maintain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedu...

Page 2: ...em to provide pedalling resistance All C842 bicycles are second generation bicycles and were first produced on February 2003 The C842 upright is manufactured under serial code NK the C842 recumbent is...

Page 3: ...sually 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...

Page 4: ...service a Precor C842 C842i C846 or C846i Upright or Recumbent Cycle Tools Phillip and flat head screwdrivers Standard and metric allen wrench set Open end wrench set Socket wrench set Chip puller Rub...

Page 5: ...ug 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 dam...

Page 6: ...2i C846 or C846i perform these preventive maintenance activities Perform the software diagnostics Check LED and keypad function Record the odometer reading See Procedure 3 1 Check speed sensor functio...

Page 7: ...5 and the QUICK START key key 7 The standard access codes use all sequential key presses The allowable delay between key presses is short If too much time is taken between key presses the access proce...

Page 8: ...C842 C842i C846 C846i Upright and Recumbent Cycle Page 8 Diagram 3 2 C846i and C846 version 2 Display Key 7 Key 6 Key 5 Reset Key 1...

Page 9: ...ven vertical rows of two dots each Each row corresponds to a key on the display Press each of the seven keys including the hidden key between the CHANGE and QUICK START key the corresponding row will...

Page 10: ...s unfiltered the F indicates filtered and P indicates Polar Release the hand held heart rate grips and repeat the test using a chest strap transmitter or heart rate test transmitter Verify that both t...

Page 11: ...ill scroll indicating that the optional external is or is not conne cted Pressing the SELECT key will cause a messageto be displayed indicating the battery condition Pressing the SELECT key again will...

Page 12: ...ies 7 Press and hold the RESET key to exit the ODOMETER program 8 The display will momentarily read INFORMATION DISPLAY 9 The display will momentarily read ODOMETER 10 The odometer will be displayed a...

Page 13: ...ns as REVOLUTIONS XXXXXX 20 Press the SELECT key to continue to the total hours display 21 The total hours the bike has been used will be displayed as HOURS XXXX 22 Press the SELECT key to continue to...

Page 14: ...displayed on th e display window The maximum workout time is the maximum time a user is allowed to use the unit 9 The maximum workout time is adjustable between 10 and 240 minutes If you wish to chan...

Page 15: ...to exit the program 23 Enter the club settings by pressing keys RESET 5 6 5 1 5 6 5 sequentially 24 The display will momentary read SELECT UNITS followed by either U S STANDARD or METRIC The or keys...

Page 16: ...it to Precor When a problem occurs record the following information Model and serial number Software version number Note Look at the PROM mounted on the upper PCA A label on the PROM indicates the so...

Page 17: ...ing noises 6 If the bike makes unusual noises or the electronic display does not change appropriately troubleshoot per Section 6 7 Press the RESISTANCE key until you reach Resistance Level 10 Operate...

Page 18: ...the primary drive belt The gauge should read approximately 60 pounds If the reading is incorrect continue with step 4 Diagram 5 1 Primary Belt Tensioning C846 version 1 5 Loosen the adjustment bolt o...

Page 19: ...minus 5 pounds If the belt tension is incorrect loosen but do remove the idler pulley locknut Insert a pry bar between the bottom side of the idler pulley and the frame tab directly below the idler p...

Page 20: ...pper span of the secondary drive belt The gauge should read approximately 60 pounds If the drive belt gauge reading is incorrect continue with step 4 Diagram 5 3 Secondary Belt Tensioning C846 version...

Page 21: ...The belt gauge should read 90 pounds plus or minus 5 pounds 10 The secondary belt tension is set by adjusting the position of the generator Loosen but do not remove the four generator mounting bolts L...

Page 22: ...ate counterclockwise 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 A...

Page 23: ...leshoot the interconnect cables is to by pass them with a known good interconnect cable 10 Remove the left hand cover per Procedure 7 1 Troubleshooting the upper interconnect cable 11 Remove the displ...

Page 24: ...eck the operation of the cycle as described in Section Four 23 If you have performed all of the previous tests and have not been able to locate the trouble call Precor customer support 24 Both the upp...

Page 25: ...the by pass cable to the junction block and the lower PCA 33 Check the operation of the cycle as described in Section Four 34 If the problem is still present troubleshoot junction block Troubleshootin...

Page 26: ...g displayed continue with step 3 If one or more keys do not function skip to step 8 3 Remove the screws that secure the upper display assembly to the upper handrail Carefully pull some excess intercon...

Page 27: ...er PCA as appropriate Diagram 6 4 J3 J4 Connectors C846 version 1 8 Substitute a known good keyboard display housing to determine if the keyboard is defective If the keys not function normally replace...

Page 28: ...easure voltages in the unit it is necessary to keep the unit powered up This can be accomplished either by pedaling on the unit or by installing the optional external power adapter 1 On C846 Version 1...

Page 29: ...While pedaling the cycle measure the voltage across the C16 capacitor with a DC voltmeter See Diagram 6 5 The measurement should be approximately 8 9 Vdc 0 5 Vdc 8 If the voltage is missing or signifi...

Page 30: ...p 15 17 If the measurement in step 12 is still significantly low or high replace the lower PCA If replacing the lower PCA does correct the problem skip to step 20 18 Remove the upper display panel and...

Page 31: ...esistor R25 See Diagram 6 5 and pedal the bike for a minute Stop pedaling the bike Slowly rotate the secondary pulley by hand until the magnet mounted on the flywheel passes the speed sensor The DC vo...

Page 32: ...ley with magnet Skip to step 6 6 Replace the lower PCA Check the lower PCA as in step 1 7 If you have performed all of the previous tests and have not been able to locate the trouble call Precor custo...

Page 33: ...Vdc but there is no resistance measure the voltage between terminals 1 red wire and 4 black wire of the J1 connector on the lower PCA The voltage should measure approximately 18 19 Vdc 1 Vdc Measure...

Page 34: ...customer support 15 Enter the manual program and set the work level at level 20 Pedal the cycleand confirm that there is no resistance or that the resistance is abnormally low Note The voltage reading...

Page 35: ...w replace the generator The eddy current magnet is furnished with the generator After replacing the generator tension the secondary belt per Procedure 5 2 20 If the measurement in step 18 was correct...

Page 36: ...dure 7 15 5 Remove the secondary drive belt per procedure 7 16 6 Turn the primary pulley secondary pulley idler pulley and alternator or generator by hand to determine which part is not turning freely...

Page 37: ...ot being received the system will accept the hand held signal Note There are four typical failure modes for the hand held chest strap heart rate system They are 1 hand held is normal no chest strap re...

Page 38: ...ted skip to step 13 11 The source of the radiated energy must be determined and relocated so that it no longer affects the heart rate PCA Televisions cell phones Cardio theatre receivers etc are possi...

Page 39: ...is being accepted measure between the ground and 5 Vdc pins on J4 for 5 Vdc If 5 Vdc is present replace the heart rate PCA 19 If 5 Vdc is not present remove the connector from J4 of the heart rate PC...

Page 40: ...nt Cycle Page 40 25 Set the on off switch in the off position and remove the spare jumper from J14 of the heart rate PCA Re locate all potential sources of radiation Set the on off switch in the on po...

Page 41: ...over 4 If you are removing the left hand cover a plastic cap covers the crankarm mounting bolt Using a thin bladed tool remove the cap from the crankarm See Diagram 7 1 continue with step 4 If you are...

Page 42: ...axle and slide the crankarm onto the axle Ensure that the crankarms are opposite 180 each other Place blue loctite on the crankarm mounting bolt and thread the crankarm mounting bolt into the axle an...

Page 43: ...cumbent Cycle Page 43 19 Slide the top edge of the left side cover under the top cover and hand start the two remaining top bolts and the two bottom bolts Hand start the two rear cover bolts 20 Secure...

Page 44: ...hand pedal is reverse threaded 9 Torque the pedal s to 150 in lb This procedure is complete 10 If you are replacing a pedal s only it is not necessary to remove the crankarm s 11 Grasp the pedal spin...

Page 45: ...cumbent Cycle Page 45 Diagram 7 2 Crankarm C842 C842i C846i and C846 version 2 17 Hand thread the pedal s into the crankarm s Remember the left hand pedal is reverse threaded 18 Torque the pedal s to...

Page 46: ...ward on the seat adjustment knob and lift the seat post out of the cycle s frame Diagram 7 3 Seat Upright Cycle 4 Pull the seat adjustment knob outward slide the replacement seat post into place in th...

Page 47: ...on 1 units continue with step 2 2 Set the on off switch in the off position 3 The seat carriage assembly consists of the following carriage seat wheels and seat adjustment assembly See Diagram 7 4 Dia...

Page 48: ...t to 120 in lb Diagram 7 5 Seat wheel Assembly 8 If you are replacing all or part of the seat adjustment assembly gently tap the roll pin out of the adjustment lever See Diagram 7 6 Loosen the nuts th...

Page 49: ...vels throughout it s full range and securely locks into position when the seat adjustment lever is released 14 If the seat movement in step 13 is too tight or there is excessive side to side wobble ad...

Page 50: ...cable back into the access hole The seat carriage must travel over this cable so it must be below the surface of the seat rail Release the seat lever hold the cable attached to the seat straight back...

Page 51: ...le is being replaced skip to step 29 If the internal cable is being replaced continue with step 25 25 Remove the screws retaining the hand held heart rate contact plates from both the left and right s...

Page 52: ...place the cover plate mounting screws be sure that the cable is centered on the cover plate so that the cover plate mounting screws will not damage the external hand held heart rate cable 31 With the...

Page 53: ...ps 1 4 5 Disconnect the upper interconnect cable from the junction block located near the base of the column see Diagram 7 13 Diagram 7 13 Interconnect Cable Junction Blocks 6 Remove the four bolts fr...

Page 54: ...fully move the column away from the bike frame taking care not to damage the cables shown in Diagram 6 2 Lay the column on the floor near the front of the bike 16 Extract both cables from the column 1...

Page 55: ...not replacing the upper interconnect cable skip to step 15 10 Remove the display housing per Procedure 7 12 steps 1 4 11 Disconnect the upper interconnect cable from the junction block located near t...

Page 56: ...to the seat cable Feed all excess seat cable under the seat Replace the cable plate removed in step 27 26 Disconnect the lower interconnect cable from the upper interconnect cable Disconnect the lower...

Page 57: ...wires and disconnect them from the on off switch 5 Note the orientation of the on off switch depress the tabs on the on off switch and slide the switch out of the mounting panel 6 Orient the replaceme...

Page 58: ...speed sensor reed switch out of it s mounting bracket 5 Rotate the secondary pulley so that the magnet is next to the speed sensor mounting position 6 Slide the speed sensor into it s mounting bracket...

Page 59: ...lack wires black and orange wires on some old versions from the negative battery terminal Diagram 7 15 Battery C846 version 1 5 Remove the two battery bracket mounting screws Lift the battery bracket...

Page 60: ...s that fasten the battery bracket to the frame Remove the battery and battery bracket 14 PLace the battery bracket on the replacement battery and set them in their mounting position with the positive...

Page 61: ...ect the wire from heat generated by the resistor Diagram 7 17 Load Resistor Mounting 4 Remove the only the mounting screw shown in Diagram 7 17 Slide the load resistor mounting bracket out of the end...

Page 62: ...wrist strap connected to the cycle s frame while performing steps 4 7 5 Disconnect the J1 J2 if heart rate is equipped J3 and J4 connectors from the lower PCA 6 Remove the four lower PCA mounting scre...

Page 63: ...ring as follows Connect the wires from the external power jack to connector J4 on the lower PCA Connect the two red wires from the eddy current magnet to terminals M1 and M2 of the lower PCA it does n...

Page 64: ...mounted on the rear of the upper PCA Remove the hand held heart rate cable C846 version 2 only from the hand held heart rate PCA 6 Note the orientation of the keypad cable connected to the J3 connect...

Page 65: ...ctor and the heart rate cable from the J1 connector when equipped 15 Disconnect the keypad cable from the J2 connector 16 Remove the screws the retain the upper PCA to the display Remove the upper PCA...

Page 66: ...alternator Balancing can only be maintained if the flywheel is mounted on it s original alternator 1 Set the on off switch in the off position 2 Remove both covers per Procedure 7 17 3 Loosen the uppe...

Page 67: ...d tighten the upper alternator mounting bolt Securely tighten the upper and lower mounting bolts 9 Replace the alternator wiring as shown in Diagram 7 21 torque the nuts the retain the alternator s wi...

Page 68: ...rive belt Diagram 7 22 Primary Drive Belt C846 version 1 5 Set the replacement primary drive belt in it s mounting position as shown in Diagram 7 22 Snug but do not tighten the upper idler bracket mou...

Page 69: ...remove tension from the primary belt Diagram 7 23 Primary Drive Belt C842 C842i C846i and C846 version 2 10 Remove the primary belt Route the replacement primary belt around the primary pulley over t...

Page 70: ...r so that tens 5 rotate the secondary pulley and guide the secondary drive belt off of the secondary pulley Diagram 7 24 Secondary Drive Belt Mounting C846 version 1 6 Remove the secondary drive belt...

Page 71: ...djustment bolt to remove tension from the secondary belt See Diagram 7 25 remove the secondary belt Diagram 7 25 Secondary Drive Belt C842 C842i C846i and C846 version 2 13 Route the replacement secon...

Page 72: ...the primary pulley shaft assembly out of the cycle 5 If you are not replacing the primary shaft bearings skip to step 7 6 Using a long thin tool tap the primary bearings out of the frame Diagram 7 26...

Page 73: ...out of the frame The left hand bearing is in the frame bearing pocket the right side bearing is part of the primary pulley assembly 18 If the bearings are being replaced slide the left hand bearing ou...

Page 74: ...y drive belt per Procedure 7 14 steps 1 3 3 Remove the secondary drive belt per Procedure 7 15 steps 1 4 4 Remove the retaining clip from the secondary shaft Slide the Secondary pulley off of the inte...

Page 75: ...p 16 Loosen the idler pulley locknut and release tension from the primary belt 16 Loosen the secondary belt adjustment bolt and remove tension from the secondary belt 17 Remove the retaining ring from...

Page 76: ...hers onto the secondary pulley shaft 26 Slide the replacement secondary pulley onto the secondary pulley shaft 27 Slide the remaining thrust washer onto the secondary pulley shaft Replace the outside...

Page 77: ...idler pulley shaft 5 Slide the replacement idler pulley onto the idler pulley shaft 6 Replace the retaining clip 7 Replace the primary drive belt per procedure 7 14 steps 4 6 This procedure is complet...

Page 78: ...quare package PLCC44 Each of these packages should be removed with a proper IC removal tool see the illustrators below 4 The IC s may inserted into their socket by hand by carefully aligning the notch...

Page 79: ...generator mounting bolts See Diagram 7 30 Diagram 7 30 Generator Mounting C842 C842i C846i and C846 version 2 6 Remove the generator with the lower PCA from the bike 7 Using anti static protection rem...

Page 80: ...does not matter which red wire goes on terminal M1 or M2 Connect the red wire from the generator to terminal M3 connect the black wire from the generator to terminal M4 and the white wire from the gen...

Page 81: ...ring has two retaining screws like the screws just removed from the left hand bearing It is necessary to rotate the primary pulley until theaccess hole in the primary pulley aligns with the retainings...

Page 82: ...right hand bearing requires replacement replace Precor part number 45439 102 primary pulley assembly See Diagram 7 33 Diagram 7 33 Primary Pulley Assembly 10 Slide the primary pulley assembly into the...

Page 83: ...rimary belt around the primary pulley over the idler pulley and around the secondary axle as shown in Diagram 7 23 14 Tension the primary belt per Procedure 5 1 15 Replace the crankarm covers and fast...

Page 84: ...C842 C842i C846 C846i Upright and Recumbent Cycle Page 84 Wiring Diagram C846 version 1 6...

Page 85: ...C842 C842i C846 C846i Upright and Recumbent Cycle Page 85 Block Diagram C846 version 1...

Page 86: ...C842 C842i C846 C846i Upright and Recumbent Cycle Page 86 Wiring Diagram C842 C842i C846i and C846 version 2...

Page 87: ...C842 C842i C846 C846i Upright and Recumbent Cycle Page 87 Block Diagram C842 C842i C846i C846 version 2 BK W R M2 M1 Magnet R R...

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