Cateye EC-3700, EC-3600 User Manual

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Page 1

CATEYE ERGOCISER

AUTOMATIC TYPE

Applicable Models: EC-1200/EC-1600/EC-3600/EC-3700

SERVICE MANUAL

Page 2

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

INDEX

INDEX INTRODUCTION

• How to Use This Service Manual

• Name of Parts

1. Upright Type (w/o Flywheel)---------------------------------------------------------- 4~5 Upright Type (with Flywheel)--------------------------------------------------------- 6~7

2. Recumbent Type (EC-3600 & EC-3700) ------------------------------------------- 8~9

3. Belt Drive (EC-1200B, EC-1600B, EC-3600B & EC-3700B) ----------ADD.1~2

• Circuit Diagram----------------------------------------------------------------------------------10

Part A

 Symptoms of Problems & Causes

T-1: No Display on Control Unit after Power ON-----------------------------------11~12 T-2: No Display of Cadence --------------------------------------------------------------------13 T-3: No Display of Pulse Rate ----------------------------------------------------------------- 14 T-4: No Printer Operation -----------------------------------------------------------------------15 T-5: No Loading -------------------------------------------------------------------------------16~17 T-6: No Pedal Rotation (Locked) -------------------------------------------------------------18 T-7: Unusual Noise

1. Continuous and Increasing. ------------------------------------------------------- 19

2. Periodical.--------------------------------------------------------------------------------20

3. Noise occurs when the pedal is rotated with a large loading. ---------21

Part B

 Removing the Frame Covers

D-1: Upright Type (EC-1200 & EC-1600)----------------------------------------------------22 D-2: Recumbent Type (EC-3600 & EC-3700) ----------------------------------------------23

 Repair & Adjustment Methods

EC-1200 EC-1600 EC-3600 EC-3700

ES-1: Replacing the Wiring within the Frame ----------------------- 24 ES-2: Replacing the 5P Cable ---------------------------------------25~26 ES-3: Replacing the Power Supply Board---------------------------- 27 ES-4: Correcting the Position of Solenoid Coil--------------------- 28 ES-5: Replacing the CDC Sensor --------------------------------------- 29

-  -  ES-6: Replacing the Panel Keyboard ---------------------------------- 30  -  - ES-7: Replacing the Button Panel -------------------------------------- 31  -  - ES-8: Replacing the Printer ----------------------------------------------- 32  -  - ES-9: Adjusting the Printing Darkness-------------------------------- 33  -  - ES-10: Paper Jamming in Printer -----------------------------------------24  -  - MS-1: Replacing the Workload Unit (w/o Flywheel) ----------35~37

G MS-2: Replacing the Workload Unit (w/ Flywheel) --------------- 38

 -  - MS-3: Adjusting the Flywheel--------------------------------------------- 39 MS-4: Replacing the Chain------------------------------------------------- 40 MS-5: Replacing the Free Wheel Set ----------------------------------- 41 MS-6: Replacing the Derailleur Set-------------------------------------- 42 MS-7: Replacing the Idler Set --------------------------------------------- 43 MS-8: Replacing the Crank Set -------------------------------------- 44~45 MS-9: Replacing the BB Set ----------------------------------------------- 46  -  - MS-10: Replacing the Post Spacer---------------------------------------- 47  -  - MS-11: Adjusting the Spacer Spring ------------------------------------- 48  -  - MS-12: Replacing the Inner Pipe Spacer-------------------------------- 49  -  - MS-13: Replacing the Vertical Pipe Spacer ---------------------------- 50  -  - MS-14: Replacing the Leg Cover ------------------------------------------ 51  -  - MS-15: Replacing the Caster/Level Adjuster -------------------------- 52  -  - MS-16: Replacing the Seat Post Knob----------------------------------- 53  -  - MS-17: Replacing the Lock Pin -------------------------------------------- 54 MS-18: Replacing the Crank Cover --------------------------------------- 55  -  - MS-19: Replacing the Center Cover of Upright Type --------------- 56  -  - MS-20: Replacing the Center Cover of Recumbent Type --------- 57 MS-21: Replacing the Handlebar Grip ----------------------------------- 58  -  - MS-22: Replacing the Printer Cover -------------------------------------- 59  -  - MS-23: Replacing the Paper Cutter --------------------------------------- 60

PART C  List of Genuine Parts -------------------------------------------------------------------------------------------- 61~65

Cateye Ergociser Series 1000 Service Manual

Page 3

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

How to Use This Service Manual

The manual consists of Part A, Part B and Part C. Part A refers to trouble-shooting which allows you to identify the cause and areas to be fixed depending on typical symptoms. Part B shows how to repair and/or adjust specific defects. This part consists of repair methods for electrical parts [ES] and those for mechanical parts [MS].

Part C lists up all genuine parts and corresponding part numbers that will be necessary for replacement or stock

Whenever any problem has occurred on the main unit, take the following actions to repair or adjust it.

1. Check and identify the cause by referring to Part A.

2. Identify the parts name by referring to Name of Parts.

3. Perform repair or adjustment in accordance with the instructions in Part B.

4. Replacement, if required, should be done by using genuine parts as specified in Part C.

EC-1600

N O

F F O

EC-3

How to Use This Service Manual

Cateye Ergociser Series 1000 Service Manual

Page 4

Applicable Models:

Name of Parts for Upright Type (w/o Flywheel)

EC-1200 EC-1600 EC-3600 EC-3700

Crank

Post Spacer Lock Nut

Frame

5P Cable

Cable Holder

Large Gear

CDC Magnet

Connector Cover 5P Cable Connector

CDC Sensor

Frame

Adjust Screw

Spacer Spring

Crank Cap

BB Set

Post Spacer

Lock Nut

Adjust Screw

Spacer Spring

Seat Pipe

Timing Belt

Inlet Metal Base Power Switch

Copper Plate Idler

Idler Fixing Bolt [M6x16]

Idler Metal Base Idler Spring

Leg Cover

Leg Pipe

Leg Pipe Fixing Screw

Caster

Name of Parts for Upright Type (w/o Flywheel)

Levelling Knob

Cateye Ergociser Series 1000 Service Manual

Power Supply Board

Power Supply Board Fixing Screw

[Tapping Screw(2) 4x12c]

SW Nut (M6)

Workload Unit

Solenoid Coil Mounting Base

Solenoid Coil

Plastic Pulley

Workload Unit Mounting Base

[Screw Set (+) (M6x16)]

Wiring within Frame

Levelling Knob

Page 5

Cable Holder

Frame Cover

Crank Cover

Handlebar Post

Seat Post

Center Cover

EC-1200

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

Tapping Screw (4x12) with Washer

Inlet Metal Base AC Adapter Inlet

Chain

Workload Unit Reinforcing Metal Base Nut

Workload Unit Reinforcing Metal Base

Hexagon Nut (M8-3)

Derailleur Spring

Leg Pipe Fixing Screw Leg Pipe

Lever Cover

Levelling Knob

Free Wheel Set

Hexagon Head U Nut

Workload Unit Fixing Bolt

Derailleur Mounting Bolt

Thrust Washer (9x15.5x0.25)

Derailleur

Solenoid Coil

Crank Nut

Power Supply Board

Screw Set(+) (M6x16)

Name of Parts for Upright Type (w/o Flywheel)

Cateye Ergociser Series 1000 Service Manual

Page 6

Applicable Models:

Name of Parts for Upright Type (w/ Flywheel)

5P Cable

Post Spacer

EC-1200 EC-1600 EC-3600 EC-3700

5P Cable Connector

Lock Nut

Adjust Screw

Cable Holder

Large Gear

CDC Magnet

CDC Sensor

Flywheel Mounting Metal Base

BB Set

Crank Cap

Crank

Post Spacer

Lock Nut

Adjust Screw [M8x10] Spacer Spring

Seat Pipe

Flywheel Metal

Flywheel Fixing Screw [SW Nut(M6)]

Flywheel Metal Base Fixing Screw

[Screw Set (+) (M6x16)]

Inlet Metal Base Power Switch

Copper Plate Idler

Frame

Caster

Leg Pipe Fixing Screw Leg Pipe

Name of Parts for Upright Type (w/ Flywheel)

Cateye Ergociser Series 1000 Service Manual

SW Nut (M6)

Power Supply Board Fixing Screw [Tapping Screw(2) 4x12c]

Power Supply Board

Solenoid Coil Mounting Base

Solenoid Coil

Plastic Pulley

Workload Unit

Workload Unit Mounting Base

[Screw Set (+) (M6x16)]

Idler Mounting Bolt [M6x16]

Idler Metal Base Idler Spring

Timing Belt Wiring within Frame

Leg Pipe

Levelling Knob

Page 7

Flywheel Flywheel Fixing Screw

Flywheel Mounting Metal Base

Power Supply Board

Applicable Models:

Frame Cover

Crank Cover

CDC Magnet

EC-1200 EC-1600 EC-3600 EC-3700

Handlebar Post Cover

Seat Post

Center Cover

Flywheel Metal Base Fixing Screw Flywheel Metal Base

AC Adapter Inlet Inlet Metal Base

Plain Belt Chain

Workload Unit Reinforcing Nut

[Hexagon Nut (M6-3)] Workload Unit Reinforcing Metal Base

Hexagon Nut (M8-3)

Hexagon Head U Nut

Free Wheel Set

Derailleur Spring

Workload Unit

Workload Unit Mounting

Bolt (M6x16)

Derailleur

Solenoid Coil

Derailleur Mounting Bolt

Thrust Washer (9x15.5x0.25)

Crank Nut (M10x1.25)

Screw Set(+) (M6x16)

Tapping Screw (4x12) with Washer

Name of Parts for Upright Type (w/ Flywheel)

Cateye Ergociser Series 1000 Service Manual

Page 8

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

Name of Parts for Recumbent Type (EC-3600 & EC3700)

Wiring within Frame

Flywheel Metal Base Fixing Screw

Flywheel

Flywheel Fixing Screw

Flywheel Metal Base

Plain Belt

Power Supply Board Fixing Bolt

Power Supply Board

Crank

Crank Nut

5P Cable Connector 5P Cable Set

Cable Holder

Frame

BB Set

Copper Plate Timing Belt

Idler Idler Metal Base

Idler Fixing Bolt

Idler Spring

Frame Cover

Center Cover

Crank Cover

Name of Parts for Recumbent Type

Cateye Ergociser Series 1000 Service Manual

Inner Pipe

Seat Pipe

Rear Support Pipe

Leg Pipe Fixing Screw

Solenoid Coil Mounting Base

Solenoid Coil

Workload Unit Mounting Base [Screw Set (+) (M6x16)]

Plastic Pulley

Workload Unit

Page 9

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

Cable Holder Chain

CDC Sensor

Screw Set (+) [M6x16]

Workload Unit Reinforcing Nut

Workload Unit Reinforcing Metal Base

Workload Unit

Solenoid Coil

Power Supply Board

CDC Magnet

Cable Holder Flywheel

Plain Belt

Flywheel Fixing Screw

Flywheel Metal Base Fixing Screw

Inlet Metal Base

Free Wheel Set

Hexagon Head U Nut

Workload Unit Mounting Base

[Screw Set (+) (M6x16)]

Derailleur

Derailleur Mounting Bolt

AC Adapter Inlet Power Switch Front Leg with Casters

Caster

Name of Parts for Recumbent Type

Cateye Ergociser Series 1000 Service Manual

Page 10

Applicable Models:

Belt Drive

EC-1600B EC-1200B

EC-1200B EC-1600B

Pulley 2-A Set

Pulley 1-B

Teethed Timing Belt (P8M15-1192)

Pulley 1-A Set

Pulley Flange

Pulley 2-A Set

Teethed Timing Belt (P8M15-1192)

Pulley 1-A Set

Pulley Flange

Workload Unit

Name of Parts for Belt Drive Type

Cateye Ergociser Series 1000 Service Manual

ADD. 1

Idler A Set

Idler Spring A

Pulley 1-B Idler A Set

Workload Unit Idler Spring A

Page 11

Belt Drive

EC-3600B/EC-3700B

Applicable Models:

Pulley 1-A Set

Pulley Flange

EC-3600B/EC-3700B

Teethed Timing Belt (P8M15-1080)

Pulley 2-A Set

Pulley 1-B

Workload Unit

Name of Parts for Belt Drive Type

Idler A Set

Idler Spring A

Cateye Ergociser Series 1000 Service Manual

ADD. 2

Page 12

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

Circuit Diagram for Automatic Type Cateye Ergociser

AC Plug

100V AC

DC Power Supply

CN4

+ –

Power Supply Control Circuit for Printer

AC Adapter

12V DC*

*Fluctuate depending on the electric load

About 16V when the load is zero.

(Connector 4)

REG

– +

TR2

– +

TR1

DC Connector

IC1

Solenoid Coil Current Control Circuit

AC Adapter Inlet

VR1

Wiring within Frame

Black Cable (-)

Red Cable (+)

Power Supply Board

CN3

CN2

CN1

CN4 (Connector 4)

Switch

Cadence Sensor

5P Cable to Control Unit

Common Line Cadence Signal Control Unit Power Supply Solenoid Coil Current Control Signal

Printer Power Supply (+5V)

––– +

Magnet

Circuit Diagram

Cateye Ergociser Series 1000 Service Manual

Coil

Electromagnet

Metal Pulley

Timing Belt

Copper Disk Plate

Plastic Pulley

Chain

Free Wheel

Cadence Sensor

Large Gear

Pedal

Magnet

Crank

Page 13

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-1

Check the power is available at the wall socket before proceeding to checking of causes.

[1] Checking the AC Adapter

1. Detach the plug of AC adapter from the AC adapter inlet of the main unit.

2. Connect the wall socket plug of the AC adapter to the wall socket.

3. Using a tester, measure the voltage at the plug which will be connected to the main unit. (Fig. 1)

t The AC adapter will be working fine, if the voltage is minus

t When the measured voltage is 0V, or less than 14V, the

Note: Never short-circuit the plug of AC adapter. This will

[2] Checking the Wiring within the Frame

1.When the AC adapter is found to be correct, proceed to checking of wiring within the frame. Loosen the four screws on the handlebar stem to remove the control unit. (Fig. 2)

2. Remove the 5P cable which is connected to the back of the control unit. (Fig. 2)

3. Connect the AC adapter, and turn on the main unit.

4. Using a tester, measure the voltage across the terminals 1 (-) and 3 (+) of the 5P cable. (Fig. 3)

t The main unit side will be working fine if the meter reading

No Display on Control Unit after Power ON. (1)

Check Method of Causes Repair Method Explanation Figures

(-) at the inner area and plus (+) at the outer area of the connector and also the meter reading is in the range of 14V and 19V.

AC adapter will be defective.

damage the AC adapter.

is in the range of 14V and 19V. This means the control unit will be defective.

Replace the AC adapter.

Replace the control unit.

Fig. 1

Fig. 3

Normal for 14V thru 19V

Red Cable

DC Connector

Black Cable

Normal for 14V thru 19V

Black Cable

5P Cable

Terminal 1 (-)

Cable Connector

Fig. 2

Red Cable

Terminal 3 (+)

Cateye Ergociser Series 1000 Service Manual

No Display on Control Unit after Power ON. (1)

T-1

Page 14

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-1

[3] When the meter reading at step 2. is 0V or less than 14V, check the

main unit in accordance with the following procedures:

1. Remove the frame cover. (See sections D-1 and D-2 "Removing the Frame Covers.")

2. With the control unit removed, connect the AC adapter, and turn on the power switch. Measure the voltage across the electrolytic capacitor C1 on the power supply board (25V 1000µV). (Fig. 4)

Note: The layout of the power supply board may be different from

lot to lot. (Figs. 5 and 6)

t The wiring within the frame is correct when the measured

t When the measured voltage is 0V, the wiring within the

t When the problem cannot be remedied even if the 5P cable

No Display on Control Unit after Power ON. (2)

Check Method of Causes Repair Method Explanation Figures

voltage is in the range of 14V and 19V. When the voltage across the electrolytic capacitor on the power supply board is correct, the 5P cable, which connects the power supply board and the control unit, may be defective.

frame is defective.

is replaced, the power supply board may be defective.

Replace the 5P cable. (See the Section ES-2 "Replacing the Frame.")

Replace the Inlet Metal Base Set. (See the Section ES-1 "Replacing the Wiring within the Frame."

Replace the power supply board. (See the Section ES-3 "Replacing the Power Supply Board. "Fig. 4

Fig. 4

Black Cable

Red Cable

Power Supply Board A

Correct for 14V thru 19V

Power Supply Board

Power Supply Board B

No Display on Control Unit after Power ON. (2)

T-1

Cateye Ergociser Series 1000 Service Manual

Fig. 5

Fig. 6

Page 15

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-2

No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.)

Check Method of Causes Repair Method Explanation Figures

[1] Checking the Control Unit

1. Turn off the power. Loosen the four screws on the handlebar stem to remove the control unit.

2. Remove the cable connector which is connected to the back of control unit.

3. Slowly rotate the pedal while measuring the resistance across the connector terminals 1 and 2 of the 5P cable. (Fig. 1) t When there is one short-circuiting (resistance becomes

zero) during one rotation of the pedal, the control unit is defective.

When there is no short-circuiting, proceed to the following check procedures. [2] Checking the Main Unit

1.Remove the frame cover. (See the Section D-1 and D-2 "Removing the Frame Covers.")

2. Remove the CN-3 connector on the power supply board. (Fig.

3. Slowly rotate the pedal while checking shortcircuit across the two terminals of the CN-3 connector by using a tester to see if there is one short-circuiting during one rotation of the pedal. (Fig. 3) t If short-circuiting is found, the 5P cable which connects the

power supply board and the control unit is defective.

When there is no short-circuiting, proceed to the following check procedures.

[3] Check the positional relation between the CDC sensor and the

magnet of the large gear. (Fig. 4)

1. Align the line on the CDC sensor with the center of the CDC magnet. (Fig. 5)

2. Secure a gap of about 2mm between the surface of the CDC sensor and that of the CDC magnet. (Fig. 5)

Check if there is any short-circuiting in the CN-3 connector again.

t When a short-circuiting is found, the positional relation

between the CDC sensor and the CDC magnet of the large gear is incorrect.

t When there is no shortcircuit, the CDC sensor is defective.

Replace the control unit with a brand new one.

Replace the 5P cable. (See the Section ES-2 "Replacing the 5P Cable.")

Replace the CDC sensor. (See the Section ES-5 "Replacing the CDC Sensor".)

The case of no short-circuiting

The case a short-circuiting is found. One zero (0) is detected during one rotation of the pedal.

Fig. 1

Power Supply Board

The case a short-circuiting is found. One zero (0) is detected during one rotation of the pedal.

Fig. 2

Line on CDC Sensor

Black Cable

Red Cable

5P Cable

The case of no shortcircuiting

CN-3 Connector

Fig. 3

Gap of 2mm between CDC Sensor and CDC Magnet

Line on CDC Sensor

Red Cable

Terminal 2

Terminal 1

Black Cable

No Display of Cadence

Center of CDC Magnet

Fig. 4

Center of CDC Magnet

Fig. 5

Cateye Ergociser Series 1000 Service Manual

T-2

Page 16

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-3

1. Turn on the power to display the in-training screen (any exercise program).

2. Install a brand new pulse sensor, and check if pulse rate will be displayed.

t When the pulse rate can be displayed, the pulse sensor is

t When the pulse rate cannot be displayed, the control unit is

No Display of Pulse Rate

Check Method of Causes Repair Method Explanation Figures

defective.

Replace the pulse sensor with a brand new one.

Replace the control unit with a brand new one.

No Display of Pulse Rate

T-3

Cateye Ergociser Series 1000 Service Manual

Page 17

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-4

No Printer Operation

Check Method of Causes Repair Method Explanation Figures

In such cases as display of the LCD panel, etc. operate without problem, but the printer does not operate, the following cases are possible:

[1] Checking the Control Unit

1. Check that the printer symbol is displayed on the LCD panel and the printer is in a working status. (Fig. 1)

2. Check if the setting of control unit is in the setting that the printer is not used. (Check if the No.4 select switch on the back of the control unit is in the "OFF" position.) (Fig. 2)

3 Check if the thermal paper is not jammed at the printer head.

t Remove the thermal paper if it is jammed. (Fig. 3)

4. When no other problems are found, replace the control unit with a brand new one.

5. With the new control unit installed, check the printer operation. t When the printer works fine, the control unit is defective.

When the printer does not operate after the above-stated checks, proceed to the following procedures: [2] Checking the Main Unit

1. Turn off the power, and loosen the four screws on the handlebar stem to remove the control unit. (Fig. 4)

2. Remove the cable connector which is connected to the back of the control unit. (Fig. 4)

3. Remove the frame cover. (See the Section D1 & D2 "Removing the Frame Covers.")

4. Remove the CN-2 connector on the power supply board. (Fig.

5. Using a tester, check for any short-circuiting across Terminal 1s and Terminal 5s at both ends of the 5P cable which connects the power supply board and the control unit. (Fig. 6)

t When there is no shortcircuit, the 5P cable is disconnected.

In case the printer symbol is not indicated on the LCD panel, press the printer button to have the symbol indicated.

Replace the control unit with a brand new one.

Replace the 5P cable. (See the Section ES-2 "Replacing the 5P Cable.")

Control Unit

Fig. 1

Tweezer

Printer Cover

Paper Cutter

Fig. 3

RESET

Printer Symbol

10 1

TIME

MODE

ADV

Back of Control Unit

123

Select Switch

OFF

Fig. 2

Cable Connector

Fig. 4

Power Supply Board

Normal when zero (0)

t When it is short-circuited, the power supply board is

defective.

Replace the power supply board. (See the Section ES-3 "Replacing the Power Supply Board.")

Fig. 5

Connector Terminal 5

5P Cable

Connector Terminal 5

Fig. 6

Cateye Ergociser Series 1000 Service Manual

No Printer Operation

T-4

Page 18

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-5

[1] Checking the Mechanical Systems See the Section D1 & D2 "Removing the Frame Covers" to remove

the frame cover, and check the inside of frame.

1. Check if the chain has not been broken. (Fig. 1)

2. Rotate the crank and check if the belt of the workload unit will rotate. (Fig. 2)

3. Check if the free wheel set is not idling. (Fig. 2)

4. Check if the belt (timing belt) of the workload unit has not been broken. (Fig. 2)

5. Check if the plastic pulley of the workload unit has not been broken. (Fig. 2)

No Loading (Check of mechanical systems)

Check Method of Causes Repair Method Explanation Figures

Chain

Replace the chain with a brand new one. (See the Section MS-4 "Replacing the Chain.")

Replace the free wheel with a brand new one. (See the Section MS-5 "Replacing the Free Wheel Set.")

Spray CRC into the gap as shown in Fig. 2, and rotate the pedal in forward and backward directions.

Replace the workload unit. (See the Sections MS-1 & MS-2 "Replacing the Workload Unit.")

No Loading (Check of Mechanical Systems)

T-5

Fig. 1

Fig. 2

Free Wheel

Timing Belt

Plastic Pulley

Derailleur

Crank

Gap

Free Wheel

Cateye Ergociser Series 1000 Service Manual

Page 19

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-5

[2]Checking the Electrical Systems

1. Connect the AC adapter, and turn on the power of the main unit.

2.Obtain the manual training program, set the pedal torque setting to 4.0kg·m, and rotate the pedal at the rate of 50 rpm. If you can rotate it quite easily, no load will be applied.

3. Replace the control unit with a brand new one.

4.Again, check the torque status under the manual training program.

t When the pedal torque is loaded, the control unit is

When no torque loading is possible, proceed to the following procedures.

1. Turn off the power, and loosen the four screws on the handlebar stem to remove the control unit. (Fig. 1)

2. Remove the cable connector which is connected to the back of the control unit. (Fig. 1)

3. Remove the frame cover. (See the Sections D1 & D2 "Removing the Frame Covers.")

4. Remove the CN-2 connector on the power supply board. (Fig.

5. Using a tester, check for any short-circuiting across Terminal 1s and Terminal 4s at both ends of the 5P cable which connects the power supply board and the control unit. (Fig. 3)

t When there is no shortcircuit, the 5P cable is disconnected.

When it is short-circuited, proceed to the following procedures:

1. Remove the connector CN-1 from the power supply board, and measure the resistance across Terminals 2 and 3 of the connector. When the reading is in the range of 9Ω and 14Ω, the connector is all right. (Figs. 4 & 5)

t When the meter reading is exceedingly large, the solenoid

t When the meter reading is in the acceptable range, the

No Loading (Check of Electrical Systems)

Check Method of Causes Repair Method Explanation Figures

defective.

coil is defective.

power supply board may be defective.

Replace the control unit with a brand new one.

Replace the 5P cable with a brand new one. (See the Section ES-2 " Replacing the 5P Cable.")

Replace the workload unit. (See the Sections MS-1 & MS-2 "Replacing the Workload Unit.")

Replace the power supply board. (See the Section ES-3 "Replacing the Power Supply Board.")

Fig. 1

Normal when zero (0)

Connector Terminal 4

5P Cable

Fig. 3

Normal for 14V thru 19V

Power Supply Board

CN-2 Connector

Fig. 2

CN-1 Connector

Fig. 4

Connector Terminal 4

Connector Terminal 3

Fig. 5

Connector Terminal 2

To Solenoid Coil

No Loading (Check of Electrical Systems)

CN-1 Connector

T-5

Cateye Ergociser Series 1000 Service Manual

Page 20

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-6

1. Remove the frame cover, and check the inside of frame. (See the Sections D1 & D2 "Removing the Frame Covers.")

2. Check if the plain belt of the flywheel has not been detached. (Fig. 1)

t No damage on the plain belt

t The plain belt is damaged.

No Pedal Rotation (Locked)

Check Method of Causes Repair Method Explanation Figures

Apply the plain belt correctly. (See the Section MS-2 "Replacing the Workload Unit (w/ Flywheel).")

Replace the workload unit and free wheel with brand new ones. (See the Section MS-2 "Replacing the Workload Unit (w/ Flywheel).")

Plain Belt

No Pedal Rotation (Locked)

T-6

Fig. 1

Cateye Ergociser Series 1000 Service Manual

Page 21

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-7-1

The noise generating source will be different depending on the cases whether it is of continuous noise or periodical noise (several times per rotation of pedal).

[1] Noise is continuous and increasing.

1. Remove the frame cover. (See the Sections D-1 & D-2

"Removing the Frame Covers.")

Apply grease to the following points. (Figs 1 & 2)

· Chain

· Inner surface of the timing belt (mating surface with the

2. Check if the derailleur has been worn out. (Fig. 1)

3. Check if the idler has been worn out. (Fig. 2)

4. Check if the plain belt has been deviated in position, thus

causing friction.

Unusual Noise (Continuous and Increasing)

Check Method of Causes Repair Method Explanation Figures

plastic pulley)

When it has been worn out, replace it with a brand new derailleur set. (See the Section MS-6 "Replacing the Derailleur Set.")

When it has been worn out, replace it with a brand new idler set. (See the Section MS-7 "Replacing the Idler Set.")

When the plain belt is shifted and is going to be damaged, replace both the workload unit and the flywheel set with new ones.

Fig. 1

Idler

Derailleur

Idler Set

Chain

Plain Belt

Fig. 2

Timing Belt

Plastic Pulley

Fig. 3

Cateye Ergociser Series 1000 Service Manual

Unusual Noise

T-7-1

Page 22

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-7-2

[2] Noise is Periodical.

1. Noise occurs around once per rotation of the pedal. t The pedal installation may not be perfect. (Fig. 1)

2. Sliding noise occurs around 17 times per rotation of the pedal.

Remove the frame cover, and check the inside of frame. (See the Sections D-1 & D-2 "Removing the Frame Covers.")

t The copper disc plate of the workload unit may touch the

Unusual Noise (Periodical)

Check Method of Causes Repair Method Explanation Figures

solenoid coil. (Figs. 2 & 3)

Use a No.15 wrench and securely fasten the pedal to the crank. (both sides)

See the Section ES-4 "Correcting the Position of Solenoid Coil," and correct the position of the copper disc plate.

[If the plate is warped and the position of solenoid coil cannot be corrected, replace the workload unit. (See the Sections MS-1 & MS-2 "Replacing the Workload Unit.")]

No.15 Wrench

Crank

Pedal

Fig. 1

Unusual Noise

T-7-2

Cateye Ergociser Series 1000 Service Manual

Fig. 2

Fig. 3

Core Slit

Correct Position

Solenoid Coil

Copper Disc Plate

Core

Solenoid Coil

Core Slit

Copper disc plate is in contact with the core.

Fig. 4

Copper Disc Plate

Core

Solenoid Coil

Page 23

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

T-7-3

[3] Noise occurs when the pedal is rotated with a large torque. A large sound "bang" occurs when the pedal is abruptly rotated with

a large torque. Remove the frame cover, and check the inside of frame. (See the

Sections D-1 & D-2 "Removing the Frame Covers.")

1. Check if the idler spring is detached.

2. Check if the idler mounting bolt is detached or loosened.

Unusual Noise (Noise occurs when the pedal is rotated with a large torque.)

Check Method of Causes Repair Method Explanation Figures

Hook the idler spring on the pawl of the idler. Securely fasten the idler mounting bolt.

Idler

Pawl

Idler Mounting Bolt

Idler Spring

dler Metal Base

Fig. 1

Cateye Ergociser Series 1000 Service Manual

Unusual Noise

T-7-3

Page 24

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

D-1

Removing the Frame Covers

Upright Type (EC-1200 & EC-1600) When any repair or adjustment of parts within the frame is required,

remove the frame covers in the following procedures. REMOVAL

1. Remove the pedals at both the left and right sides. (The right side pedal can be removed by turning it in the clockwise direction, and the left side pedal can be removed in the counter-clockwise direction.) (Fig. 1)

2. Remove the crank cover fixing screws. The narrow-width area of the crank cover should be positioned in between the frame cover and the crank. (Fig. 2)

3. Remove the leg pipe fixing screws. (Fig. 3) * You do not have to remove the leg pipe itself. * For the model EC-1600, remove the leg pipe cover.

4. Shift the rubber base at the seat post lock knob away from the center cover.

5. Loosen the center cover fixing screw a little, and lift the center cover upward. (Do not remove it.) (Fig. 4)

6. Loosen the four screws on the inlet cover. (Fig. 5)

7. Remove the frame cover fixing screw with a screwdriver before removing the frame cover. (Fig. 6)

ASSEMBLING

1. Place the frame covers onto the frame at both right and left sides, paying attention to the position of the crank.

2.Fix the right and left frame covers with frame cover fixing screws.

3. Mount the inlet cover with four screws. (Fig. 5)

4. Set the center cover to the frame cover correctly in position, and fix it with the center cover fixing screws. (Fig. 4)

5. Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws. (Fig. 2)

6.Set the rubber base for the seat post lock knob, and then mount the right and left pedals.

7. Fix the leg pipe with the leg pipe fixing screws. (For the model EC-1600, mount the leg pipe cover.)

Removing the Frame Covers

No. 15 Wrench

Fig. 1

Front

Crank

Leg Pipe Fixing Screw

Pedal

Crank Cover

Fig. 2

OFF

Rear

Leg Pipe Fixing Screw

OFF

Center Cover Fixing Screw

Fig. 3 Fig. 4

Frame Cover

OFF

Inlet Cover

Four (4) Screws

Lift upward.

Center Cover

D-1

Cateye Ergociser Series 1000 Service Manual

Fig. 5 Fig. 6

Page 25

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

D-2

Recumbent Type (EC-3600 & EC-3700) When any repair or adjustment of parts within the frame is required,

remove the frame covers in the following procedures. àREMOVAL

2. Remove the crank cover fixing screws. The narrow-width area of the crank cover should be positioned in between the frame cover and the crank. (Fig. 2)

3. Remove the leg pipe fixing screws. (Fig. 3) * You do not have to remove the leg pipe itself.

4. Remove the frame cover fixing screw with a screwdriver before removing the frame cover. (Fig. 4)

àASSEMBLING

1. Place the frame covers onto the frame at both right and left sides, paying attention to the position of the crank. At the same time, the center cover should be built in.

2.Fix the right and left frame covers with frame cover fixing screws.

3. Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws. (Fig. 2)

4. Fix the front leg with casters with the leg pipe fixing screws.

5. Mount the pedals.

Removing the Frame Covers

Fig. 1

Frame Cover

No. 15 Wrench

Crank

Pedal

Center Cover

Screw

Crank Cover

Fig. 2

Leg Pipe Fixing Screw

Front Leg with Casters

Fig. 3

Fig. 4

Removing the Frame Covers

D-2

Cateye Ergociser Series 1000 Service Manual

Page 26

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-1

Replacing the Wiring within the Frame

[A]Removing the Wiring Parts

1.Remove the frame cover. (See the Sections D-1 & D-2

"Removing the Frame Covers.")

2. Loosen the two screws on the inlet metal base to remove

them. (Fig. 1)

3. With the stopper being held with fingers, pull the CN-4

connector off the power supply board. (Fig. 2)

4. Cut the cable holder with a nipper. (Fig. 3)

[B]Mounting the Brand New Wiring Parts

1. Mount the brand new inlet metal base to the frame with two

screws.

2. Pass the wiring cable from beneath the DC jack of the power

supply board along with the square pipe (21mm x 21mm) to the left direction, and then pass it through the back of the inlet metal base along with the square pipe toward the switch.

3. Connect the CN-4 connector to the power supply board.

4.Refer to the Section (2) "Checking the Wiring within the

Frame" of T-1 "No Display on the Control Unit after Power ON" (1) , measure the voltage across the electrolytic capacitor C-1 to check that it is in the correct range of 14V and 19V.

5. Use the cable holder to fix the CDC sensor cable together with

the solenoid coil cable. (Fig. 3)

6. Provisionally connect the control unit, and check the unit works

fine after turning on the power. Then, completely assemble the frame cover.

Power Supply Board

EC-1200 & EC-1600

Inlet Metal Base (for Upright Type)

Screws

OFF

DC Jack

Inlet Metal Base

EC-3600 & EC-3700

Inlet Metal Base (for Recumbent Type)

Screws

OFF

Inlet Metal Base

DC Jack

Power Supply Board

OFF

Replacing the Wiring within the Frame

ES-1

Cateye Ergociser Series 1000 Service Manual

Fig. 1

Hold the stopper.

Fig. 2

Power Supply Board

Cable Holders

Fig. 3

Page 27

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-2

Procedures are different depending on the type of model as shown below:

àUpright Type (EC-1200) T Removing the Existing Cable

1. Loosen the four screws which fix the control unit to remove the control unit. Also, remove the cable connector. (Fig. 1)

2.Remove the cable holder which fixes the 5P cable to the handlebar post.

3. Remove the frame cover. (See the Section D-1 "Removing the Frame Covers.")

4. Remove the CN-2 connector from the power supply board. (Fig. 2)

5. Cut the cable holders which fix the 5P cable to the frame, and remove the 5P cable.

T Mounting the Brand New Cable

1. Mark the 5P cable at a point approx. 87cm from the unit-side cable connector (Fig. 3), and connect the leading end of the CN-2 connector to the power supply board.

2. (1)Using cable holders, fix the 5P cable at the bottom of the handlaber pipe of the main unit frame.(2)Fix the cable at the marked point of the cable to the handlebar pipe just beneath the horizontal frame.(3)Pass the 5P cable along with the handlebar pipe, and the sagging portion should be binded with a cable holder. (Fig. 4)

3. Connect the cable connector to the control unit, and apply the connector cover.Then, fix the control unit to the handlebar post by using four screws. (Fig. 1)

4. Provisionally turn on the power, and check if the control unit works fine.

5.Fix the 5P connector to the handlebar post with the cable holder.

6. Mount the frame cover. (See the Section D-1 "Removing the Frame Covers.")

àUpright Type (EC-1600) T Removing the Existing Cable

5P Cable Handleber Post

1. Loosen the four screws which fix the control unit to remove the control unit. Also, remove the cable connector. (Fig. 4) Slide the inner handlebar post cover upward, and unplug the cable connector. (Fig. 5)

2. Remove the screws of both the handlebar stem and the outer handlebar post cover to remove the 5P cable. (Fig. 6)

5P Cable within the Frame

1. Remove the frame cover. (See the Section D-1 "Removing the Frame Covers.")

2. Remove the CN-2 connector at the end of the 5P cable from the power supply board.

3. Cut the cable holders which fix the 5P cable to the handlebar pipe, and remove the 5P cable.

To be continued on the next page.

Replacing the 5P Cable (1)

EC-1200

Fig. 1

Cable Holders

EC-1200

Fig. 4

Screws

(2)

Cable Connector

Screws

Handlebar Pipe

Horizontal Frame

(3)

(1)

Handlebar Stem Cover

Fig. 2

Power Supply Board

EC-1600

Fig. 5

Cable Connector

Cable Holder

Cable Connector

Screws

5cm

Unit-Side Cable Connector

Mark this point.

87cm

Fig. 3

Inner Handlebar Post Cover

Unplug

Fig. 6

Replacing the 5P Cable (1)

Fig. 7

Fig. 8

ES-2

Cateye Ergociser Series 1000 Service Manual

Page 28

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-2

T Mounting the Brand New Cable 5P Cable within the Handlebar Post

1. Using cable holders, bind the 5P cable, leaving approx. 5cm portion from the control unit side cable connector, to the handlebar post. (Fig. 7) Assemble the handlebar post cover and the handlebar stem cover. (Fig. 6)

2. Connect the cable connector to the control unit, and fix the unit to the handlebar post by using four screws. (Fig. 5)

5P Cable within the Frame

1. Connect the CN-2 Connector at the end of the 5P cable to the power supply board.

2. (1)Using cable holders, fix the 5P cable to the frame, leaving the extra portion of 10cm from the top of the handlebar pipe.(2) Fix the 5P cable at the bottom of the handlebar pipe.(3) Pass the 5P cable along the handlebar pipe, and bind the sagging portion to the point (3) by using cable holders. (Fig. 8)

3. Provisionally connect the intermediate cable connector, and turn on the power. Then, check if the control unit works fine.

4. Mount the frame cover to restore the original shape. (See the Section D-1 "Removing the Frame Covers.")

àRecumbent Type (EC-3600 and EC-3700) T Removing the Existing Cable

1. Loosen the four screws which fix the control unit to remove the control unit. Also, remove the cable connector. (Fig. 10)

2. Remove the frame cover. (See the Section D-2 "Removing the Frame Covers.")

3. Remove the 5P connector from the power supply board. (Fig.

4. Cut the cable holders which fix the cable to remove the 5P cable.

T Mounting the Brand New Cable

1. Leaving approx. 30cm from the end of the frame, fix the 5P cable to the frame by using cable holders.

2. Connect the 5P cable to the power supply board, and bind the sagging portion to the point (2) of the frame. (Fig. 11)

3. Provisionally turn on the power, and check if the control unit works fine.

4. Mount the frame cover. (See the Section D-2 "Removing the Frame Covers.")

Replacing the 5P Cable (2)

10cm

Cable Holders

EC-1600

Fig. 9

(1)

(3)

Power Supply Board

Control Unit

5P Cable

Screws

Fig. 10

(2)

30cm

Cable Holders

Replacing the 5P Cable (2)

ES-2

Cateye Ergociser Series 1000 Service Manual

Fig. 11

Page 29

Applicable Models:

K６０２０

COIL

LOT No.

EC-1200 EC-1600 EC-3600 EC-3700

ES-3

[1] Replacing the Power Supply Board

1. Remove the frame cover. (See the Sections D-1 & D-2 "Removing the Frame Covers.")

2. Remove all connectors CN-1, CN-2, CN-3 and CN-4 which are connected to the power supply board.

3. Loosen the two screws which fix the power supply board to remove the board. (Fig. 1)

4. Securely fix the brand new power supply board by using two fixing screws.

5. Connect three connectors, CN-2, CN-3 and CN-4.

[2] Adjustment of Coil Current Value

1. Connect the cables for measuring coil current between the female connector of the solenoid coil and the male connector (CN-1) on the power supply board, and then connect the cables to an ammeter. (Fig. 2)

2. Turn on the power switch of the main unit, set the control unit to the manual mode, set the load display to 4.0kg m, and start the system.

3. Adjust the potentiometer (as shown in Figs. 3 and 4) on the power supply board with a blade-head screwdriver so that the coil current will be the value indicated on the workload unit solenoid coil. (A clockwise turn will increase the current, while a counter-clockwise turn will reduce the current.)

Example: When the indication is 630 as shown in Fig. 5,

4.Upon completion of the adjustment, detach the cable for measuring coil current, and connect the CN-1 connector directly to the power supply board.

Replacing the Power Supply Board

adjust the potentiometer so that the coil current value will be 630mA.

Fixing Screws

Fig. 1

Power Supply Board

Power Supply Board A

EC-1200 & EC-1600

Cable for Measuring Coil Current

Fig. 2

Power Supply Board

Power Supply Board B

EC-3600 & EC-3700

Solenoid Coil

Fig. 3

Fig. 4

Replacing the Power Supply Board

Location of Coil Current Value Indication

Fig. 5

ES-3

Cateye Ergociser Series 1000 Service Manual

Page 30

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-4

Correcting the Position of Solenoid Coil

Perform the positional correction of the core slit section after detaching the frame cover and turning off the power. (See the Sections D-1 & D-2 "Removing the Frame Covers.")

[1] Correction with Nuts of Workload Unit Reinforcing Metal Base This correction is a minor correction method which allows

adjustment by the fastening force of the frame-side nuts of the workload unit reinforcing metal base.

1. Check the contacting area by slowly rotating the copper disk plate with your hands.

2. Adjust the two frame-side nuts of the workload unit reinforcing metal base in the following procedures. (Fig. 1)

A.Loosen the nut on the workload unit side, and the nut on the

frame side (Fig. 1).

B.If the right side of the copper disk plate contacts the core,

when the main unit is viewed from the direction as depicted in Fig. 3, fasten the frame-side nut.

C. Then, fasten the frame-side nut on the other side until the

copper disk plate comes close to the center of the core slit (Fig. 2). [ Rotate the copper disk plate slowly, and check for any contacts on the entire area of the plate.

D.Fasten the nuts which had been tightened in the above step

A. [2] In case correction is not possible by the method stated in [1]. Replace the whole workload unit. (See the Section MS-2 "Replacing

the Workload Unit (w/ Flywheel).")

Workload Unit Reinforcing Metal Base

EC-1200 & EC-1600

Workload Unit Reinforcing Metal Base

Frame-Side Nut

Fig. 1

Solenoid Coil

Workload-UnitSide Nut

Core Slit

Correct Position

Workload Unit Reinforcing Metal Base

EC-3600 & EC-3700

Copper Disk Plate

Core

Solenoid Coil

Core Slit

Copper disk plate contacts the core.

OFF

Copper Disk Plate

Core

Solenoid Coil

Correcting the Position of Solenoid Coil

ES-4

Cateye Ergociser Series 1000 Service Manual

Fig. 2

Fig. 3

Page 31

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-5

1. Remove the frame cover. (See the Sections D-1 & D-2 "Removing the Frame Covers.")

2. Detach the CN-3 connector from the power supply board. (Fig.

3. Cut the cable holders which fix the CDC sensor cable to the frame.

4. Remove the defective CDC sensor set by loosening the screws, and mount and fix the brandnew CDC sensor set. (Fig. 2)

5. Perform the following adjustments. (Figs. 3 and 4)

T Align the line on the CDC sensor with the center of the line

T Adjust the gap between the surface of CDC sensor and the

* If the gap is inadequate, bend the metal base to secure the

6. Securely connect the CN-3 connector to the power supply board. (Fig. 1)

7.Rotate the crank, and check if the pedal cadence will be displayed on the control unit.

8. Fix the CDC sensor cable to the frame by using cable holders. (Fig. 5)

9.Assemble the frame cover. (See the Sections D-1 & D-2 "Removing the Frame Covers.")

Replacing the CDC Sensor

on the CDC magnet. (Fig. 3)

surface of CDC magnet to be approx. 2mm. (Fig. 4)

specified gap.

CDC Sensor

EC-1200 & EC-1600

Power Supply Board

CN-3 Connector

Power Supply Board

EC-3600 & EC-3700

CDC Sensor

Power Supply Board

OFF

Fig. 1

Line on CDC Sensor

Center of CDC Magnet

Fig. 3

Fig. 2

Approx. 2mm gap between CDC sensor and CDC magnet

Center of CDC Magnet

Line on CDC Sensor

Fig. 4

Cable Holders

Replacing the CDC Sensor

Fig. 5

ES-5

Cateye Ergociser Series 1000 Service Manual

Page 32

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-6

1.Remove the control unit by loosening four screws. Also remove the cable connector from the control unit. (Fig. 1)

2. The control unit can be separated into upper and lower parts when the eight screws on the bottom of the lower body of the unit are removed (Fig. 2). Be careful to separate them slowly since the upper and lower bodies are connected with a flat cable.

3. Remove the connector on the panel keyboard which is located at the upper body side, loosen the nine screws on the substrate, and remove them from the upper body. (Fig. 3)

4.Since the panel keyboard is fixed to the control unit with silicon, cut the silicon with a sharp cutter (Fig. 4). Peel the panel keyboard off the surface of upper body. (Fig. 5)

5. If the silicon remains at the upper body, remove it thoroughly.

6. Place the brandnew panel keyboard. The cable from the keyboard should be pulled in through the hole on the upper body. Press and adhere the panel keyboard in position.

7. Apply silicon at two depicted areas to prevent intrusion of sweat. (Figs. 4 and 6)

8. Mount the substrate and fix it with nine screws, and insert the connector of the panel keyboard. (Fig. 3)

9. Put the upper and lower body together, and fix them with eight screws.

10.Connect the cable connector to the control unit, and mount the unit to the main unit.

Replacing the Panel Keyboard

Control Unit

Fig. 1

Fig. 4

Cable Connector

Silicon

Fig. 2

Screw

Control Unit

Upper Body

Fig. 5

Control Unit

Panel Keyboard

Substrate Fixing Screw

Fig. 3

Substrate

Connector

Replacing the Panel Keyboard

ES-6

Cateye Ergociser Series 1000 Service Manual

Silicon

Fig. 6

Page 33

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-7

1. Insert a thin cutting knife, while paying cautions not to damage the control unit, in between the button panel and the body, and carefully peel off the button panel. (Fig. 1)

2. Clean the adhesive agent, if any, on the control unit before placing a brandnew button panel.

* Sufficiently press the button panel thus placed.

Replacing the Button Panel

Control Unit

Fig. 1

Button Panel

Cateye Ergociser Series 1000 Service Manual

Replacing the Button Panel

ES-7

Page 34

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-8

1. Open the control unit into upper and lower bodies by referring to the Section ES-6 "Replacing the Panel Keyboard (1) & (2)."

2. unit is fixed to the lower body with two screws. Remove these two screws. (Fig. 1)

3. The printer unit can be removed after detaching cable connectors CN-2 and CN-3 of the printer unit. To remove the connector CN-3, just pull it, while to remove connector CN-2, the use of tweezer will be recommended. (Fig. 2)

4.Connect the connector CN-2 of the brandnew printer unit. Then, connect CN-3. For the connection, press it while moving it to right and left side alternatively.

5. Fix the printer unit with two screws. (Fig. 1)

6. Put the upper and lower bodies together, and fix them with eight screws.

7. Adjust the printing darkness by referring to the Section ES-9 "Adjusting the Printing Darkness."

8. Mount the control unit to the main unit.

Replacing the Printer

Fig. 1

Printer Unit

Printer Fixing Screws

CN-2 Connector

CN-3 Connector

Fig. 2

Replacing the Printer

ES-8

Cateye Ergociser Series 1000 Service Manual

Page 35

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-9

1. Remove the control unit from the main unit. (Fig. 1)

2.Loosen four screws on the bottom of the control unit, and remove the cable connector from the unit. (Fig. 1)

3. Remove the black metal base on the bottom of the control unit. (Fig. 2)

4. Provisionally connect the 5P connector on the bottom of the control unit to the main unit.

5. Turn on the power. Check if the printer symbol appears on the LCD panel and the printer is in the operating condition.

6. Check if the thermal paper is set in position.

7. Adjustment should be done with the control unit positioned horizontally. Press the ADV button on the control panel twice to perform a test printing. A counter-clockwise turn of the potentiometer PR on the bottom of the control unit will decrease the darkness, while a clockwise turn will increase it (Fig. 2). Set it to an appropriate darkness level. (An extreme clockwise turn of the potentiometer may distort the printed characters.)

NOTE: Never touch the potentiometer DCV.

Adjusting the Printing Darkness

Upright Type

Control Unit

Cable Connector

Recumbent Type

Fig. 2Fig. 1

DCV

Control Unit

Cable Connector

Fig. 3

Potentiometer PR

Adjusting the Printing Darkness

ES-9

Cateye Ergociser Series 1000 Service Manual

Page 36

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

ES-10

1. Open the control unit into upper and lower bodies by referring to the Section ES-6 "Replacing the Panel Keyboard (1) & (2)."

2. Remove the jammed paper with a tweezer or the like. (Fig. 1)

3. Assemble the control unit by referring to the Section ES-6 "Replacing the Panel Keyboard (9) & (10)."

4. Set the printer paper. (See the Operation Manual.)

Paper Jamming in Printer

Pincette

Printer Unit

Fig. 1

Paper Jamming in Printer

ES-10

Cateye Ergociser Series 1000 Service Manual

Page 37

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-1

àRemoving the Workload Unit

1. Remove the frame cover, by referring to the Sections D-1 & D2 "Removing the Frame Covers."

2. Detach the CN-1 connector on the power supply board.

3. Using a nipper or the like, cut the cable holder which fixes the CN-1 connector, while paying attention not to damage the cable. (Fig. 2)

4.Remove the gear crank, by referring to the Section MS-8 "Replacing the Crank Set." Also, remove the chain together with the gear crank.

5. Using a wrench, loosen the nuts, which fix the workload unit reinforcing metal base, on both the workload unit side and the frame side, and remove the metal base. (Fig. 3)

6. Remove the hexagon head bolts which fix the workload unit (two bolts on either right and left sides). Lift the entire workload unit upward until it comes off the workload unit fixing metal base, and remove the unit by shifting it either in the right or left side (Fig. 4). Be careful that the copper disk plate does not touch the frame.

Replacing the Workload Unit (w/o Flywheel) (1)

EC-1200

Workload Unit

Power Supply Board

CN-1 Connector

Fig. 1

Wrench

Workload Unit Reinforcing Metal Base

Fig. 2

Workload Unit

Fig. 4

Cable Holder

Fig. 3

Replacing the Workload Unit (w/o Flywheel) (1)

Workload Unit Fixing Hexagon Head Bolt

MS-1

Cateye Ergociser Series 1000 Service Manual

Page 38

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-1

àMounting the Brandnew Workload Unit

1. Assemble the brandnew workload unit so that it will engage with the workload unit mounting metal base of the frame (Fig.

1). Be careful that the copper disk plate will not touch the frame.

2. Tighten the crank nut by using a cotterless gear crank removing/ fastening tool and a wrench (Figs. 2 and 3). Tightening torque should be 350kg cm to 400kg·cm, and tighten the nut until the end of the crank shaft can level with the end surface of the nut. Then, put the crank cap with a coin or the like. (Fig. 4)

3. Assemble the chain. Chain should first be set on the free wheel before setting it to the upper part of the large gear. Then, a forward rotation of the crank will enable the complete setting on the large gear. (Fig. 5)

4. Set the derailleur spring to the pawl of the derailleur to give tension to the chain. (Fig. 6)

5. Adjust the position of the workload unit so that the tension of the chain at the workload unit can be adequate. Move the workload unit back and forth so that the longer edge of the derailleur fixing metal base can be positioned at a right angle to the derailleur spring. (Fig. 6)

6. Tighten the workload unit fixing screw (two screws on either right and left sides). (Fig. 7) The tightening torque is 90kg·cm to 120kg·cm.

7. Assemble the workload reinforcing metal base in between the bolts at the workload side and the frame side, and tighten the bolts with nuts. (Fig. 8)

* In case the nut is screwed in at the position where the

workload-unit-side workload unit metal base is supposed to be mounted, remove the nut.

* The tightening torque at the workload unit side should be

90kg·cm to 120kg·cm, and the nut at the frame side should be provisionally tightened.

Replacing the Workload Unit (w/o Flywheel) (2)

Workload Unit

Fig. 1

Coin

Fig. 4

Workload Unit Fixing Metal Base

Crank Cap

Workload Unit Fixing Screw

Fig. 5

Wrench

Cotterless Gear Crank Removing/Fastening Tool

Fig. 2

Upper Part of Large Gear

Chain

Workload Unit Reinforcing Metal Base

Frame-Side Bolt

Wrench

Cotterless Gear Crank Removing/ Fastening Tool

Fig. 3

Derailleur Spring

Derailleur

Fig. 6

Workload-UnitSide Bolt

Replacing the Workload Unit (w/o Flywheel) (2)

MS-1

Cateye Ergociser Series 1000 Service Manual

Fig. 7

Fig. 8

Page 39

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-1

à Checking the Positions of Copper Disk Plate and Solenoid Coil

Core Slit

T Regarding the workload unit, positions of copper disk plate

T Rotate the copper disk plate slowly to check if it does not

Correction Method Correction can be made by tightening the frame-side nuts of the

workload reinforcing metal base. Tighten the metal base toward the direction in which the positional correction of the copper disk plate should be made, until the plate comes close to the center of the core slit (Fig. 1). (See the Section ES-4 "Correcting the Position of Solenoid Coil.")

1. After checking the correction direction, use a wrench to tighten the frame-side nut of the workload unit reinforcing metal base. Give the even tightening to both right and left sides.

2. As shown in Fig. 2, set a cable for measuring coil current in between the CN-1 female connector and the CN-1 male connector at the side of power supply board, and connect the cable to an ammeter.

3. Turn on the power switch of the main unit, set the control unit to the manual mode, select the torque at 4.0kg·m, and start the

system.

4. Using a blade-head screwdriver, adjust the potentiometer on the power supply board so that the meter reading shows the coil current which is specified on the solenoid coil of the workload unit.

Example:As shown in Fig. 3, when 630 is indicated, adjust the potentiometer so that the coil current will be 630mA.

5. After having adjusted the coil current, remove the measuring cable, and connect the female connector of the CN-1 cable directly to the male connector at the power supply board side.

6. Fix the cable onto the seat pipe with cable holders.

Replacing the Workload Unit (w/o Flywheel) (3)

and solenoid coil core slit have been adjusted before mounting the frame so that they will not touch each other while the plate is rotating. However, due to positional distortion caused by tightening the bolts while the frame is being mounted, the copper disk plate may touch the core. (Fig. 1)

touch the core. If it does, it is necessary to eliminate the positional distortion caused by the tightening.

Correct Position

Core Slit

Fig. 1

CN-1 Female Connector

Fig. 3

Copper Disk Plate

Core

Cable for Measuring Coil Current

Frame-Side Nut

Fig. 2

Power Supply Board

CN-1 Connector

Workload Unit Reinforcing Metal Base

Workload-Unit-Side Nut

LOT No.

Fig. 4

COIL

K6020

àAdjusting the Flywheel

1. Adjust the flywheel by referring to the Section MS-3 "Adjusting the Flywheel."

Replacing the Workload Unit (w/o Flywheel) (3)

MS-1

Cateye Ergociser Series 1000 Service Manual

Page 40

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-2

àRemoving the Workload Unit

1. Remove the gear crank and the chain by referring to Items 1 through 4 of the Section MS-1 "Replacing the Workload Unit (w/o Flywheel) (1)."

2. Loosen the flywheel fixing nut which is fixed to the flywheel metal base. (Fig. 1)

3. Remove the four bolts which fix the flywheel metal base, and remove the plain belt. (Fig. 2)

4. Remove the workload unit by referring to Items 5 and 6 of the Section MS-1 "Replacing the Workload Unit (w/o flywheel) (1)."

àMounting the Brandnew Workload Unit

1. Assemble the brandnew workload unit so that it will engage with the workload unit mounting metal base of the frame (Fig.

1). [See the Item 1 of the Section MS-1 "Replacing the Workload Unit (w/o flywheel) (2)."]

2. Hang the plain belt on the flywheel, and fix it to the flywheel metal base with the flywheel fixing nut.

3. Provisionally fasten the metal base fixing screw (4 pieces) to the flywheel fixing metal base and the frame respectively. (Fig.

4. Mount the workload unit by referring to Items 2 to 6 of the Section MS-1 "Replacing the Workload Unit (w/o flywheel) (2)."

àAdjusting the Flywheel

1. Adjust the flywheel by referring to the Section MS-3 "Adjusting the Flywheel."

Replacing the Workload Unit (w/ Flywheel)

Fig. 1

Flywheel

Workload Unit

Flywheel Fixing Nut

Flywheel

EC-1600

Workload Unit

Flywheel Fixing Nut

Flywheel Metal Base

Metal Base Fixing Screw

Fig. 2

Flywheel

EC-3600 & EC-3700

Plain Belt

Flywheel Fixing Metal Base

Replacing the Workload Unit (w/ Flywheel)

MS-2

Cateye Ergociser Series 1000 Service Manual

Page 41

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-3

àAdjustment Method of Flywheel Since the plain belt which delivers the rotation of both the workload

unit and flywheel requires an adequate tension, a specified tension should be given to the plain belt in the following adjustment procedures. For this adjustment, use commercial tools, since no purpose-designed tool is not prepared.

1.Set a commercial wire around the flywheel metal base as depicted in Fig. 1, and tie up the both ends outside the frame.

2. Hang a commercial spring scale at the top of the wire thus tied up, and lift the scale upward with a pulling force of 5 to 6 kg.

3. Keeping this status, fully tighten the four metal base fixing screws which had been fastened provisionally. (Fig. 2)

Adjusting the Flywheel

Spring Scale

Wire

Metal Base Fixing Screws

Flywheel Metal Base

Flywheel

Metal Base Fixing Screw

Fig. 2

Fig. 1

Adjusting the Flywheel

MS-3

Cateye Ergociser Series 1000 Service Manual

Page 42

Applicable Models:

OFF

EC-1200 EC-1600 EC-3600 EC-3700

MS-4

1. Remove the frame cover by referring to the Sections D-1 & D2 "Removing the Frame Covers."

2. Use a screwdriver or the like to remove the derailleur spring which is hung on the derailleur metal base, thus loosening the chain.

3. First detach the chain at the upper part of the large gear, and then rotate the crank forward to detach the entire chain. (Fig.

4. The brandnew chain should be hung firstly on the free wheel, and then hang it over the upper part of the large gear. A forward rotation of the crank will allow complete setting of the entire chain. (Fig. 3)

5. Adjust the tension of chain. Hang the spring on the derailleur, loosen the workload fixing screw, and adjust the tension while sliding the workload unit back and forth. (Fig. 4)

* Be careful not to give excessive tension to the chain.

6. Assemble the frame cover by referring to the Sections D-1 & D-2 "Removing the Frame Covers."

Replacing the Chain

EC-1200 & EC-1600

Derailleur Spring

Chain

EC-3600 & EC-3700

Crank

Large Gear

Replacing the Chain

MS-4

Cateye Ergociser Series 1000 Service Manual

Fig. 1

Large Gear

Fig. 3

Derailleur

Fig. 2

Crank

Approx. 3 to 7mm of slack

Free Wheel

Fig. 4

Page 43

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-5

1.Detach the chain. (See the Section MS-4 "Replacing the Chain.")

2. Hold the D-cut section on the free wheel shaft with a No.13 wrench, and remove the hexagon U-nut. Then, pull off the free wheel set by using a free wheel remover. (Figs. 1 & 2)

3. Mount the brandnew free wheel set, and firmly tighten the hexagon nut. Tightening should be done while holding the Dcut section with a No.13 wrench. (Fig. 1)

4. Set the chain by referring to the Section MS-4 "Replacing the Chain."

Replacing the Free Wheel Set

Free Wheel Set

EC-1200 & EC-1600

Idler

Free Wheel Set

EC-3600 & EC-3700

OFF

Free Wheel

D-Cut Section

Fig. 1

Timing Belt

Hexagon U-Nut

Free Wheel

Fig. 2

Replacing the Free Wheel Set

MS-5

Cateye Ergociser Series 1000 Service Manual

Page 44

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-6

1. Detach the derailleur spring from the pawl of the derailleur metal base. (Fig. 1)

2. Loosen the derailleur fixing bolt with a No.10 socket wrench, and remove the derailleur set. (Fig. 2)

3. Mount the brandnew derailleur set with fixing screws.

4. Set the derailleur spring on the pawl of the metal base to give tension to the chain.

Replacing the Derailleur Set

Derailleur Set

EC-1200 & EC-1600

Derailleur Set

EC-3600 & EC-3700

Replacing the Derailleur Set

MS-6

Derailleur Spring

Fig. 1

Derailleur

Fig. 2

Derailleur Fixing Bolt

Derailleur

Cateye Ergociser Series 1000 Service Manual

Page 45

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-7

1. Remove the frame cover by referring to the Sections D-1 & D2 "Removing the Frame Covers."

2. Remove the idler spring from the pawl of the idler metal base. (Fig. 1)

3. Loosen the idler mounting bolts, and detach the idler set. (Fig.

4. Mount a brandnew idler set by using an idler mounting bolt.

5. Hang the idler spring on the pawl of the idler to give tension to the belt.

Replacing the Idler Set

EC-1200 & EC-1600

Idler

Idler Set

EC-3600 & EC-3700

Idler

Fig. 1

Idler Fixing Bolt

Idler Spring

Fig. 2

Replacing the Idler Set

MS-7

Cateye Ergociser Series 1000 Service Manual

Page 46

Applicable Models:

OFF

EC-1200 EC-1600 EC-3600 EC-3700

MS-8

àRemoving the Gear Crank (Crank)

1. Remove the frame cover by referring to the Sections D-1 & D2 "Removing the Frame Covers."

2. Detach the chain by referring to the Section MS-4 "Replacing the Chain." (Fig. 1)

3. Detach the crank cap with a coin or the like. (Fig. 2)

4. Use a cotterless gear crank removing/fastening tool and a wrench, rotate the crank nut to remove it. (Fig. 3)

5. Change the sides of a cotterless gear crank removing/ fastening tool, and rotate it clockwise to remove the gear crank (crank) from the crank shaft. (Fig. 4)

- to be continued to the next page -

Replacing the Crank Set (1)

EC-1200 & EC-1600

Crank Set

EC-3600 & EC-3700

Upper Part of Large Gear

Coin

Replacing the Crank Set (1)

MS-8

Cateye Ergociser Series 1000 Service Manual

Fig. 1

Cotterless Gear Crank Removing/Fastening Tool

Fig. 3

Chain

Crank Cap

Fig. 2

Wrench

Cotterless Gear Crank Removing/Fastening Tool

Fig. 4

Page 47

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-8

àAssembling the Gear Crank (Crank)

1. Mount the gear crank (crank) to the crank shaft.

2. Securely fasten the crank nut by using a socket wrench (or by a cotterless gear crank removing/fastening tool and a wrench). (Figs. 1 & 2)

* Respective cranks should be positioned each other to from

3. Fasten the crank cap by using a coin, etc. (Fig. 4)

4. The chain should be first set on the free wheel, and then on the upper part of the large gear. A forward rotation of the crank will enable the complete setting of the gear. (Fig. 5)

5. Adjust the tension of chain. Loosen the workload fixing screw [two screws at each right and left side (Fig. 6)], and adjust the tension while sliding the workload unit. The tension of chain should be adjusted as illustrated in Fig. 7.

* Be careful not to give excessive tensioning to the chain.

6. Adjust the clearance between the magnet mounted on the large gear and the CDC sensor, and also adjust the positions of the indication lines, by referring to Item (5) Section ES-5 "Replacing the CDC Sensor."

7. Provisionally turn on the power, and check if the pedal cadence is displayed on the control unit.

8. Assemble the frame cover by referring to the Sections D-1 & D2 "Removing the Frame Covers."

Replacing the Crank Set (2)

an angle of 180° against the gear.(Fig.3)

Wrench

Cotterless Gear Crank Removing/Fastening Tool

Fig. 1

Coin

Crank Cap

Fig. 4

Wrench

Cotterless Gear Crank Removing/Fastening Tool

Fig. 2

Fig. 5

Right-Side Crank

Left-Side Crank

Fig. 3

Upper Part of Large Gear

Chain

Workload Unit Fixing Screw

Fig. 6

Approx. 3 to 7mm of Slack

Replacing the Crank Set (2)

Fig. 7

MS-8

Cateye Ergociser Series 1000 Service Manual

Page 48

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-9

àREMOVAL

1. Remove the frame cover, by referring to the Sections D-1 & D2 "Removing the Frame Covers."

2. Remove the gear crank/crank from the crank shaft(BB axle), by referring to the Section MS-8 "Replacing the Crank Set."

3. Remove the BB cup locking with a hanger rotating jig. (Fig. 1)

4. Remove the BB adjusting cup, by using a pin face wrench. (Fig. 2)

5. Remove the crank shaft(BB axle).

6. Remove the BB fixing cup, by using the hanger rotating jig. (Fig. 3) The CDC sensor metal base will be removed at the same time.

àASSEMBLING

1. Check if no retainer remains within the hanger, and mount the BB fixing cup. Be sure that the CDC sensor metal base should first be mounted before mounting the BB fixing cup.

2. Assemble the crank shaft(BB axle), retainer, BB fixing cup, BB adjusting cup, BB cup locking and CDC sensor metal base as depicted in Fig. 4.

3. Mount the gear crank/crank, by referring to Mounting Items (1) thru (5), Section-MS-8 "Replacing the Crank Set." Also, adjust the tension of the chain.

4. Adjust the following:

1. Align the line on the CDC sensor with the center of the line

2. Adjust the clearance between the CDC sensor surface and

* When the specified clearance has not been established,

5. Provisionally turn on the power, and check if the pedal cadence is displayed on the control unit.

6. Assemble the frame cover, by referring to the Sections D-1 & D-2 "Removing the Frame Covers."

Replacing the BB Set

on the magnet. (Fig. 5)

the magnet surface to be approx. 2mm. (Fig. 6)

bend the metal base to have the clearance.

EC-1200 & EC-1600

Hanger Rotating Jig

Fig. 1

CDC Sensor Metal Base BB fixing cup

Retainer

BB Set

BB cup locking

Fig. 2

Retainer

BB adjusting cup

EC-3600 & EC-3700

BB adjusting cup

Pin Face Wrench

CDC Magnet

Line

BB fixing cup

Fig. 3

BB Set

Hanger Rotating Jig

CDC Sensor Metal Base

Approx. 2mm Clearance between CDC Sensor and Magnet

CDC Sensor

CDC Magnet

Replacing the BB Set

MS-9

Cateye Ergociser Series 1000 Service Manual

Fig. 4

Crank Shaft (BB axle)

Hanger Pipe

BB cup locking

Fig. 5

Center

CDC Sensor

Fig. 6

Line

Center

Page 49

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-10

àREMOVAL

1. Remove the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type."

2. Remove the lock nut located at the side of the frame, and then remove the adjust screw. (Fig. 1)

3. Pull out the spacer spring. (Fig. 1)

4. The post spacer can be pulled out upward while the boss at the side of the post is being pressed in with a screwdriver (for both right and left sides). (Fig. 2)

àASSEMBLING

1. Insert a brandnew post spacer.

2. Insert the spacer spring, and slightly fasten the adjust screw. (Fig. 3)

3. Insert the seat post (handleber post), and adjust the adjust screw so that the post will drop slowly.

4. Fasten the lock nut to lock the adjust screw.

5. Assemble the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type."

Replacing the Post Spacer

Fig. 1

Lock Nut

Spacer Spring

Adjust Screw

Lock Nut

Adjust Screw

Post Spacer

Boss

Press in.

Fig. 2

Fig. 3

Replacing the Post Spacer

MS-10

Cateye Ergociser Series 1000 Service Manual

Page 50

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-11

1. Remove the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type."

2. Slightly loosen the lock nut at the side of the frame. (Fig. 1)

3. Fasten the adjust screw so that the seat post (handleber post) will drop slowly.

4. Fasten the lock nut to fix the adjust screw.

5. Assemble the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type."

Adjusting the Spacer Spring

Lock Nut

Adjust Screw

Fig. 1

Adjusting the Spacer Spring

MS-11

Cateye Ergociser Series 1000 Service Manual

Page 51

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-12

àREMOVAL

1. Slide the seat pipe to the utmost back end, and set it at a position where the screw head can bee seen through the hole on the top surface of the seat pipe.

2. Remove the stopper screw. (Fig. 1)

3.Pull out the seat pipe and the inner pipe spacer A, while depressing the two bosses, located at the right and left sides of the seat pipe, at the same time. (Fig. 2)

4. Remove the spacer B at the end of the inner pipe. (Fig. 3)

àASSEMBLING

1. Set a brandnew inner pipe spacer B into the seat pipe. (Fig. 4)

2. Insert the inner pipe spacer A and B together into the seat pipe.

3. Align the hole on the top surface of the seat pipe with the screw hole, and apply the stopper screw. (Fig. 1)

Replacing the Inner Pipe Spacer

Stopper Screw

Seat Pipe

Fig. 1

Inner Pipe Spacer B

Inner Pipe Spacer A

Inner Pipe

Pull out.

Inner Pipe

Boss

Fig. 2

Inner Pipe Spacer A

Inner Pipe Spacer B

Insert.

Fig. 3

Seat Pipe

Inner Pipe

Fig. 4

Replacing the Inner Pipe Spacer

Cateye Ergociser Series 1000 Service Manual

MS-12

Page 52

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-13

1. Remove the seat hite lock knob, and pull out the rear support pipe.(Fig. 1)

2. Remove the rear support pipe spacer at the rear support pipe insertion area on the top surface of the seat pipe. The rear support pipe spacer is fixed on the pipe with an adhesive tape.

3. Apply and set a brandnew rear support pipe spacer with an adhesive tape.(Fig. 2)

4. Insert the rear support pipe, and fix it with the seat hite lock knob.

Replacing the Vertical Pipe Spacer

Seat Hite Lock Knob

Fig.1

Rear Support Pipe

Rear Support Pipe Insertion Area

Rear Support Pipe Spacer

Fig.2

Replacing the Vertical Pipe Spacer

MS-13

Cateye Ergociser Series 1000 Service Manual

Page 53

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-14

àREMOVAL

1. Remove the leg pipe from the main body. Also, remove the levelling knob. (Fig. 1)

2. Apply a screwdriver or the like to the damaged leg cover, and knock the cover off, paying attention not to damage the caster. (Fig. 2)

àASSEMBLING

1. Set the legcover onto the leg, and hammer it in. The use of a wood block is recommended as a buffer. (Fig. 2)

* A direct hammering of the leg cover may damage the

2. Mount the levelling knob and assemble it to the frame.

Replacing the Leg Cover

legcover.

Levelling Knob

Fig. 1

Leg Cover

Screwdriver

Fig. 2

Fig. 3

Leg Cover

Replacing the Leg Cover

MS-14

Cateye Ergociser Series 1000 Service Manual

Page 54

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-15

1. Loosen the screw and remove the front leg with casters (rear leg with level adjuster) from the main unit (leg).

2. The caster (level adjuster) has been press-fitted into the front leg with casters (rear leg with level adjuster). It can be removed by hammering it through a wooden block. (Fig. 1)

3. Press fit a brandnew caster (level adjuster) with a hammer and a wood block. (Fig. 2)

4. Mount the front leg with casters (rear leg with level adjuster) to the main unit (leg).

Replacing the Caster and Level Adjuster

Front Leg with Casters (Rear Leg with Level Adjuster)

Wood Block

Fig. 1

Caster (Level Adjuster)

Wood Block

Front Leg with Casters (Rear Leg with Level Adjuster)

Fig. 2

Replacing the Caster and Level Adjuster

MS-15

Cateye Ergociser Series 1000 Service Manual

Page 55

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-16

1. Pull out the seat post.

2.Remove the seat post knob by rotating and loosening the guide screw in the counter-clockwise direction.

3. Mount a brandnew seat post knob by securely tightening the guide screw.

4. Insert the seat post.

Replacing the Seat Post Knob

Knob Rubber Base

Seat Post Knob

Guide Screw

Fig. 1

Cateye Ergociser Series 1000 Service Manual

Replacing the Seat Post Knob

MS-16

Page 56

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-17

1. Remove the lock pin by rotating and loosening the guide screw in the counter-clockwise direction.

2. Mount a brandnew lock pin by securely tightening the guide screw.

Replacing the Lock Pin

Lock Pin

Wrench

Guide Screw

Fig. 1

Replacing the Lock Pin

MS-17

Cateye Ergociser Series 1000 Service Manual

Page 57

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-18

àREMOVAL

1. Remove both right and left pedals. (Fig. 1)

2.Loosen and remove the fixing screw on the surface of the crank cover. The narrow-width area of the crank cover should position in between the frame cover and the crank. (Figs 2 & 3)

àASSEMBLING

1. Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws. (Figs. 2 & 3)

2. Set the right and left pedals.

Replacing the Crank Cover

Fig. 1

Recumbent Type

No.15 Wrench

Crank

Pedal

Upright Type

Crank Cover

Fig. 2

OFF

Crank Cover

Fig. 3

Replacing the Crank Cover

Cateye Ergociser Series 1000 Service Manual

MS-19

Page 58

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-19

1. Loosen the four screws on the bottom of the control unit, remove the control unit, and then detach the cable connector. (Fig. 1)

2. For EC-1600, slide the inner pipe of the handlebar post cover upward, and detach the 5P cable connector (Fig. 2). For EC1200, remove the cable holder from the handlebar post.

3. Loosen the handlebar post knob, and pull out the handlebar post from the main unit. (Fig. 3)

4. Pull the seat post knob upward, and pull out the seat post from the main unit. (Fig. 4)

5. Loosen and remove the guide screw of the seat post knob. (Fig. 5)

6. Remove the rubber base of the seat post knob. (Fig. 6)

7. Slightly loosen the center cover fixing screws (6 pieces), and remove the center cover by pulling it upward. (Fig. 7)

8.The assembling of the center cover can be made in the procedures opposite to the above.

Replacing the Center Cover of Upright Type

Fig. 1

5P Cable

Fig. 2

Seat Post Knob

Handlebar Post

Handlebar Post Cover

Handlebar Post Knob

Fig. 3

Replacing the Center Cover of Upright Type

Seat Post Knob

Fig. 4

Center Cover

Center Cover Fixing Screws

Seat Post

Fig. 5

Guide Screw

Rubber Base

Fig. 6

MS-19

Cateye Ergociser Series 1000 Service Manual

Fig. 7

Page 59

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-20

* Remove the pulse rate sensor, if it is connected, before

proceeding to the following procedures.

1. Remove the control unit fixing screws (4 pieces) from the main unit. (Fig. 1)

2. Detach the cable connector from the control unit. (Fig. 2)

3. Loosen and remove the inner pipe from the joint metal base. (Fig. 3)

4. Remove the frame cover fixing screws, and the frame cover will be separated into right and left parts. (Fig. 4)

5. Remove the latch of the center cover from the frame cover, and pull the center cover toward the joint metal base to remove it. (Fig. 5)

6. Assembling of the center cover can be performed in reversed procedure of the above.

* Pull the 5P cable connector out of the center cover through

Replacing the Center Cover of Recumbent Type

the hole on the cover, and tentatively hold it with an adhesive tape so that it may not be retracted.

Control Unit

Fig. 1

Frame Cover Fixing Screw

Control Unit Fixing Screw

Fig. 2

Inner Pipe

Joint Metal Base

5P Cable

Fig. 3

Frame Cover

Fig. 4

Fig. 5

Center Cover

3600

Joint

Replacing the Center Cover of Recumbent Type

Cateye Ergociser Series 1000 Service Manual

MS-20

Page 60

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-21

1. In case the handlebar grip is damaged, cut the grip with a thin cutting knife and peel it off the handlebar.(Fig. 1)

2. Fit a brandnew handlebar grip onto the handlebar, utilizing compressed air from a compressor, etc. Press the grip into the handlebar while applying compressed air at one end.(Fig. 2)

* When a compressor is not available, apply a soap water on

* When the above replacing work is difficult to achieve,

Replacing the Handlebar Grip

the handlebar, and insert the grip while twisting and pressing the grip.

remove the handlebar before the work.

Fig.1

Brandnew Grip

Air Gun,etc

Handlebar

Existing Grip(Old)

Fig.2

Replacing the Handlebar Grip

MS-21

Cateye Ergociser Series 1000 Service Manual

Page 61

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-22

1.See the Items (1 &2), Section ES-6 "Replacing the Panel Keyboard."

2. Detach the existing printer cover, and mount the brandnew printer cover.

3.See the Item (8 & 9), Section ES-6 "Replacing the Panel Keyboard."

Replacing the Printer Cover

Printer Cover

Upper Body of Control Unit

Fig.1

Cateye Ergociser Series 1000 Service Manual

Replacing the Printer Cover

MS-22

Page 62

Applicable Models:

EC-1200 EC-1600 EC-3600 EC-3700

MS-23

1. See the Items (1 &2), Section ES-6 "Replacing the Panel Keyboard."

2. Loosen and remove four screws. Also, remove the spring. (Fig. 1)

3. Remove the existing printer cutter, and mount a brandnew paper cutter.

4. Set the spring so that it will fit into the groove of the paper cutter, and fix it with four screws.

5. See the Item (8 & 9), Section ES-6 "Replacing the Panel Keyboard."

Replacing the Paper Cutter

Paper Cutter

Screws

Spring

Fig. 1

Replacing the Paper Cutter

MS-23

Cateye Ergociser Series 1000 Service Manual

Page 63

Applicable Models

ADVANCEMODE

SOUND ON/OFF

VALUE ADJUST

EC-1200 EC-1600 EC-3600 EC-3700

PNR.780-6101 EC-1200 Control Unit(E) Ivory PNR.780-6102 EC-1200 Control Unit(G) Ivory PNR.780-6106 EC-1200 Control Unit(E) Black PNR.780-6107 EC-1200 Control Unit(G) Black unit: pieces

PNR.781-5901 EC-3700 Control Unit(E) Ivory PNR.781-5902 EC-3700 Control Unit(G) Ivory PNR.781-5916 EC-3700 Control Unit(E) Black PNR.781-5917 EC-3700 Control Unit(G) Black unit: pieces

PNR.780-6108 EC-1200 Control Unit Multi Ivory PNR.780-6109 EC-1200 Control Unit Multi Black unit: pieces

MODE

RESET

10 1

ADV

PNR.780-5160 EC-1600/3700 Panel Keybord unit: sets

PNR.780-6501 EC-1600 Control Unit(E) Ivory PNR.780-6502 EC-1600 Control Unit(G) Ivory PNR.780-6506 EC-1600 Control Unit(E) Black PNR.780-6507 EC-1600 Control Unit(G) Black unit: pieces

PNR.780-6120 EC-1200 Button Panel(E) PNR.780-6121 EC-1200 Button Panel(G) unit: sets

PNR.781-5601 EC-3600 Control Unit(E) Ivory PNR.781-5602 EC-3600 Control Unit(G) Ivory PNR.781-5606 EC-3600 Control Unit(E) Black PNR.781-5607 EC-3600 Control Unit(G) Black unit: pieces

VALUE ADJUST

SOUND ON/OFF

ADVANCEMODE

PNR.781-5611 EC-3600 Button Panel(E) PNR.781-5610 EC-3600 Button Panel(G) unit: sets

PNR.000-0000 EC-1200 Decal(E) PNR.000-0000 EC-1200 Decal(G) PNR.000-0000 EC-1200 Decal(F) unit: sets

PNR.000-0000 EC-3700 Unit Base unit: pieces

EC-1200

EC-1600

PNR.000-0000 EC-1600 Decal(E) PNR.000-0000 EC-1600 Decal(G) PNR.000-0000 EC-1600 Decal(F) unit: sets

PNR.722-6502 Thermal Paper(E) unit: sets

EC-1200

PNR.000-0000 EC-3600 Decal(E) PNR.000-0000 EC-3600 Decal(G) PNR.000-0000 EC-3600 Decal(F) unit: sets

PNR.736-6000 EC-1600/3700 Printer Unit unit: sets

EC-3700

PNR.000-0000 EC-3700 Decal(E) PNR.000-0000 EC-3700 Decal(G) PNR.000-0000 EC-3700 Decal(F) unit: sets

List of Genuin Parts

PNR.780-5111 EC-1600/3700 Printer Cover unit: pieces

Cateye Ergociser Series 1000 Service Manual

Page 64

Applicable Models

EC-1200 EC-1600 EC-3600 EC-3700

PNR.780-1031 EC-1600/3700 Paper Cutter unit: pieces

PNR.780-1110 Pluse Sensor Cover Set unit: sets

PNR.703-3101 EC-3600/3700 Recumbent Seat unit: sets

PNR.780-1020 Paper Case unit: pieces

PNR.780-1200 Sensor Clip unit: pieces

PNR.724-3410 EC-1200 Handlebar PNR.780-6450 EC-1600 Handlebar unit: pieces

PNR.780-1030 Paper Roller unit: pieces

PNR.737-5500 AC Adepter J (100V) PNR.737-5511 AC Adepter UL (120V) PNR.737-5520 AC Adepter EC (220V) PNR.737-5523 AC Adepter UK (240V) unit: sets

PNR.781-9000 Sporty Handlebar Set (HB-100) unit: pieces

PNR.780-1100 EC-1200/1600 Pluse Sensor Set (1M) PNR.780-1102 EC-1200/1600 Pluse Sensor Set (1.5M) PNR.780-1101 EC-3600/3700 Pluse Sensor Set (2M) unit: sets

PNR.781-9100 Saddle (SMP1209) unitsets

PNR.781-5130 EC-3600/3700 Handlebar unit: pieces

PNR.725-0000 EC-1200 Handlebar Grip PNR.780-6470 EC-1600 Handlebar Grip PNR.781-5060 EC-3600/3700 Handlebar Grip unit: pieces

List of Genuin Parts

PNR.758-5000 EC-1200/1600 Hadlebar Lever Set unit: sets

Cateye Ergociser Series 1000 Service Manual

PNR.781-3200 Handlebar Cap unit: pieces

PNR.780-6170 EC-1200/1600 Hadlebar Stem unit: sets

PNR.781-0210 EC-1200/1600 Hadlebar Post unit: pieces

PNR.785-1416 Adjusting Knob/Seat Hite Lock Knob unit: pieces

PNR.780-6430 EC-1600 Hadlebar Post Cover Set unit: sets

PNR.780-6190 EC-1200/1600 Seat Post unit: pieces

Page 65

Applicable Models

EC-1200 EC-1600 EC-3600 EC-3700

PNR.780-6050 EC-1200/1600 Post Spacer Set unit: sets

PNR.781-5120 EC-3600/3700 Lock Pin unit: pieces

PNR.780-6010 EC-1200/1600 Center Cover unit: pieces

PNR.780-9610 EC-1200/1600 Seat Pillar unit: pieces

PNR.780-6040 EC-1200/1600 Rubber Base for Knob unit: pieces

PNR.781-5500 EC-3600/3700 Center Cover unit: pieces

PNR.780-6260 EC-1200 New Seat Pillar unit: pieces

PNR.780-6000 EC-1200/1600 Frame Cover(L/R) Ivory PNR.780-6001 EC-1200/1600 Frame Cover(L/R) Black unit: sets

EC-12

0 0 2

C E

PNR.780-6020 EC-1200 Crank Cover(L,R)Set unit: sets

PNR.785-1417 EC-1200/1600 Seat Post Knob unit: pieces

PNR.781-5000 EC-3600/3700 Frame Cover(L/R) Ivory PNR.781-5001 EC-3600/3700 Frame Cover(L/R) Black unit: sets

0 0

C-1

600

EC-1

PNR.780-6420 EC-1600 Crank Cover(L,R)Set unit: sets

EC-3600

PNR.781-5520 EC-3600 Crank Cover(L,R)Set unit: sets

PNR.780-6160 EC-1200/1600 Rear Leg with Level Adjuster unit: pieces

EC-3700

PNR.781-5810 EC-3700 Crank Cover(L,R)Set unit: sets

PNR.780-6160 EC-1200/1600 Mod. Rear Leg unit: pieces

PNR.781-5100 Pedal(L,R) unit: sets

PNR.780-0140 EC-1200/1600 Leveler Set unit: sets

PNR.781-9300 Pedal Belt E-16 (L,R) unit: sets

List of Genuin Parts

PNR.724-3950 EC-1200/1600 Levelling Knob unit: pieces

Cateye Ergociser Series 1000 Service Manual

Page 66

Applicable Models

EC-1200 EC-1600 EC-3600 EC-3700

PNR.780-6180 EC-1200/1600 Caster Pipe Set unit: sets

PNR.786-2409 EC-3600/3700 Rear Leg with Level

Adjuster

unit: pieces

PNR.781-5030 EC-3600/3700 Pipe Spacer Set unit: sets

PNR.780-6550 EC-1600 Vibration-proof Rubber unit: pieces

PNR.781-0140 EC-3600/3700 Leveler Set unit: pieces

PNR.781-5040 EC3600/3700 Rear Support Pipe

Spacer Set

unit: sets

PNR.780-6445 EC-1200/EC-1600 Front Leg with unit: sets

PNR.787-2409 EC-3600/3700 Caster Pipe Set unit: pieces

PNR.780-2000 EC-1200 Workload Unit PNR.780-6310 PNR.781-5580 unit: pieces

Cover Set

EC-1600/1200G Workload Unit (w/Flywheel) EC-3600/3700 Workload Unit (w/Flywheel)

PNR.780-6446 EC-1200/EC-1600 Rear Leg with

Cover Set

unit: sets

PNR.781-0150 EC-3600/3700 Caster Set unit: pieces

PNR.780-2240 Freewheel Set unit: sets

PNR.724-4802 Crank Cap unit: sets

List of Genuin Parts

PNR.720-1110 Derailleur Spring unit: set

Cateye Ergociser Series 1000 Service Manual

PNR.718-0450 EC-1200/1600 Workload Unit

Reinforcing Metal Base

unit: pieces

PNR.780-2220 Idler Set unit: sets

PNR.781-5580 EC-3600/3700 Workload Unit

Reinforcing Metal Base

unit: pieces

PNR.720-1110 Idler Spring unit: pieces

PNR.780-2200 Derailleur Set unit: set

PNR.780-2240 Freewheel Set unit: sets

Page 67

Applicable Models

EC-1200 EC-1600 EC-3600 EC-3700

PNR.780-6230 EC-1200/1600 Chain PNR.781-5570 EC-3600/3700 Chain unit: pieces

PNR.780-6241 EC-3600/3700 Inlet Metal Base unit: sets

PNR.781-5550 EC-3600/3700 5PCable unit: sets

PNR.781-9200 Cartridge BB (YST-986A) unit: sets

PNR.780-6030 EC-1200/1600 Inlet Cover unit: sets

PNR.780-6241 CDC Sensor Set unit: sets

PNR.780-6250 Crank Set unit: sets

PNR.780-6220 EC-1200 5PCable unit: sets

PNR.780-6210 Power Supply Board unit: sets

PNR.780-6240 EC-1200/1600 Inlet Metal Base unit: sets

PNR.780-6480 EC-1600 5PCable (Upper) PNR.780-6481 EC-1600 5PCable (Lower) unit: sets

PNR.729-5010 Cable Clip Small(CV200) unit: pieces

PNR.729-5025 Cable Clip Large(CV250) unit: pieces

PNR.718-5140 EC-1200 Cable Holder unit: pieces

PNR.722-4950 Date Card unit: sets

PNR.701-6701 Wireless Heart Rate Senaor Kit (TM-

1000)

unit: sets

I N

5 V

U T

I N

-1

DF-231

List of Genuin Parts

PNR.701-6801 Wireless Heart Rate Receiving Circuit unit: sets

PNR.000-0000 Wireless Heart Rate Senaor unit: sets

PNR.000-0000 HR Senaor Belt unit: sets

PNR.701-5701 RS232C Communication Kit PNR.701-5703 RS232C Communication Kit (220V) unit: sets

Cateye Ergociser Series 1000 Service Manual

Page 68

Applicable Models

Belt Drive

EC-1200B EC-1600B EC-3600B EC-3700B

PNR.780-7050 EC-1600B/1200B Workload Unit PNR.781-5581 EC-3700B/3600B Workload Unit unit: pieces

PNR.780-6990 Pulley 1-A Set unit: sets

PNR.780-7030 Idler A Set unit: sets

PNR.780-7020 Pulley 2-A Set unit: sets

PNR.780-7040 Idler Spring A unit: pieces

PNR.780-7000 Pulley Flange unit: pieces

PNR.780-7010 Pulley 1-B unit: pieces

PNR.724-1021 EC-1600B/1200B Teethed Timing Belt

(P8M15-1192)

PNR.724-1022 EC-3700B/3600B Teethed Timing Belt

(P8M15-1080)

unit: pieces

List of Genuin Parts (Belt Drive)

Cateye Ergociser Series 1000 Service Manual

Page 69

Applicable Models

EC-1200 EC-1600 EC-3600 EC-3700

PNR.752-1085 Hexagon Nut M8-3 unit: pieces

PNR.752-1063 Hexagon Nut M6-3 unit: pieces

PNR.723-2080 Thrust Washer 9x15.5x0.25 unit: pieces

PNR.753-5410 Screw Set M6x12 unit: pieces

4567

PNR.750-9616 Screw Set(+) M6x16 unit: pieces

PNR.756-1412 Tapping Screw 4x12 with Washer unit: pieces

PNR.750-1390 Spacer Spring unit: pieces

PNR.724-4803 Crank Nut M10x1.25 unit: pieces

PNR.750-8616 Cross-recessed Head Hexagon Screw

M6x16

unit: pieces

PNR.751-5208 Tapping Screw(2) 2x8 unit: pieces

PNR.750-6810 Seat Post Adjust Screw M8x10 unit: pieces

PNR.751-5206 Tapping Screw(2) 2x6 unit: pieces

PNR.753-6412 Tapping Screw(2) 4x12C unit: pieces

PNR.752-5600 SW Nut M6 unit: pieces

PNR.751-5330 Tapping Screw(2) 3x30 unit: pieces

List of Genuin Parts

Cateye Ergociser Series 1000 Service Manual

Page 70

Applicable Models

EC-1200 EC-1600 EC-3600 EC-3700

PNR.780-6350 EC-1200/1600 Tool Kit unit: sets

PNR.758-1010 Freewheel Set Removing Tool unit: sets

PNR.780-6111 EC-1200 Operating Instructions E PNR.780-6112 EC-1200 Operating Instructions G PNR.780-6113 EC-1200 Operating Instructions F unit: sets

PNR.781-5180 EC-3600/3700 Tool Kit unit: sets

PNR.758-1080 Pin Face Wrench unit: sets

PNR.780-6511 EC-1600 Operating Instructions E PNR.780-6512 EC-1600 Operating Instructions G PNR.780-6513 EC-1600 Operating Instructions F unit: sets

PNR.758-1000 Cotterless Gear Crank Removing /

Fastening Tool

unit: sets

PNR.737-7000 Tester unit: sets

PNR.781-5701 EC-3600 Operating Instructions E PNR.781-5702 EC-3600 Operating Instructions G PNR.781-5703 EC-3600 Operating Instructions F unit: sets

PNR.781-9210 Cartridge BB Removing Tool unit: sets

PNR.747-8000 Coil Current Measuring Cable unit: sets

PNR.781-5991 EC-3700 Operating Instructions E PNR.781-5992 EC-3700 Operating Instructions G PNR.781-5993 EC-3700 Operating Instructions F unit: sets

List of Genuin Parts

Cateye Ergociser Series 1000 Service Manual

Page 71

2-8-25, Kuwazu, Higashi Sumiyoshi-ku, OSAKA, 546-0041 JAPAN

TEL: 81-6-6719-2631 FAX: 81-6-6719-2363

ECSM1E-991007-PDF

.,LTD.

Cateye EC-3700, EC-3600 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual