Cateye EC-3700, EC-3600 User Manual
CATEYE ERGOCISER
AUTOMATIC TYPE
Applicable Models: EC-1200/EC-1600/EC-3600/EC-3700
SERVICE MANUAL
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
2
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
T
E
S
E
R
E
D
O
M
V
D
A
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
00
7
R
EC-3
How to Use This Service Manual
Cateye Ergociser Series 1000 Service Manual
3
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
9
Spacer Spring
6
Crank Cap
BB Set
Post Spacer
Lock Nut
Adjust Screw
9
Spacer Spring
6
Seat Pipe
Timing Belt
Inlet Metal Base
Power Switch
Copper Plate
Idler
Idler Fixing Bolt [M6x16]
8
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
4
q
Power Supply Board
Power Supply Board Fixing Screw
0
[Tapping Screw(2) 4x12c]
SW Nut (M6)
Workload Unit
Solenoid Coil Mounting Base
Solenoid Coil
Plastic Pulley
Workload Unit Mounting Base
4
[Screw Set (+) (M6x16)]
Wiring within Frame
Levelling Knob
Cable Holder
Frame Cover
Crank Cover
Handlebar Post
Seat Post
Center Cover
EC-1200
Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
5
Tapping Screw (4x12) with Washer
Inlet Metal Base
AC Adapter Inlet
Chain
Workload Unit Reinforcing Metal Base Nut
2
Workload Unit Reinforcing Metal Base
Hexagon Nut (M8-3)
1
Derailleur Spring
Leg Pipe Fixing Screw
Leg Pipe
Lever Cover
Levelling Knob
4
Free Wheel Set
Hexagon Head U Nut
Workload Unit
Fixing Bolt
Derailleur Mounting Bolt
Thrust Washer (9x15.5x0.25)
3
Derailleur
Solenoid Coil
Crank Nut
9
Power Supply Board
4
Screw Set(+) (M6x16)
Name of Parts for Upright Type (w/o Flywheel)
Cateye Ergociser Series 1000 Service Manual
5
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
9
Adjust Screw [M8x10]
Spacer Spring
6
Seat Pipe
Flywheel Metal
Flywheel Fixing Screw [SW Nut(M6)]
q
Flywheel Metal Base Fixing Screw
4
[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
6
SW Nut (M6)
q
0
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
4
[Screw Set (+) (M6x16)]
Idler Mounting Bolt [M6x16]
4
Idler Metal Base
Idler Spring
Timing Belt
Wiring within Frame
Leg Pipe
Levelling Knob
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
2
[Hexagon Nut (M6-3)]
Workload Unit Reinforcing Metal Base
Hexagon Nut (M8-3)
1
Hexagon Head U Nut
Free Wheel Set
Derailleur
Spring
Workload Unit
Workload Unit Mounting
4
Bolt (M6x16)
Derailleur
Solenoid Coil
Derailleur Mounting Bolt
Thrust Washer (9x15.5x0.25)
3
Crank Nut (M10x1.25)
7
5
Screw Set(+) (M6x16)
4
Tapping Screw (4x12) with Washer
Name of Parts for Upright Type (w/ Flywheel)
Cateye Ergociser Series 1000 Service Manual
7
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
4
Flywheel
Flywheel Fixing Screw
q
Flywheel Metal Base
Plain Belt
Power Supply Board Fixing Bolt
0
Power Supply Board
7
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
8
Idler Spring
Frame Cover
Center Cover
Crank Cover
R
Name of Parts for Recumbent Type
Cateye Ergociser Series 1000 Service Manual
8
Inner Pipe
Seat Pipe
Rear Support Pipe
Leg Pipe Fixing Screw
Solenoid Coil
Mounting Base
Solenoid Coil
4
Workload Unit Mounting Base [Screw Set (+) (M6x16)]
Plastic Pulley
Workload Unit
Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Cable Holder
Chain
CDC Sensor
Screw Set (+) [M6x16]
4
Workload Unit Reinforcing Nut
2
Workload Unit Reinforcing Metal Base
Workload Unit
Solenoid Coil
Power Supply Board
CDC Magnet
Cable Holder
Flywheel
Plain Belt
Flywheel Fixing Screw
q
Flywheel Metal Base Fixing Screw
4
O
N
O
F
F
Inlet Metal Base
Free Wheel Set
Hexagon Head U Nut
Workload Unit Mounting Base
4
[Screw Set (+) (M6x16)]
Derailleur
3
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
9
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
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
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
+ –
C1
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
R1
C2
–
+
TR2
–
+
R8
TR1
DC Connector
R2
R3
R7
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
10
Coil
Electromagnet
Metal Pulley
Timing Belt
Copper Disk Plate
Plastic Pulley
Chain
Free Wheel
D1
Cadence Sensor
Large Gear
Pedal
Magnet
Crank
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
11
No Display on Control Unit after Power ON. (1)
T-1
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
12
Fig. 5
Fig. 6
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.
2)
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
5
4
3
2
1
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
13
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.
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
14
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)
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
10 1
TIME
MODE
ADV
Back of Control Unit
123
Select Switch
ON
4
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
15
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.")
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
16
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.
2)
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
17
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
18
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
19
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
20
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
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