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CATEYE ERGOCISER MANUAL LOAD-CHANGE TYPE Applicable Models: EC-3200/EC-3500 SERVICE MANUAL Applicable Models EC-3200 EC-3500 INDEX INTRODUCTION • How to Use This Service Manual -------------------------------------------------------------------------------------------------------------------------------------------------- 3 • Name of Parts 1.(EC-3200) Upright Type --------------------------------------------------------------------------------------------------------------------------------------------------------- 4 2.(EC-3500) Recumbent Type --------------------------------------------------------------------------------------------------------------------------------------------------- 6 3.(EC-3200B) Belt Drive Type --------------------------------------------------------------------------------------------------------------------------------------------- ADD-1 • Circuit Diagram ------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 8 PART A Symptoms and Cause of Problems ----------------------------------------------------------------------------------------------------------------------------------------------- 9 PART B INDEX Repair and Adjustment Methods EC-3200 EC-3500 D-1 E-1 Removing the Frame Covers ----------------------------------------------------------------------------------------------------------- 11 Replacing the 7P Cable Set ------------------------------------------------------------------------------------------------------------- 12 E-2 E-3 Replacing the CDC Sensor -------------------------------------------------------------------------------------------------------------- 13 Replacing the Workload Sensor Set -------------------------------------------------------------------------------------------------- 14 E-4 M-1 Replacing the Button Panel ------------------------------------------------------------------------------------------------------------- 15 Replacing the Workload Unit ------------------------------------------------------------------------------------------------------------ 16 M-2 M-3 Replacing the Chain ----------------------------------------------------------------------------------------------------------------------- 18 Replacing the Belt and Pulley "B" Set ------------------------------------------------------------------------------------------------ 19 M-4 M-5 Replacing the Pulley "A" Set ------------------------------------------------------------------------------------------------------------ 20 Replacing the Idler Set ------------------------------------------------------------------------------------------------------------------- 21 M-6 M-7 Replacing the Crank Set ----------------------------------------------------------------------------------------------------------------- 22 Replacing the BB Set --------------------------------------------------------------------------------------------------------------------- 24 M-8 M-9 Replacing the Magnet Set --------------------------------------------------------------------------------------------------------------- 25 Replacing the Workload Shift Lever --------------------------------------------------------------------------------------------------- 26 - M-10 Replacing the Post Spacer -------------------------------------------------------------------------------------------------------------- 27 M-11 Adjusting the Spacer Spring ------------------------------------------------------------------------------------------------------------- 28 - M-12 Replacing the Inner Pipe Spacer ------------------------------------------------------------------------------------------------------- 29 M-13 Replacing the Vertical Pipe Spacer --------------------------------------------------------------------------------------------------- 30 - M-14 Replacing the Seat Post Knob ---------------------------------------------------------------------------------------------------------- 31 M-15 Replacing the Lock Pin ------------------------------------------------------------------------------------------------------------------- 32 - M-16 Replacing the Caster & Level Adjuster ----------------------------------------------------------------------------------------------- 33 M-17 Removing the EC-3200 Center Cover ------------------------------------------------------------------------------------------------ 34 M-18 Removing the EC-3500 Center Cover ------------------------------------------------------------------------------------------------ 35 M-19 Replacing the Handlebar Grip ---------------------------------------------------------------------------------------------------------- 36 PART C List of Genuin Parts -------------------------------------------------------------------------------------------------------------------------------------------------------------------- 37 Cateye Ergociser Series 3000 Service Manual 2 Applicable Models EC-3200 EC-3500 How to Use This Service Manual This service manual describes how to repair and adjust the Ergociser of manual loadchange type which utilizes a permanet magnet. 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. Part C lists up all genuin parts and corresponding part numbers that will be necessary for replacement or stock. Also, please refer to Operating Instructions which comes with the Cateye Ergociser. Whenever any problem has occurred on the unit, take the following actions to repair or adjust it. 1. Check and identify the cause by referring to Part A. 2. Identify the part name by referring to Name of Parts. How to Use This Service Manual 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. Cateye Ergociser Series 3000 Service Manual 3 Applicable Models EC-3200 Name of Parts Upright Type (EC-3200) Workload Shift Lever Pulley B Mounting Nut / S Washer 1q PostSpacer Idler Spring Post Spacer Spacer Spring Adjust Nut u o Handlebar Post Fixing Screw 8wt Plane Washer Frame Cable Holer (L) Copper Plate Crank Pulley B 7P Cable BB Set Crank Nut Cross-Recessed Head Hexagon Bolt r Magnet Set 2 Name of Parts (EC-3200) Upright Type Slit Plate Link Mounting Set 39w Slit Plate Link Set Cable Holder (L) 8wt i Workload Unit Aluminum Frame Rear Leg with Level Adjuster Cable Holder (S) Level Adjuster Pulley A Fixing Set 1q Workload Unit Fixing Bolt (4 pcs.) 8wt 2P Connector Connector Cover 7P Cable Connector Caster Pipe Caster Cateye Ergociser Series 3000 Service Manual 4 Workload Sensor Applicable Models EC-3200 Cable Holder Handlebar Post Seat Post Idler Workload Shift Lever Handlebar Post Fixing Screw Rubber Base Stopper Metal Plate Center Cover a Workload Shift Lever Fixing Bolt Set 0p 1 Crank Cover Frame Cover s Large Gear Frame Gear Crank Chain Joint Bar Crank Cap CDC Magnet 6ey Idler Fixing Screw 0 Name of Parts (EC-3200) Upright Type CDC Sensor Magnet Set Joint Free Wheel Magnet Mounting Base Pulley "A" Workload Frame Metal Leg Pipe Fixing Screw (4 pcs.) d f Workload Unit Reinforcing Metal Plate Timing Belt Cateye Ergociser Series 3000 Service Manual 5 Applicable Models EC-3500 Name of Parts Recumbent Type (EC-3500) 7P Cable Connector Workload Shift Lever Cable Holer (L) 7P Cable Crank BB Set Hanger Pipe Crank Nut Joint Fitting Workload Unit Fixing Bolts 8wt Cross-Recessed Head Hexagon Bolt r Cable Holder (L) Workload Unit Aluminum Frame Frame Name of Parts (EC-3500) Recumbent Type Idler Spring Pulley "A" Fixing Set 1q Pulley "B" Mounting Nut/Spring Washer 1q i Plane Washer 2P Connector Copper Plate Workload Sensor Pulley "B" 7P Connector Magnet Set Workload Unit Fixing Bolt (3 pcs.) 8wt Magnet Mounting Base Slit Board Link Set Slit Board Link Mounting Set 39w 2 Caster Pipe Caster Cateye Ergociser Series 3000 Service Manual 6 Applicable Models EC-3500 Stopper Metal Plate Workload Shift Lever Mounting Bolt Set 0p Workload Shift Lever Joint Bar Large Gear Chain Gear Crank CDC Sensor Crank Cap CDC Magnet Idler Mounting Screw 0 Idler Pulley "B" Frame Free Wheel 1 Pulley "A" Workload Frame Metal Plate Timing Belt Workload Unit Reinforcing Metal Plate Name of Parts (EC-3500) Recumbent Type 0p 6ey Magnet Set Joint Frame Cover Control Panel Cover Joint Bar Center Cover Crank Cover Leg Pipe Fixing Screw (2 pcs.) d Rear Support Pipe Inner Pipe Seat Pipe Cateye Ergociser Series 3000 Service Manual 7 Applicable Models EC-3200B Belt Drive Crank Pulley 1-A Teethed Timing Belt (PM8x15-896) Idler A Reinforcing Plate Name of Parts (EC-3200B) Belt Drive Type Idler B Set Pulley 1-B Idler A Set Pulley 2-A Cateye Ergociser Series 3000 Service Manual ADD-1 Pulley 2-B V-ribbed Belt (280-J6) Idler B Spring Applicable Models EC-3200 EC-3500 Cateye Ergociser Manual Load-Change Type Circuit Diagram Workload Sensor Circuit Board 2P Connector 7P Connector 7P Cable CN1 CN2 1 1 2 2 CDC Magnet CDC Signal 3 CDC Sensor 4 PH3 PH2 PH1 Slit Board 5 Common LED3 6 R3 LED2 R2 LED1 R1 LED Control 7 Circuit Diagram To Cont rol Unit Workload Level Position Signal Cateye Ergociser Series 3000 Service Manual 8 Applicable Models EC-3200 EC-3500 Symptom of Problem The display of Pedal Rotations, Current Speed and/ or Distance remains at zero (0). Check Method/Cause of Problem Remedy Possible causes include: 1) Faulty connections (at three points) 2) Defective control unit 3) Defective CDC sensor 4) Breakage of cable Check the cause as per the following procedures. Workload Shift Position Mark will not be displayed. Workload Shift Position Mark will not change. 1. Ensure if the 7P connector, which is on the back side of the control unit, is securely plugged. If a correct display is restored, the control unit will not be defective. However, ensure firm plugging of the connector. 2. Check if normal operation is restored when the 7P connector is plugged to a new control unit. If a correct display is restored, the control unit will be defective. 3. Remove the frame cover, and check if the two2P and 7P connectors are securely plugged to the workload sensor. If a correct display is restored, the control unit will not be defective, but the plugging of two connectors (2P) and (7P) are insufficient. 4. Disconnect the 2P connector from the workload sensor. Replace the control unit. The CDC sensor will be defective if the two terminals are Replace the CDC sensor. Refer to Section E-2 "Re- Place two probes of a multimeter across the two terminals of the 2P connector. Rotate the pedal and check if not conductive once per revolution of the pedal. placing the CDC Sensor." the two terminals are conductive. 7P cable will be broken if the two terminals are conductive once per revolution of the pedal. Replace the cable set. Refer to Section E-1 "Replacing the 7P Cable Set." Possible causes include: 1) Faulty connections (at three points) 2) Defective control unit Symptoms and Cause of Problems 1 3) Defective CDC sensor 4) Breakage of cable Check the cause as per the following procedures. 1. Ensure if the 7P connector, which is on the back side of the control unit, is securely plugged. 2. Check if normal operation is restored when the 7P connector is plugged to a new control unit. 3. Remove the frame cover, and check if the 7P connectors is securely plugged to the workload sensor. 4. Disconnect the 7P connector from the workload sensor. If a correct display is restored, the control unit will not be defective. However, ensure firm plugging of the connector. If a correct display is restored, the control unit will be defective. If a correct display is restored, the control unit will not be defective, but the plugging of the connector (7P) are insufficient. Place two probes of a multimeter across the end terminals If all the seven wires are found conductive, the of 7P connector to check the conductivity. * Place the probes at the connector slots of the same No. workload sensor will be defective. Replace the sensor. Refer to Section E-3 "Replacing the Workioad both across the large and small connectors. The cable will be broken if a specific wire of the cable shows no conductivity. The operation of workload shift lever will not result in correct display of the workload shift lever position. Cateye Ergociser Series 3000 Service Manual 9 The position of the workload sensor is incorrect. Replace the control unit. Sensor." Replace the cable set. Refer to Section E-1 "Replacing the 7P Cable Set." Adjust the position of the workload sensor. Refer to Section E-3 "Replacing the Workload Sensor Set." Applicable Models Symptom of Problem Check Method/Cause of Problem An "All Clear" operation will not rectify abnormal displays. The control unit will be defective. The pulse rate reading remains at zero (0), and it Follow the section "Checking the Pulse Sensor" When the check revealed any breakage or damage of does not count. in the Operating Instructions to check if the pulse sensor works correctly. wires, the pulse sensor is defective. No workload. EC-3200 EC-3500 Remedy Replace the control unit. In case the pulse sensor is normal, the control unit will be defective. Replace the pulse sensor. Replace the control unit. Remove the frame cover, and check the following points. Refer to Section D-1 "Removing the Frame Cover." 1. Check if there are any problems with the chain. Replace the chain if it is broken. Refer to the Section M-2 "Replacing the Chain." 2. Check if the free wheel is idle-running. *Rotate the pedal, and check if the belt rotates. Replace the pulley "A" set if the free wheel is idle-running. Refer to the Section M-4 "Replacing the Pulley "A" Set." 3. Check if there are any problems with the belt. Replace the belt if it is broken or worn out. Refer to the Section M-3 "Replacing the Belt and Pulley "B" Set." 4. Check if the pulleys are damaged. Replace the pulley "A" set if it is broken or worn out. Refer to the Section M-4 "Replacing the Pulley "A" Set." Replace the pulley "B" set if it is broken or worn out. Refer to the Section M-3 "Replacing the Belt and Pulley "B" Set." Seat post slips down abruptly. Incorrect adjustment of the spacer spring. Adjust the spacer spring. Refer to the Section M-11 "Adjusting Abnormal sounds in the unit. The operating noise (continuous) has become larger. Lack of chain lubrication. Grease the chain. Greasing of the inner surface of the belt (mading surface with the pulley) will also contribute to reduce the noise level. Refer to the Section D-1 "Removing the Frame Cover." Noise occurs periodically. Incorrect tensioning of the chain. Adjust and set the tensioning as specified. Refer to the Section M-2 "Replacing the Chain." Fastening of the pedal is loose. Fasten the pedal onto the crank with a No. 15 wrench. Bearings of the pedal are defective. Replace the pedal. The copper plate contacts the magnet set. Adjust the position of the magnet set. Refer to the Section M-8 "Replacing the Magnet Set." 1. Noise occurs once per rotation of the pedal. 2. Abnormal noise is heard while the pedal is being rotated. Cateye Ergociser Series 3000 Service Manual 10 Symptoms and Cause of Problems 2 the Spacer Spring." Applicable Models D-1 EC-3200 EC-3500 Removing the Frame Covers Leg Pipe Fixing Screw No. 15 Wrench When any repairs or adjustments of parts within the frame cover is required, remove the frame covers in the following procedures. àREMOVAL Crank Cover (1) Remove the pedals at both the left and right sides.(Fig. 1) Crank (2) Remove the crank cover fixing screws. The narrow-width area of the crank cover should position in between the frame cover and the crank.(Fig. 2) Pedal (3) Remove the leg pipe fixing screws.(Fig. 3) * You do not have to remove the leg pipe itself. (4) For the upright type (EC-3200), disassembling should be made in the following procedures: 1. Detach the rubber base at the seat post lock knob from the cen ter cover. Center Cover Lift upward. 2. Loosen the center cover fixing screw a little, and lift the center cover upward. (Do not remove it.)(Fig. 4) * In the case of the recumbent type model, no center cover fixing screws are available. Center Cover Fixing Screw (5) Remove the frame cover fixing screw with a screwdriver before removing the frame cover.(Fig. 5) àASSEMBLING (1) Place the frame covers onto the frame at both right and left sides, paying attention to the position of the crank. * In the case of the recumbent type model, the center cover should be placed in between the right and left frame two covers are to be mated each other. Removing the Frame Covers covers when the (2) Fix the right and left frame covers with frame cover fixing screws. (3) Set the center cover to the frame cover correctly in position, and fix it with the center cover fixing screws.(Fig. 4) * Frame Cover Fixing Screw This procedure is for the upright type model only. (4) Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws.(Fig. 2) (5) Set the rubber base at the seat post lock knob, and then mount the right and left pedals. Remove the frame cover sideways. D-1 Frame Cover Cateye Ergociser Series 3000 Service Manual 11 Applicable Models E-1 EC-3200 EC-3500 Replacing the 7P Cable Set Control Unit Cable Connector (1) Procedures are different depending on the type of model as shown below: TUpright Type (EC-3200) Remove the 7P cable connector to the control unit, and then remove the cable from the cable holder of the handlebar post. TRecumbent Type (EC-3500) Remove the control panel cover before taking out the control unit, and disconnect the 7P cable connector.(Figs. 2,3) (2) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Cover." (3) Remove the 7P cable connector to the workload sensor.(Fig. 6) Control Panel Cover Cable Connector Cable Holder Fig.1 (4) Cut the two cable clips which fix the cable to the frame, and remove the existing cable. Fig.2 Fig.3 7P Cable (5) Mark the brandnew cable set as per the following procedures.Fig. 7) 7P Cable EC-3200: Mark the cable at the position 78cm from the large cable connector. EC-3500: Mark the cable at the position 36cm from the large cable connector. (6) Apply a cable clip at the position marked in step (5) above, and fix the cable to the square pipe at a position just below the welded area. (For EC-3200: Fig.8, EC-3500: Fig. 9) Also, fix the cable at the lower part of the square pipe. To apply a cable clip, strongly pull the clip by using a plier, and cut the excessive part. Workload Sensor Workload Sensor (8) Pull the cable out of the center cover through the hole on the cover, and connect the 7P cable connector (larger) to the control unit. Check if the control unit operates correctly. In the case of the recumbent type model, pull the 7P cable connector out of the center cover through the hole on the cover, and tentatively hold it with an adhesive tape so that it may not be retructed. (9) Reassemble the frame cover, by referring to the Section D-1 "Removing the Frame Cover." EC-3200 Fig.4 EC-3500 Fig.5 Cable Holder (at marked position) Cable Holder (at marked position) Workload Sensor * (10) Cateye Ergociser Series 3000 Service Manual 12 Cable Connector (L) 7P Connector 78cm for Upright Type Connect the 7P cable connector to the control unit. TUpright Type (EC-3200) Set the connector cover, and fix the cable holder to the handlebar post. TRecumbent Type (EC-3500) Mount the control unit to the frame along with the control panel cover. E-1 Replacing the 7P Cable Set (7) Firmly connect the 7P cable connector (smaller) to the workload sensor.(Fig. 6) Cable Holder Mark 36cm for Recumbent Type 7P Cable Fig.6 Fig.7 Fig.8 Fig.9 Applicable Models E-2 EC-3200 EC-3500 Replacing the CDC Sensor (1) Disconnect the frame cover, by referring to the Section D-1 "ReCDC Sensor moving the Frame Covers." (Figs. 1,2) (2) Disconnect the 2P connector from the workload sensor.(Fig. 3) CDC Sensor (3) Cut the cable clips which fix the CDC sensor cord to the workload unit aluminum frame. (4) Loosen the screws which fix the CDC sensor (defective) to remove the sensor. Mount and fix a brandnew CDC sensor.(Fig. 4) (5) Perform the following adjustment: 1. Align the line on the CDC sensor with the center of the line on the CDC magnet. (Figs. 5,6) 2. The clearance between the CDC sensor surface and the magnet surface should be approx. 2mm. (Fig. 6) * When the specified clearance has not been established, bend the metal base to have the celarance. (6) Firmly connect the 2P connector to the workload sensor.(Fig. 3) (7) Rotate the crank, and check if the number of pedal rotations is dis- EC-3200 EC-3500 Fig.1 Fig.2 played on the control unit. Workload Sensor (8) Fix the CDC sensor cord to the workload unit aluminum frame by CDC Sensor using cable clips.(Fig. 7) (9) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." 2P Connector Fig.4 Line on CDC Sensor Replacing the CDC Sensor Fig.3 Cable Clip Approx. 2mm clearance between CDC sensor and CDC magnet Line on CDC Sensor Line on CDC Magnet Fig.6 E-2 Center of CDC magnet Fig.5 Fig.7 Cateye Ergociser Series 3000 Service Manual 13 Applicable Models E-3 EC-3200 EC-3500 Replacing the Workload Sensor Set (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers." (Figs. 1 , 2) (2) Disconnect the 2P and 7P connectors from the workload sensor.(Fig. 3) (3) Remove the workload sensor by loosening screws. Do this step carefully not to damage the slit board.(Fig. 4) (4) Insert a brandnew workload sensor into the slit board.(Fig. 5) (5) Set the workload shift lever to Point 8. Adjust the position of the workload sensor set so that the center part of the slit board protrude approx. 2mm from the low end of the workload sensor set. Fix the slit board with screws.(Fig. 6) (6) Connect 2P and 7P connectors to the workload sensor.(Fig. 3) (7) Check if the control unit operates properly. Workload Sensor Workload Sensor EC-3200 EC-3500 Fig.2 Fig.1 (8) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." Workload Sensor Replacing theWorkload Sensor Set 7P Connector 2P Connector Workload Sensor Fig.3 Fig.4 Workload Sensor Slit Board E-3 Slit Board Workload Sensor Fig.5 Cateye Ergociser Series 3000 Service Manual 14 Fig.6 2mm Applicable Models E-4 EC-3200 Replacing the Button Panel (1) Insert a thin cutting knife, while paying cautions not to damage the control unit,in between the button panel and the unit, and carefully peel off the damaged button panel.(Fig. 1) C (2) Clean the adhesive agent, if any, on the control unit before placing a brandnew button panel. Sufficiently press the button panel thus placed. Button Panel Replacing the Button Panel Fig.1 E-4 * Cateye Ergociser Series 3000 Service Manual 15 Applicable Models M-1 EC-3200 EC-3500 Replacing the Workload Unit 1 (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Cover." (Figs. 1 ,2) Workload Unit (2) Remove the joint nut, by using a wrench, which is located just below the joint bar that connects the workload shift lever and the workload unit.(Fig. 3) (3) Move the workload shift lever to remove the joint bar from the joint. (Fig.3) (4) Remove a nut from the pulley "B" shaft and two bolts from the pulley "A" shaft and the frame, and remove the workload frame metal base together with the workload unit reinforcing metal base.(Fig. 4) (5) Use a screwdriver to loosen the cross-recessed head hexagon bolt Workload Unit which presses the workload unit aluminum frame to the hanger pipe, until the leading edge of the screw is concealed by the aluminum frame.(Fig. 5) (6) Use a hexagon wrench to loosen the four (three for EC-3500) workload unit fixing bolts which fix the workload aluminum frame to EC-3200 EC-3500 Fig.2 Fig.1 Joint Bar Pulley "B" Shaft Nut the main unit.(Fig. 6) Caution: Never remove these bolts, but just loosen them. - to be continued on the next page - Pulley "A" Shaft Joint Bolt Joint Nut Workload Unit Replacing the Workload Unit Workload Frame Metal Base Workload Unit Reinforcing Metal Base Bolt Frame Fig.4 Fig.3 Aluminum Frame Cross-recessed Head Hexagon Bolt M-1 Workload Unit Fixing Bolt Workload Fixing Bolt Fig.5 Cateye Ergociser Series 3000 Service Manual 16 Fig.6 Applicable Models M-1 EC-3200 EC-3500 Replacing the Workload Unit 2 (7) Slide the workload unit aluminum frame toward the side of the hanger pipe to loosen the tension of the chain, and remove the Upper Part of Large Gear Workload Sensor chain. The entire chain can be removed when it is first removed at the upper part of the large gear, and then rotate the crank forward.(Fig. 7) (8) Disconnect 2P and 7P connectors from the workload sensor.(Fig. 8) 7P Connector 2P Connector (9) Remove four workload unit fixing bolts which has been loosening in step (6), and remove the workload unit from the frame.(Fig. 9) (10)Mount a brandnew workload unit. Mounting of the workload unit can be done in the procedures opposite to disassembling. Fig.8 Chain (11)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.(Fig. 10) Fig.7 (12)Adjust the tension of chain. Fasten the cross-recessed head Upper Part of Large Gear hexagon bolt to press the aluminum frame to the hanger pipe. The tension of chain should be adjusted as illustrated in Fig. 11. * Be careful about excessive tensioning of the chain. After completing the adjustment, fasten the four (three for EC-3500) workload unit fixing bolts with a hexagon wrench.(Fig. 9) Chain (13)Fix the workload frame metal base to the pulley "B" shaft with a nut, and to the pulley "A" shaft with a bolt, fix it to the frame with bolts.(Fig. 4) (14)Connect 2P and 7P connectors from the workload sensor.(Fig. 8) (15)Assemble the frame cover, by referring to the Section D-1 "Re- Replacing the Workload Unit Workload Unit Fixing Bolt moving the Frame Covers." Workload Unit Fixing Bolt Fig.10 Fig.9 M-1 Slack of 3 to 7mm Fig.11 Cateye Ergociser Series 3000 Service Manual 17 Applicable Models M-2 EC-3200 EC-3500 Replacing the Chain (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers." (Figs. 1 ,2) Chain (2) Remove a nut from the pulley "B" shaft and two bolts from the pulley "A" shaft and the frame, and remove the workload frame metal base together with the workload unit reinforcing metal Chain base.(Fig. 3) (3) Loosen the cross-recessed head hexagon bolt which presses the workload unit aluminum frame to the hanger pipe, until the leading edge of the bolt screw is concealed within the aluminum frame.(Fig. 4) (4) Loosen the four (three for EC-3500) workload unit fixing bolts which fix the workload unit aluminum frame to the unit, by using a hexagon wrench.(Fig. 5) Caution:Never remove the workload unit fixing bolts, but just loosen them. (5) Slide the workload unit aluminum frame toward the side of hanger pipe, and loosen the tension of chain to detach it. First, detach the EC-3200 EC-3500 Fig.2 Fig.1 Aluminum Frame Pulley "B" Shaft chain at the upper part of the large gear, and then rotate the crank forward to detach the entire chain.(Fig. 6) Workload Unit (6) A brandnew 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. 7) Nut Pulley "A" Shaft (7) Adjust the tension of chain. Fasten the cross-recessed head hexagon bolt to press the aluminum frame to the hanger pipe. The tension of chain should be adjusted as illustrated in Fig. 8. * Be careful about excessive tensioning of the chain. After completing the adjustment, fasten the four (three for EC-3500) workload unit fixing bolts with a hexagon wrench.(Fig. 5) Slide Bolt Workload Frame Metal Base Workload Unit Reinforcing Metal Base Fig.4 Bolt Workload Unit Fixing Bolt Frame Fig.3 Upper Part of Large Gear (9) Assemble the frame cover, by referring to the Section D-1 Upper Part of Large Gear Workload Unit Fixing Bolt Fig.5 "Removing the Frame Covers." Chain Approx. 3 to 7mm slack Chain M-2 Replacing theChain (8) Fix the workload frame metal base to the pulley "B" shaft with a nut, and to the pulley "A" shaft with a bolt, fix it to the frame with bolts.(Fig. 3) Cross-recessed Head Hexagon Bolt Fig.6 Cateye Ergociser Series 3000 Service Manual 18 Fig.7 Fig.8 Applicable Models M-3 EC-3200 EC-3500 Replacing the Belt and Pulley "B" Set Pulley "B" àREMOVAL (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers." (Figs. 1,2) Pulley "B" (2) Remove a nut from the pulley "B" shaft and two bolts from the pulley "A" shaft and the frame, and remove the workload frame metal base together with the workload unit reinforcing metal base.(Fig. 3) (3) Remove the idler spring from the latch of the idler metal base.(Fig. 4) (4) Move the workload shift lever to the Point 8 to position the magnet horizontally.(Fig. 5) (5) Remove the bolts which fix the magnet to the magnet mounting base, by using a hexagon wrench, and remove the magnet set.(Fig. 5) (6) Detach the gear crank and chain, by referring to Steps (3) thru (8), "Removing the Gear Crank", Section M-6 "Replacing the Crank Set." (Do not remove the crank at the left side.) Timing Belt Timing Belt EC-3200 Fig.1 EC-3500 Fig.2 Pulley "A" Shaft Idler Metal Base (7) Remove nuts from the pulley "B" shaft and the pulley "A" shaft at the aluminum frame side, and then remove belt, pulley "A" and pulley "B" in this order. Magnet Latch àASSEMBLING (3) Put the magnet set on the magnet mounting base, and make position adjustment against the copper plate in the following procedures: 1. Place the magnet set so that the inner side of the magnet side can be positioned approx. 2mm inward of the outer edge of the copper plate.(Fig. 7) Workload Unit Frame Metal Base Idler Spring Hexagon Wrench Workload Unit Reinforcing Metal Base Fig.4 Magnet Mounting Base Fig.5 Fig.3 Plane Wahser 2. The copper plate should position at the center of the gap of magnet. * Rotate the copper plalte to check if it does not contact the magnet at any position during the rotation.(Fig. 8) Copper Plate Pulley "B" Approx. 2mm (4) Fix the magnet set to the magnet mounting base, by using a cap bolt, a spring washer, and a plane washer.(Fig. 5) (5) Hang the idler spring on the latch of the idler to give tension to the belt.(Fig. 4) (6) Fix the workload unit frame metal base to the pulley "B" shaft by using a nut and to the pulley "A" shaft by using a bolt, and then fix the metal base to the frame with bolts.(Fig. 3) Replacing theBelt and Pulley "B"Set (2) Mount the gear crank and chain, by referring to Steps (1) thru (5), "Assembling the Gear Crank", Section M-6 "Replacing the Crank Set." Pulley "B" Shaft Pulley "A" Magnet Fig.6 Fig.7 The copper plate aligns with The copper plate the center of the magnet. contacts the magnet. Fig.8 M-3 (1) Set a plane wahser to the pulley "B" shaft, and mount the pulley "B" and pulley "A" to the workload aluminum frame in this order, by using spring washers and nuts. Then, apply a brandnew belt. (7) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." Cateye Ergociser Series 3000 Service Manual 19 Applicable Models M-4 EC-3200 EC-3500 Replacing the Pulley "A" Set àREMOVAL (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers."(Figs. 1,2) Pulley "A" (2) Remove a nut from the pulley "B" shaft and two bolts from the pulley "A" shaft and the frame, and remove the workload frame metal base together with the workload unit reinforcing metal base.(Fig. 3) (3) Remove the idler spring from the latch of the idler metal base.(Fig. 4) (4) Loosen the chain and detach it, and then remove the gear crank. Refer to the Steps (3) thru (8), Removing the Gear Crank, Section M-6 "Replacing the Crank Set." (5) Remove the pulley "A" fixing nut by using a box wrench.(Fig. 5) (6) Detach the pulley "A" from the workload unit aluminum frame.(Fig. 5) Pulley "A" EC-3500 EC-3200 Fig.1 Fig.2 Pulley "A" Shaft àASSEMBLING (1) Assemble the pulley "A" to the workload unit aluminum frame, by using the pulley "A" fixing nut. Pulley "B" Shaft (2) Mount the gear crank and the chain. Refer to Steps (1) thru (5), "Mounting the Gear Crank", Section M-6 "Replacing the Crank Set." (3) Hang the idler spring on the latch of the idler.(Fig. 4) (4) Fix the workload unit frame metal base to the pulley "B" shaft by using a nut and to the pulley "A" shaft by using a bolt, and then fix (5) Assemble the frame cover, by referring to the Section D-1 "Re- Workload Unit Reinforcing Metal Base Fig.3 moving the Frame Covers." Washer Latch Spring Washer Pulley "A" Idler Spring Fig.4 M-4 Replacing the Pulley "A" Set the metal base to the frame with bolts.(Fig. 3) Workload Unit Frame Metal Base Cateye Ergociser Series 3000 Service Manual 20 Pulley "A" Fixing Nut Fig.5 Applicable Models M-5 EC-3200 EC-3500 Replacing the Idler Set Idler Set (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Cover."(Figs. 1 ,2) (2) Remove the idler spring from the latch of the idler metal base.(Fig. 3) Idler Set (3) Loosen the idler mounting bolts, and detach the idler set.(Fig. 4) (4) Mount a brandnew idler set by using an idler mounting bolt. (5) Hang the idler spring on the latch of the idler to give tension to the belt.(Fig. 3) EC-3500 EC-3200 Fig.2 Fig.1 Idler Set Latch Idler Spring Fig.3 Replacing the Idler Set Idler Mounting Bolt M-5 Fig.4 Cateye Ergociser Series 3000 Service Manual 21 Applicable Models M-6 EC-3200 EC-3500 Replacing the Crank Set 1 EC-3500 Crank Set àRemoving the Gear Crank (Crank) (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers." (Figs. 1 ,2) (2) Remove a nut from the pulley "B" shaft and two bolts from the pulley "A" shaft and the frame, and remove the workload frame Crank Set metal base together with the workload unit reinforcing metal base(Fig. 3) (3) Loosen the cross-recessed head hexagon bolt which presses the workload unit aluminum frame to the hanger pipe, until the leading edge of the bolt screw is concealed within the aluminum frame.(Fig. 4) (4) Loosen the four workload unit fixing bolts which fix the workload unit aluminum frame to the unit, by using a hexagon wrench.(Fig. 5) Caution:Never remove the workload unit fixing bolts, but just loosen them. EC-3200 Fig.1 (5) Slide the workload unit aluminum frame toward the side of hanger pipe, and loosen the tension of chain to detach it. First, detach the Fig.2 Pulley "B" Shaft Workload Unit Fixing Bolt chain at the upper part of the large gear, and then rotate the crank forward to detach the entire chain.(Fig. 6) (6) Use a coin to remove the crank cap.(Fig. 7) Cross-recessed Head Hexagon Bolt (7) Remove the crank nut by using a cotterless gear crank removing/ fastening tool and a spanner.(Fig. 8) Slide Pulley "A" Shaft - to be continued on the next page Workload Unit Frame Metal Base Workload Unit Reinforcing Metal Base Workload Unit Fixing Bolt Fig.3 Fig.4 Fig.5 Replacing the Crank Set Upper Part of Large Gear Chain Spanner Coin Crank Cap M-6 Cotterless Removing/ Fastening Tool Fig.6 Cateye Ergociser Series 3000 Service Manual 22 Fig.7 Fig.8 Applicable Models M-6 EC-3200 EC-3500 Replacing the Crank Set 2 Upper Part of Large Gear (8) Change the side of the cotterless removing/fastening tool, and use it to remove the gear crank (crank) from the crank shaft.(Fig. 9) àAssembling the Gear Crank (Crank) Spanner (1) Mount the gear crank (crank) to the crank shaft. Chain (2) Securely fasten the crank nut by using a socket wrench (or by a cotterless removing/fastening tool and a spanner).(Fig. 8) (3) Fasten the crank cap by using a coin, etc.(Fig. 7) (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. 10) (5) Adjust the tension of chain. Fasten the cross-recessed-head hexagon bolt to press the aluminum frame to the hanger pipe.(Fig. 4) Cotterless Removing/ Fastening Tool Fig.9 Fig.10 The tension of chain should be adjusted as illustrated in Fig. 11. * Be careful about excessive tensioning of the chain. After completing the adjustment, fasten the four workload unit fixing bolts with a hexagon wrench.(Fig. 5) Approx. 3 to 7mm slack (6) Fix the workload frame metal base to the pulley "B" shaft with a nut, and to the pulley "A" shaft with a bolt, fix it to the frame with bolts.(Fig. 3) (7) 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 Step (5) Section E-2 "Replacing the Fig.11 CDC Sensor." (8) Rotate the crank, and check if the number of pedal rotations is displayed on the control unit. M-6 Replacing the Crank Set (9) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." Cateye Ergociser Series 3000 Service Manual 23 Applicable Models M-7 EC-3200 EC-3500 Replacing the BB Set EC-3500 BB Set àREMOVAL (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers." (Figs 1 ,2) (2) Remove the gear crank/crank from the crank shaft, by referring to the Section M-6 "Replacing the Crank Set." (3) Remove the BB cup locking with a hanger rotating jig.(Fig. 3) (4) Remove the BB adjusting cup, by using a pin face wrench.(Fig. 4) (5) Remove the crank shaft (BB axle). (6) Remove the BB fixing cup, by using the hanger rotating jig.(Fig. 5) The CDC sensor metal base will be removed at the same time. BB Set 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. EC-3200 Fig.2 Fig.1 BB adjusting cup (2) Assemble the crank shaft(BB axle), retainer, BB fixing cup and BB adjusting cup, BB cup locking and CDC sensor as depicted in Fig. 6. Hanger Rotating Jig (3) Mount the gear crank/crank, by referring to Mounting Steps (1) thru Hanger Rotating Jig (6), Section M-6 "Replacing the Crank Set." Also, adjust the tension of the chain. BB fixing cup (4) Adjust the following: 1. Align the line on the CDC sensor with the center of the line on the magnet.(Figs. 7 ,8) Pin Face Wrench 2. Adjust the clearance between the CDC sensor surface and the BB cup locking magnet surface to beapprox.2mm.(Fig. 8) CDC Sensor Metal Base * When the specified clearance has not been established, bend Fig.3 Fig.4 (5) Rotate the crank, and check if the number of pedal rotations is displayed on the control unit. Fig.5 Approx. 2mm Clearance between CDC Sensor and Magnet CDC Magnet Retainer CDC Sensor Metal Base (6) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." Line BB cup locking Retainer CDC Sensor BB adjusting cup BB fixing cup Line CDC Sensor Fig.6 Cateye Ergociser Series 3000 Service Manual 24 CDC Magnet Hanger Pipe Crank Shaft (BB axle) M-7 Replacing the BB Set the metal base to have the celarance. Fig.7 Fig.8 Center Applicable Models M-8 EC-3200 EC-3500 Replacing the Magnet Set (1) Remove the frame cover, by referring to the Section D-1 "Remov- Copper Plate ing the Frame Covers."(Figs. 1 ,2) Magnet Set (2) Move the workload shift lever to the Point 8 to position the magnet horizontally.(Fig. 3) Copper Plate (3) Remove the bolts which fix the magnet to the magnet mounting base, by using a hexagon wrench, and remove a spring washer, a plane wahser and a magnet set.(Fig. 3) (4) Put the magnet set on the magnet mounting base, and make position adjustment against the copper plate in the following procedures: 1. Place the magnet set so that the inner side of the magnet can be Magnet Set positioned approx. 2mm inward of the outer edge of the copper plate.(Fig. 4) 2. The copper plate should position at the center of the gap of magnet.(Fig. 5) * Rotate the copper plalte to check if it does not contact the EC-3500 EC-3200 Fig.1 Fig.2 magnet at any position during the rotation. Magnet (5) Fix the magnet set to the magnet mounting base, by using a cap bolt, a spring washer, and a plane washer.(Fig. 3) (6) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." Replacing the Magnet Set Magnet Mounting Base Fig.3 Copper Plate Approx. 2mm Magnet Fig.4 The copper plate contacts the magnet. M-8 The copper plate aligns with the center of the magnet. Fig.5 Cateye Ergociser Series 3000 Service Manual 25 Applicable Models M-9 EC-3200 EC-3500 Replacing the Workload Shift Lever (1) Remove the frame cover, by referring to the Section D-1 "Removing the Frame Covers."(Figs. 1,2) Workload Shift Lever (2) Loosen and remove the joint nut from the joint on the magnet Workload Shift Lever mounting base.(Fig. 3) (3) Move the workload shift lever to pull the joint bar out of the joint. (4) Remove the workload shift lever mounting bolt and detach the workload shift lever set.(Fig. 4) Joint Bar (5) Mount a brandnew workload shift lever with the mounting bolt. (6) Insert the joint bar through the joint, and set the magnet mounting base horizontal (point 8). Joint Bar (7) Move the workload shift lever down until it contacts the stopper on the frame, and with this condition, fix the joint bar to the joint with two nuts from both upper and lower sides.(Fig. 3) (8) Assemble the frame cover, by referring to the Section D-1 "Removing the Frame Covers." Magnet Mounting Base Magnet Mounting Base EC-3500 EC-3200 Fig.1 Fig.2 Replacing the Workload Shift Lever Joint Bar Workload Shift Lever Stopper Joint Mounting Bolt Joint Nut Joint Bar M-9 Fig.3 Cateye Ergociser Series 3000 Service Manual 26 Fig.4 Joint Bar Applicable Models M-10 EC-3200 Replacing the Post Spacer àREMOVAL (1) Remove the center cover, by referring to the Section M-17 "Removing the EC-3200 Center Cover." Spacer Spring (2) Only in the case of the seat post spacer, remove the lock nut located at the side of the frame, and then remove the adjust screw.(Fig. 1) Post Spacer Adjust Screw (3) Only in the case of the seat post spacer, remove the spacer spring.(Fig. 1) Boss (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) Press in àASSEMBLING Lock Nut (1) Insert a brandnew post spacer. (2) For the seat post spacer, perform the following adjustments: 1. Insert the spacer spring, and slightly fasten the adjust screw.(Fig. 3) 2. Tentatively insert the seat post, and adjust the adjust screw so that the post will drop slowly. Fig.1 3. Fasten the lock nut to lock the adjust screw. Fig.2 Lock Nut (3) Assemble the center cover, by referring to the Section M-17 "Removing the EC-3200 Center Covers." Replacing the Post Spacer Adjust Screw M-10 Fig.3 Cateye Ergociser Series 3000 Service Manual 27 Applicable Models EC-3200 M-11 Adjusting the Spacer Spring (1) Remove the center cover, by referring to the Section M-17 "ReLock Nut moving the EC-3200 Center Cover." (2) Slightly loosen the lock nut at the side of the frame.(Fig. 1) (3) Fasten the adjust screw so that the seat post will drop slowly. (4) Fasten the lock nut to fix the adjust screw. (5) Assemble the center cover, by referring to the Section M-17 "Removing the EC-3200 Center Cover." Adjust Screw M-11 Adjusting the Spaser Spring Fig.1 Cateye Ergociser Series 3000 Service Manual 28 Applicable Models M-12 EC-3500 Replacing the Inner Pipe Spacer 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 Stopper Screw surface of the seat pipe. Inner Pipe Spacer "A" (2) Loosen the stopper screw to remove it.(Fig. 1) Pull out (3) Pull out the seat pipe and the inner pipe speacer A, while thedepressing the two bosses, located at the right and left sides of the seat pipe, at the sametime.(Fig. 2) Inner Pipe (4) Remove the spacer "B" at the end of the inner pipe.(Fig. 3) Boss Seat Pipe àASSEMBLING (1) Set a brandnew inner spacer "B" and a inner pipe spacer "A" at the end of the inner pipe.(Fig. 4) Fig.1 Fig.2 Inner Pipe Spacer "A" (2) Inesert the innper pipe together with the pipe spacers into the seat pipe. Inner Pipe Spacer "B" Inner Pipe Spacer "B" (3) Align the hole on the top surface of the seat pipe with the screw hole, and apply the stopper screw. (Fig. 1) Insert Seat Pipe Inner Pipe Fig.4 M-12 Fig.3 Replacing the Inner Pipe Spacer Inner Pipe Cateye Ergociser Series 3000 Service Manual 29 EC-3500 Applicable Models M-13 Replacing the Vertical Pipe Spacer (1) Remove the seat hite lock knob, and pull out the rear support pipe.(Fig. 1) Seat Hite Lock Knob (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) Rear Suppert Pipe (4) Insert the rear support pipe, and fix it with the seat hite lock knob. Fig.1 Rear Support Pipe Insertion Area Rear Support Pipe Spacer M-13 Replacing the Vertical Pipe Spacer Fig.1 Cateye Ergociser Series 3000 Service Manual 30 Applicable Models M-14 EC-3200 Replacing the Seat Post Knob (1) Pull out the seat post Knob Rubber Base (2) Remove the seat post knob by loosening the guide screw. Seat Post Knob (3) Mount a brandnew seat post knob by securely fastening the guide screw. (4) Insert the seat post. Guide Screw M-14 Replacing the Seat Post Knob Fig.1 Cateye Ergociser Series 3000 Service Manual 31 EC-3500 Applicable Models M-15 Replacing the Lock Pin (1) Remove the lock pin by loosening the guide screw. Lock Pin (2) Mount a brandnew lock pin by securely fastening the guide screw. Spanner Guide Screw M-15 Replacing the Lock Pin Fig.1 Cateye Ergociser Series 3000 Service Manual 32 Applicable Models M-16 EC-3200 EC-3500 Replacing the Caster & Level Adjuster (1) Loosen the screw and remove the caster pipe (rear leg with level adjuster) from the leg pipe. Caster Pipe/Rear Leg With Level Adjuster (2) The caster has been press-fitted into the caster pipe (rear leg with level adjuster). It can be removed by hammering it through a wooden block.(Fig. 1) (3) Press fit a brandnew caster (rear leg with lever adjuster) with a hammer and a wooden block.(Fig. 2) (4) Mount the caster pipe (rear leg with level adjuster) to the frame bottom. (Refer to the Operating Instructions.) Wooden Block Caster/Level Adjuster Wooden Block Caster/Level Adjuster Replacing the Caster & Level Adjuster Fig.2 M-16 Fig.1 Cateye Ergociser Series 3000 Service Manual 33 Applicable Models M-17 EC-3200 Removing the EC-3200 Center Cover (1) Remove the 7P cable connector from the control unit, and also remove the cable from the cable holder of the handlebar post.(Fig. 1) (2) Slightly loosen the handlebar post screw, and pull the handlebar post out of the unit frame.(Fig. 2) Handlebar Post (3) Pull the seat post knob, and pull the seat post out of the main unit.(Fig. 3) Handlebar Post Screw (4) Loosen the guide screw to remove the seat post knob.(Fig. 4) (5) Remove the rubber base of the seat post knob.(Fig. 5) (6) Loosen the screw and remove the workload shift knob.(Fig. 6) Cable Connector Hexagon Wrench (7) Slightly loosen the center cover fixing screws (8 pcs.), and remove the center cover while lifting it upward.(Fig. 7) Fig.1 Fig.2 (8) Assembling of the center cover can be performed in the reversed procedures of the above. Seat Post Knob Seat Post Knob Seat Post Rubber Base Guide Screw Fig.5 Fig.4 Replacing the EC-3200 Center Cover Center Cover Fig.3 Lift up Workload Shift Knob Screw Center Cover Fixing Screw Center Cover Fixing Screw M-17 Center Cover Fixing Screw Fig.6 Cateye Ergociser Series 3000 Service Manual 34 Fig.7 Applicable Models M-18 EC-3500 Removing the EC-3500 Center Cover Cable Connector *When the pulse sensor is connected, remove it first. (1) Remove the control panel cover to detach the control panel.(Fig. 1) (2) Remove the cable connector from the control panel.(Fig. 2) (3) Remove the workload shift knob, by loosening two screws.(Fig. 3) (4) Loosen the screws and remove the inner pipe from the joint metal base.(Fig. 4) Control Panel Cover (5) Removing of the frame cover fixing screws will split the frame cover to right and left parts.(Fig. 5) Control Unit (6) Remove the flange of center cover from the frame cover, and pull the cover in the direction toward joint metal base. (7) Assembling of the center cover can be performed in reversed pro- Fig.2 Fig.1 cedure of the above. Joint Fitting * Pull the 7P cable connector out of the center cover through the hole on the cover, and tentatively hold it with an adhesive tape so that it may not be retructed. Screw Workload Shift Knob Fig.3 Replacing the EC-3500 Center Cover Inner Pipe Fig.4 Frame Cover Fixing Screw Center Cover Frame Cover EC -35 Fig.5 M-18 Joint Fitting OO Fig.6 Cateye Ergociser Series 3000 Service Manual 35 Applicable Models M-19 EC-3200 EC-3500 Replacing the Handlebar Grip (1) In case the handlebar grip is damaged, cut the grip with a thin Brandnew Grip 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 the Air Gun, etc handlebar, and insert the grip while twisting and pressing the grip. * When the above replacing work is difficult to achieve, remove Handlebar the handlebar before the work. Existing Grip (Old) M-19 Replacing the Handlebar Grip Fig.1 Cateye Ergociser Series 3000 Service Manual 36 Fig.2 Applicable Models PNR.780-6801 PNR.780-6802 PNR.780-6806 PNR.780-6807 EC-3200Control Unit (E) EC-3200Control Unit (G) EC-3200Control Unit (E) Black EC-3200Control Unit (G) Black unit:pieces PNR.780-9206 PNR.000-0000 EC-3500Control Unit (E) Black EC-3500Control Unit (G) Black unit:pieces PNR.780-6809 PNR.780-6808 EC-3200Control Unit Multi Black EC-3200Control Unit Multi Gray unit:pieces PNR.780-9208 EC-3200 EC-3500 EC-3500Control Unit Multi unit:pieces EC-3200 TARGET PULSE ON/OFF EC-3200Decal (E) EC-3200Decal (G) PNR.000-0000 PNR.000-0000 unit:seats PNR.000-0000 PNR.780-1100 EC-3500Button Sheet EC-3200Pulse Sensor PNR.780-1110 Pulse Sensor Cover Set PNR.780-1200 unit:sets PNR.724-3410 EC-3200Handlebar unit:pieces PNR.780-1101 PNR.781-9100 Sensor Clip Sporty Handlebar Set EC-HB100 unit:pieces EC-3200Button Panel (E) EC-3200Button Panel (G) unit:seats EC-3500Pulse Sensor (Long) unit:sets PNR.780-1102 Saddle SD100 SMP1209 PNR.703-3101 EC-3500Pulse Sensor (M) unit:sets EC-3500Recumbent Seat unit:sets unit:pieces PNR.781-9000 ADVANCE unit:seats unit:sets unit:seats PNR.780-6811 PNR.780-6812 EC-3500Decal (E) EC-3500Decal (G) MODE PNR.781-5130 EC-3500Handlebar unit:sets PNR.725-0000 unit:pieces List of Genuin Parts PNR.000-0000 PNR.000-0000 VALUE ADJUST EC-3200Handlebar Grip unit:pieces Cateye Ergociser Series 3000 Service Manual 37 EC-3200 EC-3500 Applicable Models PNR.781-5060 EC-3500Handlebar Grip PNR.781-3200 Handlebar Cap unit:pieces PNR.780-6170 PNR.781-0300 EC-3200Handlebar Stem EC-3200Seat Post EC-3500Rear Support Pipe Spacer Set PNR.785-1416 unit:sets PNR.780-6040 EC-3500Lock Pin PNR.780-6050 EC-3200Post Spacer Set PNR.781-5030 EC-3500Pipe Spacer Set unit:sets unit:sets PNR.780-9610 unit:pieces EC-3200Rubber Base for Knob unit:pieces EC-3200Handlebar Lever Set unit:sets EC-3200Seat Pillar PNR.785-1417 EC-3200Seat Post Knob unit:pieces PNR.780-6600 PNR.780-6601 unit:pieces EC-3200Frame Cover EC-3200Frame Cover Black unit:sets PNR.781-5000 PNR.781-5001 EC-3500Control Panel Cover unit:pieces PNR.780-6620 EC-3500Frame Cover EC-3500Frame Cover Black unit:sets ® unit:pieces Adjusting Knob/Seat Pipe PNR.758-5000 unit:pieces ® List of Genuin Parts PNR.781-5120 EC-3200Handlebar Post unit:pieces unit:sets PNR.781-5040 PNR.780-6630 unit:pieces PNR.780-6610 PNR.781-5011 EC-3200Center Cover unit:pieces Cateye Ergociser Series 3000 Service Manual 38 EC-3500Center Cover PNR.781-5010 unit:pieces EC-3200Crank Cover unit:sets EC-3200 EC-3500 R Applicable Models R EC-3500Crank Cover PNR.781-5100 EC Pedal unit:sets PNR.781-0140 PNR.787-2409 Leveler Set EC-3500Workload Unit PNR.780-6710 Pulley "A" Set EC-3200Timing Belt PNR.724-1010 unit:pieces EC-3200Idler Spring PNR.780-6720 unit:pieces PNR.780-6700 EC-3200Workload Unit unit:sets PNR.781-2200 EC-3500Idler Set EC-3200Pulley "B" Set unit:sets PNR.787-2407 EC-3500Pulley "B" Set unit:sets PNR.724-3010 EC-3500Timing Belt Rear Leg With Level Adjuster unit:pieces unit:pieces unit:sets unit:pieces PNR.780-6730 PNR.780-6711 EC-3200Idler Set PNR.786-2409 unit:pieces unit:sets PNR.787-2408 EC-3500Idler Spring Caster Set unit:pieces unit:sets PNR.781-2210 EC Pedal Belt unit:sets PNR.781-0150 Caster Pipe Set unit:pieces PNR.781-2001 PNR.781-9300 unit:sets Chain unit:sets PNR.781-0523 unit:pieces List of Genuin Parts PNR.781-5050 Crank Set unit:sets Cateye Ergociser Series 3000 Service Manual 39 Applicable Models PNR.781-9200 Cartridge BB Set 986A PNR.780-9191 PNR.781-5110 EC-3500 7P Cable Set PNR.780-0950 Slit Board Link Set CDC Sensor Set List of Genuin Parts EC-3500Workload Shift Knob unit:sets 1 PNR.752-1081 Cateye Ergociser Series 3000 Service Manual EC-3200 7P Cable Set unit:sets Cable Clip Large (CV250) unit:pieces PNR.780-9190 Workload Sensor Set unit:sets PNR.780-6650 EC-3200Workload Shift Lever Set unit:sets PNR.781-5160 EC-3500Workload Shift Lever Set unit:sets PNR.780-6651 EC-3200Workload Shift Knob unit:sets PNR.724-4803 Crank Nut M10x1.25 PNR.724-4802 Crank Cap PNR.781-5140 Cable Holder 3 Hexagon Nut M8-3 PNR.752-1061 unit:pieces unit:pieces unit:pieces unit:pieces PNR.752-1085 unit:pieces 40 PNR.729-5025 2 Hexagon Nut M8-1 PNR.747-8100 unit:sets unit:sets unit:sets PNR.781-5161 Magnet Mounting Base Set unit:pieces unit:sets PNR.787-1402 PNR.781-2500 Magnet Set unit:sets EC-3200 EC-3500 4 PNR.719-8926 Hexagon Nut M6-1 unit:pieces Plane Washer 12-26-3.2 unit:pieces Applicable Models PNR.753-1816 6 PNR.753-2019 Plane Wahser 8-15.5-1.6 7 Plane Wahser 6-18-2.0 PNR.753-1613 0 PNR.723-2080 Plane Wahser 6-13-1.0 unit:pieces e PNR.753-0500 PNR.750-8616 unit:pieces u PNR.750-6810 a PNR.756-1440 Thrust Washer 9x15.5x0.25 PBC unit:pieces PNR.753-5410 unit:pieces PNR.756-1412 Spring Washer 6 unit:pieces unit:pieces y PNR.757-1528 Cap Bolt M6x22 PNR.753-5412 unit:pieces p PNR.753-5410 Screw Set M4x12 Bolt Set M6x12 unit:pieces unit:pieces PNR.750-8645 Cap Bolt M5x28 unit:pieces d Tapping Screw 4x12 with Washer (for HandleBar Post Cover Mounting) unit:pieces unit:pieces PNR.753-0600 Spring Washer 8 o s Tapping Screw 4x40 with Washer (for Frame Cover Mounting) unit:pieces PNR.753-0800 Cross-recessed Head Hexagon Nut M6x16 PNR.757-1622 unit:pieces Screw Set M4x10 Plane Wahser 6-15-3.2 w t i Seat Post Adjust Screw M8x10 unit:pieces PNR.753-1615 unit:pieces q r Spring Washer 5 Plane Wahser 10-18-1.0 unit:pieces unit:pieces 9 PNR.753-2017 8 List of Genuin Parts 5 EC-3200 EC-3500 f Hexagon Bolt (+) M6x45 SUS unit:pieces PNR.757-2510 Slotted Head Screw M5x10 unit:pieces Cateye Ergociser Series 3000 Service Manual 41 EC-3200 EC-3500 Applicable Models PNR.780-6890 EC-3200Tool Kit PNR.781-5180 EC-3500Tool Kit unit:sets PNR. Cotterless Gear Crank Removing/Fastening PNR.000-0000 unit:sets PNR.780-6851 PNR.780-6852 PNR.780-6853 EC-3200 Operating Instructions E(English) PNR.703-5103 EC-3200 Operating Instructions G(German) PNR.703-5104 EC-3200 Operating Instructions F(French) PNR.703-5105 unit:sets unit:sets Cartridge BB Removing Tool unit:sets R M O D EL EC -3 5O R O ® Pin Face Wrench PNR.737-7000 List of Genuin Parts unit:sets Cateye Ergociser Series 3000 Service Manual 42 Multimeter unit:sets 0 20 -3 EC PNR.758-1080 EC-3500 Operating Instructions E(English) EC-3500 Operating Instructions G(German) EC-3500 Operating Instructions F(French) unit:sets Applicable Models EC-3200B Belt Drive Crank Pulley 1-A PNR.724-1020 Teethed Timing Belt (PM8x15-896) unit:pieces PNR.780-6950 Idler A Set (for Teethed Timing Belt) unit:set PNR.780-6920 Pulley 1-B (Free Wheeling Pulley) unit:pieces Pulley 2-A (Pulley A for V-ribbed Belt) unit:pieces PNR.780-6940 Pulley 2-B (Pulley B for V-ribbed Belt) unit:pieces PNR.780-6960 Idler B Set (for V-ribbed Belt) unit:set PNR.780-6980 Idler B Spring Idler A Reinforcing Plate PNR.724-1030 unit:pieces PNR.780-6930 PNR.780-6970 unit:pieces unit:pieces List of Genuin Parts (Belt Drive) PNR.780-6990 V-ribbed Belt (280-J6) unit:pieces Cateye Ergociser Series 3000 Service Manual 43 ® CO.,LTD. 2-8-25, Kuwazu, Higashi Sumiyoshi-ku, OSAKA, 546-0041 JAPAN TEL:81-6-6719-2631 FAX:81-6-6719-2363 Copyright © Feb. 1995 CATEYE Co., Ltd. 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