Cateye | EC1600E | cateye ergociser manual load

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.
ECSM3E-991214-pdf
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