Cam Handle Service Guide Rev2001

Cam Handle Service Guide Rev2001
C
Cam
H
Handle
dl S
Service
i G
Guide
id
•Page 2. Introduction
•Page 3. Troubleshooting guide
•Page 4-5. Adjusting the clamp force
•Page 6-7
6-7. Disassembling
Disassembling, greasing and replacing components
•Page 8-9. Replacing the post bearings
Document # 300142
Revision 01
07/22/2008
How the cam handle works
The head of the dipped handle has an eccentric surface. As the handle is pushed
down, the head forces the post plunger assembly inwards. The post is clamped
between the post plunger assembly and the post bearing
bearing. The post handle pin can be
rotated to adjust the clamping force of the handle.
STRONG HOLDING
FORCE
FREE
90°
PARALLEL
(0°))
(0
Fully up = un-locked, able to
slide post up and down
Fully down = locked position
Parts breakdown
(same mechanism for both seat and handlebar clamps)
POST
CASTING CAP
2X - DOME SCREW (M4 X 10)
SLEEVE RETAINER
POST BEARING
W/ ADHESIVE
LOCK WASHER
DOME SCREW (M6 X 15)
POST HANDLE
INDICATOR
POST
PLUG
POST
HANDLE
PIN
POST HANDLE
LIMITER
POST PLUNGER
ASSEMBLY
DIPPED HANDLE
Document # 300142
Revision 01
07/22/2008
Page 2
Troubleshooting guide
Symptom
Possible Cause
Solution
Post slips down with handle
clamped
p down completely
p
y ((0°))
Clamp force adjusted too light
Adjust (increase) clamp force
((see pages
p g 4-5))
Post slips down with handle
clamped down completely (0°)
Broken or missing post bearing
Replace post bearing
(see pages 8-9)
Post slips down and handle
will not close completely
Clamp force adjusted too tight and
clamp is not locking down
Adjust (decrease) clamp force
(see pages 4-5)
Handle feels rough to open
and close
Needs lubrication, excess wear on
parts
Add grease, replace rough
parts as necessary (see
pages 6-7)
Grinding or squeaking sound
from handle during opening
and closing
Needs lubrication, excess wear on
parts
Add grease, replace rough
parts as necessary (see
pages 6-7)
Clamping assembly loosens
after several uses
Dome screw backs due to the post
handle p
pin being
g rough
g and
rotating with the handle.
Replace post handle pin, reg
grease
and reassemble ((see
pages 6-7)
Document # 300142
Revision 01
07/22/2008
Page 3
Adjusting handle clamping force
(From the factory the clamp should be set around 30-38 lbs to open and close)
1. Lift handle up (90°) to
fully release clamping force
force.
2. Using a 3mm hex
wrench, loosen the M6x15
dome screw to free the post
handle pin. Loosen the
screw about 2-3 full turns,
do not remove completely.
Push on dome screw to
disengage teeth on opposite
side.
3. Using a 6mm hex wrench,
turn the head of the post
handle pin. Turn the
indicator point on the head of
the pin towards the plus sign
to add clamp force, or
towards the minus sign to
remove clamp force. There
are each tooth represents a
change in clamp force.
NOTE: Do not rotate head
while teeth are still engaged.
Document # 300142
Revision 01
07/22/2008
Page 4
4. Tighten the M6x15 dome
screw to secure pin position.
5. Be sure that teeth are
g g to p
prevent the
fullyy engages
post handle pin from losing
its position.
6. Test clamping
p g force by
y
closing handle. The clamp
should be set strong enough
to hold the user’s weight,
yet be easy enough for all
users to close. Repeat
steps 1-6 until desired
clamp force is set.
NOTE: Proper adjustment
should require about 30-38
lbs of force to close handle.
Document # 300142
Revision 01
07/22/2008
Page 5
Replacing and re-greasing parts
1.
Disassemble handle
assembly.
Tools needed
(1) 6mm hex,
(1) 3mm hex
DOME SCREW (M6 X 15)
LOCK WASHER
POST
HANDLE
PIN
POST HANDLE
INDICATOR
POST PLUNGER
ASSEMBLY
POST HANDLE
LIMITER
DIPPED HANDLE
Step 2
Keep: handle indicator, handle, handle limiter
R l
Replace:
pin,
i plunger
l
assembly,
bl washer,
h ffastener
t
Document # 300142
Revision 01
07/22/2008
Page 6
NEW PIN
(ALL AROUND CENTER AREA)
NEW PLUNGER
(CENTER OF PLATE)
HANDLE
(CAM SURFACE)
Step 3
Add grease to surfaces shown
Step 4
Reassemble – set clamp force
as shown in pages 4-5.
Document # 300142
Revision 01
07/22/2008
Page 7
Replace post bearings
POST
CASTING CAP
SLEEVE RETAINER
ADHESIVE
POST BEARING
POST PLUG
Step 1 - Disassemble
Undo post plug - Remove post - Remove cap and retainer – Discard old post bearing and adhesive
RELEASE PAPER
NEW ADHESIVE
NEW POST BEARING
Note: the p
post bearing
g and adhesive for the handlebar are longer
g than for the seat
Step 2 – Prepare new post bearing
Remove release paper and apply new adhesive to the back of the new post bearing
Document # 300142
Revision 01
07/22/2008
Page 8
POST BEARING W/ ADHESIVE
Step 3 – Install new post bearing
Put new post bearing in aligning the tabs. Press bearing with adhesive against inside wall to secure in place.
(Steps 1-4 will be the same for both the seat and the handlebar post bearings)
Step 4 – Reassemble
Put parts back together
together, clamp force should be set from before but if needed
needed, follow
instructions on pages 4-5.
Document # 300142
Revision 01
07/22/2008
Page 9
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