Download Cateye EC-3700 Service manual
Transcript
Cateye Ergometer Belt Drive, Automatic Type Model EC-1200/EC-1600/EC-3600/EC-3700/EC-C400/EC-C400R Service Manual 9.1.2002 Ver.01 Model EC-1200 INDEX EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R •Repair & Adjustment Methods 1200 1600 3600 3700 C400 C400R INTRODUCTION •How to Use This Service Manual •Name of Parts 1. Upright Type (w/o Flywheel) --------------------------------------------------------- 6~7 Upright Type (w/ Flywheel) ---------------------------------------------------------- 8~9 ● ● ● ● ● ● ES-1: Replacing the Wiring within the Frame --- 36~37 ● ● ● ● ● ● ES-2: Replacing the 5P Cable ---------------- 38~42 ● ● ● ● ● ● ES-3: Replacing the Power Supply Board ------- 43~44 ● ● ● ● ● ● ES-4: Correcting the Position of Solenoid Coil --------------------------- 45~46 2. Recumbent Type (EC-3600, EC-3700 & EC-C400R) --------------------- 10~11 •Circuit Diagram ---------------------------------------------------------------------------------- 12 Part A •Symptoms of Problems & Causes T-1: No Display on Control Unit after Power ON --------------------------- 13~16 ● ● ● ● ● ● ES-5: Replacing the CDC Sensor ------------ 47~48 − ● − ● − − ES-6: Replacing the Panel Keyboard ------------ 49 ● − ● − ● ● ES-7: Replacing the Button Panel ---------------- 50 − ● − ● − − ES-8: Replacing the Printer ------------------------- 51 − ● − ● − − ES-9: Adjusting the Printing Darkness ----------- 52 − ● − ● − − ES-10: Paper Jamming in Printer ------------------- 53 ● ● ● ● ● ● ES-11: Replacing the Pulse Sensor Jack and Pulse Sensor Jack Board -------- 54~55 T-2: No Display of Cadence ------------------------------------------------------ 17~19 T-3: No Display of Pulse Rate -------------------------------------------------------- 20 T-4: No Printer Operation --------------------------------------------------------- 21~22 T-5: No Loading --------------------------------------------------------------------- 23~26 − ● − − ● ● ES-12: Replacing the HR Receiving Board -- 56~57 T-6: No Pedal Rotation (Locked) ---------------------------------------------------- 27 ● − − − ● − MS-1: T-7: Unusual Noise Replacing the Workload Unit (w/o Flywheel) ---------------------------- 58~63 ▲G 1. Continuous and Increasing. ---------------------------------------------- 28 ● ● ● − ● MS-2: (w/ Flywheel) ---------------------------- 64~65 2. Periodical. --------------------------------------------------------------------- 29 3. Noise occurs when the pedal is rotated with a large loading. --- 30 Part B •Removing the Frame Covers D-1: Upright Type (EC-1200, EC-1600 & EC-C400) ---------------------------- 31 Recumbent Type (EC-3600, EC-3700 & EC-C400R) -------------------- 33 D-3: Disassembly of a Control Unit -------------------------------------------------- 35 TitleNo D-2: Replacing the Workload Unit ▲G ● ● ● − ● MS-3: Adjusting the Flywheel ----------------------- 66 ● ● ● ● ● ● MS-4: Replacing the Timing Belt -------------- 67~68 ● ● ● ● ● ● MS-5: Replacing the Pulley 1-B -------------------- 69 ● ● ● ● ● ● MS-6: Replacing the Idler A Set -------------------- 70 ● ● ● ● ● ● MS-7: Replacing the Idler B Set ------------------- 71 ● ● ● ● ● ● MS-8: Replacing the Crank Pulley 1-A Set ------ 72~74 ● ● ● ● ● ● MS-9: Replacing the Cartridge BB Set ------ 75~76 ● ● − − ● − MS-10: Replacing the Post Spacer ----------------- 77 ● ● − − ● − MS-11: Adjusting the Spacer Spring --------------- 78 − − ● ● − ● MS-12: Replacing the Inner Pipe Spacer --------- 79 − − ● ● − ● MS-13: Replacing the Vertical Pipe Spacer ------ 80 ● ● − − ● − MS-14: Replacing the Leg Cover -------------------- 81 − − ● ● − ● MS-15: Replacing the Caster/Level Adjuster ----- 82 Cateye ergometer Service Manual 2 Model EC-1200 EC-1600 1200 1600 3600 3700 C400 C400R ● ● − − ● − MS-16: Replacing the Seat Post Knob ------------- 83 − − ● ● − ● MS-17: Replacing the Lock Pin ---------------------- 84 ● ● ● ● ● ● MS-18: Replacing the Crank Cover ----------------- 85 ● ● − − ● − MS-19: Replacing the Center Cover of Upright Type -------------------------------- 86 − − ● ● − ● MS-20: Replacing the Center Cover of Recumbent Type --------------------------- 87 ● ● ● ● ● ● MS-21: Replacing the Handlebar Grip ------------- 88 − ● − ● − − MS-22: Replacing the Printer Cover ---------------- 89 − ● − ● − − MS-23: Replacing the Paper Cutter ---------------- 90 ● ● − − ● − MS-24: Replacing the Handle Stem ---------------- 91 PART C •List of Genuine Parts ----------------------------------------------------------------------- 92~103 Cateye ergometer Service Manual 3 EC-3600 EC-3700 EC-C400 EC-C400R Model EC-1200 How to Use This Service Manual EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Symbol marks used for safety precautions in this manual The manual consists of Part A, Part B and Part C. Part A refers to trouble-shooting which allows you to identify the cause and areas to be fixed depending on typical symptoms. Part B shows how to repair and/or adjust specific defects. This part consists of repair methods for electrical parts [ES] and those for mechanical parts [MS]. Part C lists up all genuine parts and corresponding part numbers that will be necessary for replacement or stock Whenever any problem has occurred on the main unit, take the following actions to repair or adjust it. 1. Check and identify the cause by referring to Part A. 2. Identify the parts name by referring to Name of Parts. 3. Perform repair or adjustment in accordance with the instructions in Part B. 4. Replacement, if required, should be done by using genuine parts as specified in Part C. Warning Failure to observe this warning could result in serious injury or death. Caution Failure to observe this warning could result in physical injury or damage to the machine. Reference This symbol mark denotes helpful information or associated items. FOR SAFE OPERATION <Electrical danger> • During troubleshooting, checking the wiring, measuring voltage and electric current; be careful to avoid electric shock. • During maintenance, turn off the power unless it is required for maintenance. <Mechanical danger> • Be careful to avoid getting caught in rotation parts such as the gears, belts or rollers. Familiarize yourself with the movements of these parts before using the equipment. • It is possible that certain covers, moving parts, etc., may cause injury. Make sure to hold covers, etc., securely during work. <Important precautions> • The machine is comprised of various parts, some of which are heavy. When moving or removing such parts, be sure to hold these parts securely. • When moving the machine, be sure that at least two persons work together. Cateye ergometer Service Manual 4 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 R Model EC EC -12 00 ON OF F Recumbent Type Upright Type Cateye ergometer Service Manual 5 -37 00 EC-C400R Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Name of Parts for Upright Type (w/o Flywheel) Crank Pulley 1-A Set Post Spacer Cartridge BB Set Lock Nut Crank Cap 9 Adjust Screw 6 Spacer Spring Post Spacer Lock Nut Frame Adjust Screw 5 Spacer Spring 5P Cable Seat Pipe Cable Holder Crank Timing Belt Idler B Connector Cover 5P Cable Connector CDC Magnet CDC Sensor Inlet Metal Base Power Switch Copper Plate 3 Idler Fixing Bolt [M6x16] Frame Idler Metal Base Idler Spring B Wiring within Frame Leg Cover Leg Pipe 3 Leg Pipe Fixing Screw Caster 6 Levelling Knob Power Supply Board Power Supply Board Fixing Screw [Tapping Screw(2) 4x12c] 780-7050 Workload Unit Plastic Pulley Solenoid Coil Mounting Base Solenoid Coil 7 SW Nut M6 Cateye ergometer Service Manual 6 Levelling Knob 3 Workload Unit Mounting Base [Screw Set (+) (M6x16)] Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Handlebar Post Cable Holder Center Cover 780-6990 Crank Pulley 1-A Set Seat Post 780-7000 Pulley Flange Frame Cover Crank Cover 4 Crank Cover Fixing Screw Inlet Metal Base AC Adapter Inlet 724-1021 Timing Belt 9 Crank Bolt 2 Workload Unit Reinforcing Metal Base Nut Power Supply Board Workload Unit Reinforcing Metal Base 1 Workload Unit Reinforcing Metal Base Fixing Nut Leg Pipe Fixing Screw Leg Pipe Lever Cover 3 Screw Set(+) (M6x16) 3 Workload Unit Fixing Bolt Hexagon Head U Nut Levelling Knob 780-7010 Pulley 1-B Solenoid Coil Idler A Mounting Bolt 780-7030 Idler A 780-7040 Idler Spring A Cateye ergometer Service Manual 7 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Name of Parts for Upright Type (w/ Flywheel) 5P Cable Post Spacer Lock Nut 5P Cable Connector 780-6990 Crank Pulley 1-A Set Cartridge BB Set Crank Cap Adjust Screw Post Spacer Lock Nut Adjust Screw [M8x10] 5 Spacer Spring Seat Pipe Flywheel Mounting Metal Base Cable Holder Flywheel Metal 7 Flywheel Fixing Screw [SW Nut (M6)] 3 Flywheel Metal Base Fixing Screw Crank [Screw Set (+) (M6x16)] Timing Belt Idler B Inlet Metal Base Power Switch CDC Magnet CDC Sensor Copper Plate 3 Idler Mounting Bolt [M6x16] Frame Idler Metal Base Idler Spring B Wiring within Frame Leg Pipe 3 Leg Pipe Fixing Screw Leg Pipe Levelling Knob Workload Unit 7 SW Nut (M6) Caster Power Supply Board 6 Power Supply Board Plastic Pulley Solenoid Coil Mounting Base Fixing Screw [Tapping Screw (2) 4x12c] Solenoid Coil 3 Workload Unit Mounting Bolt [(M6x16)] Cateye ergometer Service Manual 8 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 780-6990 Crank Pulley 1-A Set 780-7000 Pulley Flange Plain Belt EC-C400R Seat Post Handlebar Post Cover (EC-1600 only) Center Cover Flywheel Frame Cover Crank Cover 1 Workload Unit Reinforcing Metal Base fixing Nut (M8-3) Power Supply Board 2 Flywheel Fixing Screw Flywheel Metal Base 3 Flywheel Metal Base Fixing Screw Inlet Metal Base AC Adapter Inlet 4 Crank Cover Fixing Screw Crank Bolt 724-1021 Timing Belt 2 Workload Unit Reinforcing Metal Base Nut [Hexagon Nut (M6-3)] Workload Unit Reinforcing Metal Base 780-7050 Workload Unit Leg Pipe Lever Cover 3 Workload Unit Levelling Knob Mounting Bolt (M6x16) Hexagon Head U Nut 780-7010 Pulley 1-B 3 Screw Set(+) (M6x16) Solenoid Coil Idler Mounting Bolt Idler A Idler Spring A Cateye ergometer Service Manual 9 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Name of Parts for Recumbent Type (EC-3600, EC3700 & EC-C400R) 6 Power Supply Board Fixing Bolt Crank Crank Bolt 5P Cable Connector Power Supply Board 5P Cable Set Cable Holder Wiring within Frame Frame Cartridge BB Set 3 Flywheel Metal Base Fixing Screw CDC Sensor Timing Belt Flywheel Copper Plate 7 Flywheel Fixing Screw Idler B Flywheel Metal Base 3 Idler Fixing Bolt Plain Belt Idler Spring B Idler Metal Base Solenoid Coil Mounting Base Frame Cover 3 Workload Unit Mounting Solenoid Coil Center Cover Crank Cover Rear Support Pipe Workload Unit Leg Pipe Fixing Screw Seat Pipe 4 Crank Cover Fixing Screw Base [Screw Set (+) (M6x16)] Plastic Pulley Inner Pipe Cateye ergometer Service Manual 10 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R 780-6990 Crank Pulley 1-A Set 780-7000 Pulley Flange Power Supply Board Cable Holder CDC Magnet 724-1022 Timing Belt Crank Cap Cable Holder Flywheel Plain Belt 7 Flywheel Fixing Screw Idler A Mounting Bolt 2 Workload Unit Reinforcing Metal Base Nut Workload Unit Reinforcing Metal Base 781-5581 Workload Unit 3 Flywheel Metal Base Fixing Screw 780-7040 Idler Spring A Solenoid Coil ON 3 Workload Unit Mounting Base [Screw Set (+) (M6x16)] 780-7010 Pulley 1-B Inlet Metal Base OFF 780-7030 Idler A Hexagon Head U Nut AC Adapter Inlet Power Switch Front Leg with Casters Caster Cateye ergometer Service Manual 11 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Circuit Diagram for Automatic Type Cateye Ergometer Wiring within Frame AC Adapter 100V AC CN4 (Connector 4) Black Cable (-) 12V DC❈ - AC Plug ❈Fluctuate depending on the electric load DC Connector AC Adapter Inlet Switch Red Cable (+) + About 16V when the load is zero. DC Power Supply CN4 Power Supply Board + - (Connector 4) Cadence Sensor CN3 Magnet C2 + C1+ ❈❈ 5P Cable to Control Unit R2 CN2 R8 Common Line Cadence Signal REG R3 Control Unit Power Supply VR1 R7 TR2 Solenoid Coil Current Control Signal IC1 TR1 Printer Power Supply (+5V) R1 Solenoid Coil Current Control Circuit Power Supply Control Circuit for Printer CN1 D1 Metal Pulley Timing Belt Plastic Pulley Timing Belt Coil Workload Unit Cadence Sensor ❈❈ Crank Pulley 1-A Set Pedal Electromagnet Copper Disk Plate Pulley 1-B Magnet Crank Cateye ergometer Service Manual 12 Model T-1 EC-1200 EC-1600 EC-3600 No Display on Control Unit after Power ON. (1) Check Maintenance Illsutrations Check the power is available at the wall socket before proceeding to checking of causes. Normal for 14V thru 19V [1] Checking the AC Adapter DC Connector 1. Detach the plug of AC adapter from the AC adapter inlet of the main unit. Red Cable 2. Connect the wall socket plug of the AC adapter to the wall socket. Black Cable 3. Using a tester, measure the voltage at the plug which will be connected to the main unit. (Fig. 1) Fig. 1 ● The AC adapter will be working fine, if the voltage is minus (-) at the inner area and plus (+) at the outer area of the connector and also the meter reading is in the range of 14V to 19V. ● When the measured voltage is 0V, or less than 14V, the AC adapter will be defective. Caution EC-3700 Replace the AC adapter. Never short-circuit the plug of AC adapter. This will damage the AC adapter. If the AC adapter is working normally, the system checks the items on the next page. Cateye ergometer Service Manual 13 EC-C400 EC-C400R Model T-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Display on Control Unit after Power ON. (2) Check Maintenance Illustrations [2] Checking the Wiring within the Frame Normal for 14V thru 19V 1. When the AC adapter is found to be correct, proceed to checking of wiring within the frame. Loosen the four screws on the handlebar stem to remove the control unit. (Fig. 2) 5P Cable Black Cable Terminal 3 (+) Cable Connector 2. Remove the 5P cable which is connected to the back of the control unit. (Fig. 2) 3. Connect the AC adapter, and turn on the main unit. 4. Using a tester, measure the voltage across the terminals 1 (-) and 3 (+) of the 5P cable. (Fig. 3) Terminal 1 (-) Fig. 2 Replace the control unit. ● The main unit side will be working fine if the meter reading is in the range of 14V to 19V. This means the control unit will be defective. Cateye ergometer Service Manual 14 Red Cable Fig. 3 Model T-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Display on Control Unit after Power ON. (3) Check Maintenance Illsutrations [3] When the meter reading at step 2. is 0V or less than 14V, check the main unit in accordance with the following procedures: Correct for 14V thru 19V 1. Remove the frame cover. (See sections D-1 and D-2 "Removing the Frame Covers.") Power Supply Board 2. With the control unit removed, connect the AC adapter, and turn on the power switch. Measure the voltage across the electrolytic capacitor C1 on the power supply board (25V 1000µV). (Fig. 4) Caution Black Cable The layout of the power supply board may be different from lot to lot. (Figs. 5 and 6) ● The wiring within the frame is correct when the measured voltage is in the range of 14V to 19V. When the voltage across the electrolytic capacitor on the power supply board is correct, the 5P cable, which connects the power supply board and the control unit, may be defective. Replace the 5P cable. ● When the measured voltage is 0V, the wiring within the frame is defective. Replace the Inlet Metal Base Set. ● When the problem cannot be remedied even if the 5P cable is replaced, the power supply board may be defective. Replace the power supply board. Reference Red Cable See the Section ES-2 "Replacing the Frame." Fig. 4 Power Supply Board A Reference Reference Power Supply Board B See the Section ES-1 "Replacing the Wiring within the Frame." See the Section ES-3 "Replacing the Power Supply Board." Fig. 5 Cateye ergometer Service Manual 15 Fig. 6 Model T-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Display on Control Unit after Power ON. (4) Check Maintenance Illustrations <MAJOR DEFECTS> Back Light • Back light does not work. (The power is on, but the back light does not work) (Only for ECC400 and C400R) ● The control unit is defective. Replace the control unit with a brand new one. 1 1 2 2 3 3 1 1 2 2 3 3 LED • Push-button operation does not work. ● The control unit is defective. Replace the control unit with a brand new one. • Cannot read data card. Check that the card has been inserted correctly and the procedure has been carried out correctly. Reference Fig. 1 See the Operation Manual. ● If the card has been inserted correctly, this indicates that the control unit is defective. Replace the control unit with a brand new one. • LED on the control unit does not light. (Only for EC400 and EC-C400R) ● The control unit is defective. Replace the control unit with a brand new one. Cateye ergometer Service Manual 16 Fig. 1 Model T-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.) (1) Check Maintenance Illsutrations [1] Checking the Control Unit The case of no short-circuiting 1. Turn off the power. Loosen the four screws on the handlebar stem to remove the control unit. Black Cable 2. Remove the cable connector which is connected to the back of control unit. In case a short-circuiting is found. One zero (0) is detected during one rotation of the pedal. 3. Slowly rotate the pedal while measuring the resistance across the connector terminals 1 and 2 of the 5P cable. (Fig. 1) ● When there is one short-circuiting (resistance becomes zero) during one rotation of the pedal, the control unit is defective. 2 5 Terminal 2 Red Cable 5P Cable Fig. 1 Cateye ergometer Service Manual 17 4 1 Replace the control unit with a brand new one. When there is no short-circuiting, proceed to the following check procedures. 3 Terminal 1 Model T-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400R No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.) (2) Maintenance Check Illustrations [2] Checking the Main Unit Power Supply Board 1. Remove the frame cover. (See the Section D-1 and D-2 "Removing the Frame Covers.") 2. Remove the CN-3 connector on the power supply board. (Fig. 2) 3. Slowly rotate the pedal while checking shortcircuit across the two terminals of the CN3 connector by using a tester to see if there is one short-circuiting during one rotation of the pedal. (Fig. 3) Caution EC-C400 Fig. 2 The case of no short-circuiting When the pedal is rotating, keep hands away from the workload unit. ● If short-circuiting is found, the 5P cable which connects the power supply board and the control unit is defective. Replace the 5P cable. Reference See the Section ES-2 "Replacing the 5P Cable." Black Cable In case a shortcircuiting is found. One zero (0) is detected during one rotation of the pedal. Red Cable When there is no short-circuiting, proceed to the following check procedures. CN-3 Connector Fig. 3 Cateye ergometer Service Manual 18 Model T-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.) (3) Check Maintenance Illsutrations [3] Check the positional relation between the CDC sensor and the magnet of the large gear. (Fig. 4) CDC Sensor 1. Secure a gap of about 2 mm between the surface of the CDC sensor and that of the CDC magnet. (Fig. 5) Approx. 2 mm Check if there is any short-circuiting in the CN3 connector again. ● When a short-circuiting is found, the positional relation between the CDC sensor and the CDC magnet of the large gear is incorrect. ● When there is no shortcircuit, the CDC sensor is defective. Pulley 1-A Magnet Fig. 4 Replace the CDC sensor. Reference See the Section ES-5 "Replacing the CDC Sensor". Cateye ergometer Service Manual 19 Model T-3 EC-1200 EC-1600 EC-3600 EC-3700 No Display of Pulse Rate Maintenance Check Illustrations 1. Turn on the power to display the in-training screen (any exercise program). 2. Install a brand new pulse sensor, and check if pulse rate will be displayed. ● When the pulse rate can be displayed, the pulse sensor is defective. Replace the pulse sensor with a brand new one. ● If the pulse rate cannot be displayed, this indicates that the pulse sensor jack or pulse sensor jack board is defective. Replace the pulse sensor jack or pulse sensor jack board with the brand new one. Reference See the Section ES-11 "Replacing the Pulse Sensor Jack and Pulse Sensor Jack Board." Cateye ergometer Service Manual 20 EC-C400 EC-C400R Model EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Printer Operation (1) In such cases as display of the LCD panel, etc. operate without problem, but the printer does not operate, the following cases are possible: [1] Checking the Control Unit 1. Check that the printer symbol is displayed on the LCD panel and the printer is in a working status. (Fig. 1) 2. Check if the setting of control unit is in the setting that the printer is not used. (Check if the No.4 select switch on the back of the control unit is in the "OFF" position.) (Fig. 2) ON Printer Symbol In case the printer symbol is not indicated on the LCD panel, press the printer button to have the symbol indicated. 1 Tweezer Printer Cover ● Remove the thermal paper if it is jammed. (Fig. 3) Paper Cutter Fig. 3 5. With the new control unit installed, check the printer operation. Replace the control unit with a brand new one. When the printer does not operate after the abovestated checks, proceed to the following procedures: Cateye ergometer Service Manual 21 3 4 OFF Select Switch Control Unit 4. When no other problems are found, replace the control unit with a brand new one. 2 TIME Fig. 1 3 Check if the thermal paper is not jammed at the printer head. ● When the printer works fine, the control unit is defective. 1 2 3 4 Illsutrations ON MD Maintenance OFF Check ON T-4 EC-1200 Back of Control Unit Fig. 2 Model T-4 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Printer Operation (2) Maintenance Check Illustrations [2] Checking the Main Unit Power Supply Board 1. Turn off the power, and loosen the four screws on the handlebar stem to remove the control unit. (Fig. 4) 2. Remove the cable connector which is connected to the back of the control unit. (Fig. 4) Cable Connector 3. Remove the frame cover. (See the Section D1 & D2 "Removing the Frame Covers.") 4. Remove the CN-2 connector on the power supply board. (Fig. 5) Fig. 4 5. Using a tester, check for any short-circuiting across Terminal 1s and Terminal 5s at both ends of the 5P cable which connects the power supply board and the control unit. (Fig. 6) Fig. 5 Normal when zero (0) ● When there is no shortcircuit, the 5P cable is disconnected. Replace the 5P cable. ● When it is short-circuited, the power supply board is defective. Replace the power supply board. Reference Reference See the Section ES-2 "Replacing the 5P Cable." Connector Terminal 5 See the Section ES-3 "Replacing the Power Supply Board." 5P Cable Fig. 6 Cateye ergometer Service Manual 22 Connector Terminal 5 Model T-5 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 No Loading (Check of mechanical systems) Check Maintenance Illsutrations [1] Checking the Mechanical Systems See the Section D1 & D2 "Removing the Frame Covers" to remove the frame cover, and check the inside of frame. 1. Check if the timing belt has not been cut. (Fig. 1) ● The timing belt is cut. 2. Rotate the crank and check if the belt of the workload unit will rotate. (Fig. 2) Caution When the crank is rotating, keep hands away from the workload unit. Timing Belt Replace the timing belt with a brand new one. Reference See the Section MS-4 "Replacing the Timing Belt." Replace the pulley 1-B with a brand new one. Reference See the Section MS-5 "Replacing the Pulley 1-B Set." ● The pulley 1-B set is idling. Pulley 1-B Idler A Crank Pulley 1-A Set 3. Check if the belt (timing belt) of the workload unit has not been cut. (Fig. 2) ● The workload unit timing belt is cut. 4. Check if the plastic pulley of the workload unit has not been broken. (Fig. 2) ● The plastic pulley is broken. Replace the workload unit. See the Sections MS-1 & MS-2 "Replacing the Workload Unit." Replace the workload unit. Reference Reference Fig. 1 Workload Unit Timing Belt See the Sections MS-1 & MS-2 "Replacing the Workload Unit." Plastic Pulley Fig. 2 Cateye ergometer Service Manual 23 Pulley 1-B EC-C400R Model T-5 EC-1200 EC-1600 EC-3700 No Loading (Check of Electrical Systems) (1) Check Maintenance Illustrations [2] Checking the Electrical Systems 1. Connect the AC adapter, and turn on the power of the main unit. 2. Select the manual training program, set the pedal torque setting to 4.0 kg·m, and rotate the pedal at the rate of 50 rpm. If you can rotate it quite easily, no load will be applied. Caution EC-3600 When the pedal is rotating, keep hands away from the workload unit. 3. Replace the control unit with a brand new one. 4. Again, check the torque status under the manual training program. ● When the pedal torque is loaded, the control unit is defective. Replace the control unit with a brand new one. When no torque loading is possible, proceed to the following procedures. Cateye ergometer Service Manual 24 EC-C400 EC-C400R Model T-5 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Loading (Check of Electrical Systems) (2) Check Maintenance Illsutrations 1. Turn off the power, and loosen the four screws on the handlebar stem to remove the control unit. (Fig. 1) Power Supply Board 2. Remove the cable connector which is connected to the back of the control unit. (Fig. 1) 3. Remove the frame cover. Reference See the Sections D1 & D2 "Removing the Frame Covers." CN-2 Connector 4. Remove the CN-2 connector on the power supply board. (Fig. 2) Fig. 1 5. Using a tester, check for any short-circuiting across Terminal 1s and Terminal 4s at both ends of the 5P cable which connects the power supply board and the control unit. (Fig. 3) ● When there is no shortcircuit, the 5P cable is disconnected. When it is short-circuited, proceed to the following procedures: Fig. 2 Normal when zero (0) Replace the 5P cable with a brand new one. Reference See the Section ES-2 " Replacing the 5P Cable." Connector Terminal 4 5P Cable Fig. 3 Cateye ergometer Service Manual 25 Connector Terminal 4 Model T-5 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R No Loading (Check of Electrical Systems) (3) Maintenance Check Illustrations 1. Remove the connector CN-1 from the power supply board, and measure the resistance across Terminals 2 and 3 of the connector. When the reading is in the range of 9Ω to 14Ω, the connector is all right. (Figs. 4 & 5) ● When the meter reading is exceedingly large, the solenoid coil is defective. ● When the meter reading is in the acceptable range, the power supply board may be defective. Normal for 14V thru 19V Replace the workload unit. Reference See the Sections MS-1 & MS-2 "Replacing the Workload Unit." Replace the power supply board. Reference Connector Terminal 2 CN-1 Connector Fig. 4 Connector Terminal 3 See the Section ES-3 "Replacing the Power Supply Board." CN-1 Connector Fig. 5 Cateye ergometer Service Manual 26 To Solenoid Coil Model T-6 EC-1200 EC-1600 EC-3600 EC-3700 No Pedal Rotation (Locked) Check Maintenance Illsutrations 1. Remove the frame cover, and check the inside of frame. Reference See the Sections D1 & D2 "Removing the Frame Covers." 2. Check if the plain belt of the flywheel has not been detached. (Fig. 1) ● No damage on the plain belt Apply the plain belt correctly. Reference ● The plain belt is damaged. See the Section MS-2 "Replacing the Workload Unit (w/ Flywheel)." Replace the workload unit and free wheel with brand new ones. Reference See the Section MS-2 "Replacing the Workload Unit (w/ Flywheel)." Plain Belt Fig. 1 Cateye ergometer Service Manual 27 EC-C400 EC-C400R Model T-7-1 EC-1200 EC-1600 EC-3600 EC-3700 Unusual Noise (Continuous and Increasing) Maintenance Check Illustrations The noise generating source will be different depending on the cases whether it is of continuous noise or periodical noise (several times per rotation of pedal). Timing Belt [1] Noise is continuous and increasing. 1. Remove the frame cover. (See the Sections D1 & D-2 "Removing the Frame Covers.") 2. Check if the idler A has been worn out. (Fig. 1) When it has been worn out, replace it with a brand new idler A set. Reference 3. Check if the idler B has been worn out. (Fig. 2) When it has been worn out, replace it with a brand new idler B set. Reference 4. Check if the plain belt has been deviated in position, thus causing friction. See the Section MS-6 "Replacing the Idler A Set." See the Section MS-7 "Replacing the Idler B Set." When the plain belt is shifted and is going to be damaged, replace both the workload unit and the flywheel set with new ones. Idler A Fig. 1 Idler Set Idler B Plain Belt Timing Belt Plastic Pulley Fig. 2 Cateye ergometer Service Manual 28 Fig. 3 EC-C400 EC-C400R Model T-7-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Unusual Noise (Periodical) Check Maintenance Illsutrations [2] Noise is Periodical. Crank 1. Noise occurs around once per rotation of the pedal. ● The pedal installation may not be correct. (Fig. 1) Use a No.15 wrench and securely fasten the pedal to the crank. (both sides) No.15 Wrench 2. Sliding noise occurs around 17 times per rotation of the pedal. Pedal Solenoid Coil Remove the frame cover, and check the inside of frame. Reference Fig. 1 See the Sections D-1 & D-2 "Removing the Frame Covers." ● The copper disc plate of the workload unit may touch the solenoid coil. (Figs. 2 & 3) Core Slit Fig. 2 Copper Disc Plate Core Slit Copper Disc Plate Core Core Correct the position of the copper disc plate. Reference See the Sections ES-4 "Correcting the Position of Solenoid Coil." [If the plate is warped and the position of solenoid coil cannot be corrected, replace the workload unit.] Reference Solenoid Coil ❍ Correct Position Fig. 3 See the Sections MS-1 & MS-2 "Replacing the Workload Unit." Cateye ergometer Service Manual 29 ✕ Copper disc plate Solenoid Coil is in contact with the core. Fig. 4 Model T-7-3 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Unusual Noise (Noise occurs when the pedal is rotated with a large torque.) Maintenance Check Illustrations [3] Noise occurs when the pedal is rotated with a large torque. Idler B A large sound "bang" occurs when the pedal is abruptly rotated with a large torque. Pawl Remove the frame cover, and check the inside of frame. Reference See the Sections D-1 & D-2 "Removing the Frame Covers." 1. Check if the idler spring B is detached. Hook the idler spring B on the pawl of the idler. Caution 2. Check if the idler mounting bolt is detached or loosened. Idler Mounting Bolt Idler Spring B Be careful that the end of the spring does not cause injury to your hands. Idler Metal Base Fig. 1 Securely fasten the idler mounting bolt. Cateye ergometer Service Manual 30 Model D-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Removing the Frame Covers (1) Upright Type (EC-1200, EC-1600 & EC-C400) Crank When any repair or adjustment of parts within the frame is required, remove the frame covers in the following procedures. No.15 Wrench REMOVAL 1. Remove the pedals at both the left and right sides. (The left side pedal can be removed by turning it in the clockwise direction, and the right side pedal can be removed in the counterclockwise direction.) (Fig. 1) 2. Remove the crank cover fixing screws. The narrow-width area of the crank cover should be positioned in between the frame cover and the crank. (Fig. 2) ON OFF Pedal Crank Cover Fig. 1 Fig. 2 Lift upward. Leg Pipe Fixing Screw ON OF F 3. Remove the leg pipe fixing screws. (Fig. 3) * You do not have to remove the leg pipe itself. * For the model EC-1600, remove the leg pipe cover. Front Center Cover Rear Leg Pipe Fixing Screw 4. Shift the rubber base at the seat post lock knob away from the center cover. 5. Loosen the center cover fixing screw a little, and lift the center cover upward. (Do not remove it.) (Fig. 4) Fig. 3 Fig. 4 Frame Cover ON 6. Loosen the four screws on the inlet cover. (Fig. 5) OF Four (4) Screws F 7. Remove the frame cover fixing screw with a screwdriver before removing the frame cover. (Fig. 6) Inlet Cover TitleNo Center Cover Fixing Screw Fig. 5 Fig. 5 Cateye ergometer Service Manual 31 Model D-1 EC-1200 EC-1600 Removing the Frame Covers (2) ASSEMBLING 1. Place the frame covers onto the frame at both right and left sides, paying attention to the position of the crank. 2. Fix the right and left frame covers with frame cover fixing screws. 3. Mount the inlet cover with four screws. (Fig. 5) 4. Set the center cover to the frame cover correctly in position, and fix it with the center cover fixing screws. (Fig. 4) 5. Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws. (Fig. 2) 6. Set the rubber base for the seat post lock knob, and then mount the right and left pedals. 7. Fix the leg pipe with the leg pipe fixing screws. (For the model EC-1600, mount the leg pipe cover.) Cateye ergometer Service Manual 32 EC-3600 EC-3700 EC-C400 EC-C400R Model D-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Removing the Frame Covers (1) Recumbent Type (EC-3600, EC-3700 & EC-C400R) When any repair or adjustment of parts within the frame is required, remove the frame covers in the following procedures. Crank ■REMOVAL No.15 Wrench 1. Remove the pedals at both the left and right sides. (The left side pedal can be removed by turning it in the clockwise direction, and the right side pedal can be removed in the counterclockwise direction.) (Fig. 1) 2. Remove the crank cover fixing screws. The narrow-width area of the crank cover should be positioned in between the frame cover and the crank. (Fig. 2) Leg Pipe Fixing Screw Pedal Crank Cover Fig. 1 Fig. 2 Frame Cover Center Cover 3. Remove the leg pipe fixing screws. (Fig. 3) * You do not have to remove the leg pipe itself. R 4. Remove the frame cover fixing screw with a screwdriver before removing the frame cover. (Fig. 4) Screw Fig. 4 Cateye ergometer Service Manual 33 Front Leg with Casters Fig. 3 Model D-2 EC-1200 EC-1600 Removing the Frame Covers (2) ■ASSEMBLING 1. Place the frame covers onto the frame at both right and left sides, paying attention to the position of the crank. At the same time, the center cover should be built in. 2. Fix the right and left frame covers with frame cover fixing screws. 3. Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws. (Fig. 2) 4. Fix the front leg with casters with the leg pipe fixing screws. 5. Mount the pedals. Cateye ergometer Service Manual 34 EC-3600 EC-3700 EC-C400 EC-C400R Model D-3 EC-1200 EC-3600 EC-3700 EC-C400 EC-C400R Disassembly of a Control Unit 1. Turn off the power and remove the control unit, loosening the four screws before doing so. Remove the cable connector from the control unit, too. (Fig.1) Reference EC-1600 Control Unit Cable Connector See the operation manual for details relating to each model. 2. Turn over the control unit to remove the six to eight screws on the back side. This can be separated to the upper and lower body. As the upper and lower bodies are connected with cables, open the unit slowly. 5P Cable Screws Screws EC-3600 3700 C400R EC-1200 1600 C400 Fig. 1 Screws Screws Screws EC-1200 3600 EC-1600 3700 Fig. 2 Cateye ergometer Service Manual 35 EC-C400 C400R Model ES-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Wiring within the Frame (1) [A] Removing the Wiring Parts 1. Remove the frame cover. Reference Power Supply Board Inlet Metal Base Power Supply Board See the Sections D-1 & D-2 "Removing the Frame Covers." 2. Loosen the two screws on the inlet metal base to remove them. (Fig. 1) 3. With the stopper being held with fingers, pull the CN-4 connector off the power supply board. (Fig. 2) ON 4. Cut the cable holder (two places) with a nipper. (Fig. 3) OFF EC-1200 & EC-1600 C400 EC-3600 & 3700 C400R Inlet Metal Base (for Upright Type) Inlet Metal Base (for Recumbent Type) ON Screws DC Jack OFF ON DC Jack Screws OFF Fig. 1 Power Supply Board Hold the stopper. Cable Holders Fig. 2 Fig. 3 Cateye ergometer Service Manual 36 Inlet Metal Base Model ES-1 EC-1200 EC-1600 Replacing the Wiring within the Frame (2) [B] Mounting the Brand New Wiring Parts 1. Mount the brand new inlet metal base to the frame with two screws. 2. Pass the wiring cable from beneath the DC jack of the power supply board along with the square pipe (21mm x 21mm) to the left direction, and then pass it through the back of the inlet metal base along with the square pipe toward the switch. 3. Connect the CN-4 connector to the power supply board. 4. Refer to the Section (2) "Checking the Wiring within the Frame" of T-1 "No Display on the Control Unit after Power ON" (1) , measure the voltage across the electrolytic capacitor C-1 to check that it is in the correct range of 14V to 19V. 5. Use the two cable holders to fix the CDC sensor cable together with the solenoid coil cable. (Fig. 3) 6. Provisionally connect the control unit, and check the unit works fine after turning on the power. Then, completely assemble the frame cover. Cateye ergometer Service Manual 37 EC-3600 EC-3700 EC-C400 EC-C400R Model ES-2 EC-1200 EC-1600 EC-3600 Replacing the 5P Cable : For the model EC-1200 and EC-C400 (1) ● Removing the Existing Cable EC-1200 1. Loosen the four screws which fix the control unit to remove the control unit. Also, remove the cable connector. (Fig. 1) 2. Remove the cable holder which fixes the 5P cable to the handlebar post. Power Supply Board Cble Connector 3. Remove the frame cover. Reference See the Section D-1 "Removing the Frame Covers." Screws Fig. 1 Fig. 2 4. Remove the CN-2 connector from the power supply board. (Fig. 2) 5. Cut the cable holders which fix the 5P cable to the frame, and remove the 5P cable. Cateye ergometer Service Manual 38 EC-3700 EC-C400 EC-C400R Model ES-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the 5P Cable : For the model EC-1200 & EC-C400 (2) ● Mounting the Brand New Cable 1. Mark the 5P cable at a point approx. 87cm (341/4”) from the unit-side cable connector (Fig. 3), and connect the leading end of the CN-2 connector to the power supply board. (Fig. 4) 2. (1)Using cable holders, fix the 5P cable at the bottom of the handlebar pipe of the main unit frame. (2)Fix the cable at the marked point of the cable to the handlebar pipe just beneath the horizontal frame. (3)Pass the 5P cable along with the handlebar pipe, and the sagging portion should be binded with a cable holder. (Fig. 4) Power Supply Board Unit-Side Cable Connector Horizontal Frame 87cm (34-1/4”) Mark this point. Fig. 3 (2) (3) Fig. 4 Cable Holders (1) Fig. 5 3. Connect the cable connector to the control unit, and apply the connector cover. Then, fix the control unit to the handlebar post by using four screws. (Fig. 1) 4. Provisionally turn on the power, and check if the control unit works fine. 5. Fix the 5P connector to the handlebar post with the cable holder. 6. Mount the frame cover. Reference Handlebar Pipe See the Section D-1 "Removing the Frame Covers." Cateye ergometer Service Manual 39 Model ES-2 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the 5P Cable : For the model EC-1600 (1) ● Removing the Existing Cable 5P Cable Handlebar Post 1. Loosen the four screws which fix the control unit to remove the control unit. Also, remove the cable connector. (Fig. 1) Slide the inner handlebar post cover upward, and unplug the cable connector. (Fig. 2) 2. Remove the screws of both the handlebar stem and the outer handlebar post cover to remove the 5P cable. (Fig. 3) Cable Connector EC-1600 Inner Handlebar Post Cover Unplug Screws Screws Fig. 1 Fig. 2 Fig. 3 Power Supply Board 5P Cable within the Frame Handlebar Pipe 1. Remove the frame cover. Reference Horizontal Frame See the Section D-1 "Removing the Frame Covers." (2) (3) 2. Remove the CN-2 connector at the end of the 5P cable from the power supply board. (Fig. 4) 3. Cut the cable holders which fix the 5P cable to the handlebar pipe, and remove the 5P cable. (Fig. 5) Cable Holders Fig. 4 To be continued on the next page. (1) Fig. 5 Cateye ergometer Service Manual 40 Handlebar Stem Cover Model ES-2 EC-1200 EC-1600 EC-3600 Replacing the 5P Cable : For the model EC-1600 (2) ● Mounting the Brand New Cable 5P Cable within the Handlebar Post 1. Using cable holders, bind the 5P cable, leaving approx. 5 cm (2”) portion from the control unit side cable connector, to the handlebar post. (Fig. 11) Assemble the handlebar post cover and the handlebar stem cover. (Fig. 8) 2. Connect the cable connector to the control unit, and fix the unit to the handlebar post by using four screws. (Fig. 6) 10 cm (4”) Cable Connector 5 cm (2”) (1) Cable Holder (3) Cable Holders Fig. 11 5P Cable within the Frame 1. Connect the CN-2 Connector at the end of the 5P cable to the power supply board. (Fig. 9) 2. (1)Using cable holders, fix the 5P cable to the frame, leaving the extra portion of 10 cm (4”) from the top of the handlebar pipe. (2) Fix the 5P cable at the bottom of the handlebar pipe. (3) Pass the 5P cable along the handlebar pipe, and bind the sagging portion to the point (3) by using cable holders. (Fig. 12) (2) Fig. 12 3. Provisionally connect the intermediate cable connector, and turn on the power. Then, check if the control unit works fine. 4. Mount the frame cover to restore the original shape. Reference See the Section D-1 "Removing the Frame Covers." Cateye ergometer Service Manual 41 EC-3700 EC-C400 EC-C400R Model ES-2 EC-1200 EC-1600 EC-3600 Replacing the 5P Cable : For the model EC-3600, EC-3700 & EC-C400R ● Removing the Existing Cable 1. Loosen the four screws which fix the control unit to remove the control unit. Also, remove the cable connector. (Fig. 1) Control Unit 2. Remove the frame cover. 5P Cable Reference Power Supply Board See the Section D-2 "Removing the Frame Covers." 3. Remove the 5P connector from the power supply board. (Fig. 2) Screws Fig. 1 Fig. 2 4. Cut the cable holders which fix the cable to remove the 5P cable. 10 cm (12”) Power Supply Board ● Mounting the Brand New Cable (1) 1. Leaving approx. 30 cm (12”) from the end of the frame, fix the 5P cable to the frame by using cable holders. Cable Holders (2) 2. Connect the 5P cable to the power supply board, and bind the sagging portion to the point (2) of the frame. (Fig. 3) 3. Provisionally turn on the power, and check if the control unit works fine. 4. Mount the frame cover. Reference Fig. 3 See the Section D-2 "Removing the Frame Covers." Cateye ergometer Service Manual 42 EC-3700 EC-C400 EC-C400R Model ES-3 EC-1200 EC-1600 EC-3600 Replacing the Power Supply Board (1) [1] Replacing the Power Supply Board Power Supply Board 1. Remove the frame cover. Reference Power Supply Board See the Sections D-1 & D-2 "Removing the Frame Covers." 2. Remove all connectors CN-1, CN-2, CN-3 and CN-4 which are connected to the power supply board. 3. Loosen the two screws which fix the power supply board to remove the board. (Fig. 1) EC-1200 & 1600 C400 4. Securely fix the brand new power supply board by using two fixing screws. 5. Connect three connectors, CN-2, CN-3 and CN-4. Power Supply Board Fixing Screws Fig. 1 Cateye ergometer Service Manual 43 EC-3600 & 3700 C400R EC-3700 EC-C400 EC-C400R Model ES-3 EC-1200 EC-1600 EC-3600 EC-3700 Replacing the Power Supply Board (2) [2] Adjustment of Coil Current Value Power Supply Board A 1. Connect the cables for measuring coil current between the female connector of the solenoid coil and the male connector (CN-1) on the power supply board, and then connect the cables to an ammeter. (Fig. 2) 2. Turn on the power switch of the main unit, set the control unit to the manual mode, set the load display to 4.0 kg•m, and start the system. 3. Adjust the potentiometer (as shown in Figs. 3 and 4) on the power supply board with a bladehead screwdriver so that the coil current will be the value indicated on the workload unit solenoid coil. (A clockwise turn will increase the current, while a counter-clockwise turn will reduce the current.) Example: When the indication is 630 as shown in Fig. 5, adjust the potentiometer so that the coil current value will be 630mA. 4. Upon completion of the adjustment, detach the cable for measuring coil current, and connect the CN-1 connector directly to the power supply board. Potentiometer Cable for Measuring Coil Current Fig. 3 Fig. 2 Power Supply Board B Solenoid Coil Location of Coil Current Value Indication I mA COIL LOT No. Potentiometer Fig. 4 Fig. 5 Cateye ergometer Service Manual 44 K6020 EC-C400 EC-C400R Model ES-4 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Correcting the Position of Solenoid Coil (1) Perform the positional correction of the core slit section after detaching the frame cover and turning off the power. Reference EC-1200 Workload Unit Reinforcing Metal Base Workload Unit Reinforcing Metal Base See the Sections D-1 & D-2 "Removing the Frame Covers." [1] Correction with Nuts of Workload Unit Reinforcing Metal Base This correction is a minor correction method which allows adjustment by the fastening force of the frame-side nuts of the workload unit reinforcing metal base. 1. Check the contacting area by slowly rotating the copper disk plate with your hands. Caution Be careful that the copper disk Workload Unit Reinforcing Metal Base Lock Nut EC-1200 1600 C400 Solenoid Coil Workload Unit Reinforcing Metal Base plate does not cause injury to your hands. Be careful not to bend or damage the copper disk plate. Move to the Left Lock Nut Workload Unit Reinforcing Metal Base Lock Nut EC-3600 3700 C400R Core Slit ON Solenoid Coil OFF Copper Disk Plate Core Slit Copper Disk Plate Core Core Move to the Right Belt I mA I mA COIL COIL Fig. 1 Solenoid Coil ❍ Correct Position Fig. 2 Cateye ergometer Service Manual 45 Solenoid Coil ✕ Copper disk plate contacts the core. Fig. 3 Model ES-4 EC-1200 EC-1600 Correcting the Position of Solenoid Coil (2) 2. Adjust the position of the two lock nuts on the workload unit reinforcing metal base in the following procedures. (Fig. 1) The base is fixed by the fastening force of the two lock nuts. A. Loosen the two lock nuts temporarily. (Fig.1). B. If the right side of the copper disk plate makes contact with the core as shown in Fig.3, fasten the left-side nut. The plate moves to the left gradually. Adjust the plate until it comes close to the center of the core center. (Fig.2). At this position, rotate the plate slowly, and check for any contact over the entire area of the plate. C. Fasten the lock nuts once again. [2] In case correction is not possible by the method stated in [1]. Replace the whole workload unit. Reference See the Section MS-1 or MS-2 "Replacing the Workload Unit." Cateye ergometer Service Manual 46 EC-3600 EC-3700 EC-C400 EC-C400R Model ES-5 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the CDC Sensor (1) 1. Remove the frame cover. Reference See the Sections D-1 & D-2 "Removing the Frame Covers." Power Supply Board Power Supply Board 2. Detach the CN-3 connector from the power supply board. (Fig. 1) CDC Sensor 3. Cut the cable holders which fix the CDC sensor cable to the frame. 4. Remove the defective CDC sensor set by loosening the screws, and mount and fix the brandnew CDC sensor set. (Fig. 2) CDC Sensor Reference EC-3600 & 3700 C400R EC-1200 & 1600 C400 5. Adjust the gap between the surface of CDC sensor and the surface of CDC magnet to be approx. 2 mm. (Fig. 3) CDC Sensor Power Supply Board If the gap is inadequate, bend the metal base to secure the specified gap. CDC Metal Base Approx. 2 mm Pulley 1-A CDC Sensor CN-3 Connector Magnet Fig. 1 Fig. 2 Cateye ergometer Service Manual 47 Fig. 3 Model ES-5 EC-1200 EC-1600 Replacing the CDC Sensor (2) 6. Securely connect the CN-3 connector to the power supply board. (Fig. 1) 7. Rotate the crank, and check if the pedal cadence will be displayed on the control unit. 8. Fix the CDC sensor cable to the frame by using cable holder. (Fig. 5) Cable Holder 9. Assemble the frame cover. Reference See the Sections D-1 & D-2 "Removing the Frame Covers." Fig. 5 Cateye ergometer Service Manual 48 EC-3600 EC-3700 EC-C400 EC-C400R Model ES-6 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Panel Keyboard 1. Remove the control unit by loosening four screws. Also remove the cable connector from the control unit. (Fig. 1) Control Unit 2. The control unit can be separated into upper and lower parts when the eight screws on the bottom of the lower body of the unit are removed (Fig. 2). Be careful to separate them slowly since the upper and lower bodies are connected with a flat cable. 3. Remove the connector on the panel keyboard which is located at the upper body side, loosen the ten screws on the substrate, and remove them from the upper body. (Fig. 3) Substrate Cable Connector Connector Control Unit Fig. 1 Fig. 2 Fig. 3 Control Unit 4. Since the panel keyboard is fixed to the control unit with silicon, cut the silicon with a sharp cutter (Fig. 4). Peel the panel keyboard off the surface of upper body. (Fig. 5) Upper Body 5. If the silicon remains at the upper body, remove it thoroughly. 6. Place the brandnew panel keyboard. The cable from the keyboard should be pulled in through the hole on the upper body. Press and adhere the panel keyboard in position. Substrate Fixing Screw Screw Silicon Fig. 4 Panel Keyboard Silicon Fig. 5 Fig. 6 7. Apply silicon at two depicted areas to prevent intrusion of sweat. (Figs. 4 and 6) 8. Mount the substrate and fix it with ten screws, and insert the connector of the panel keyboard. (Fig. 3) TitleNo 9. Put the upper and lower body together, and fix them with eight screws. 10. Connect the cable connector to the control unit, and mount the unit to the main unit. Cateye ergometer Service Manual 49 Model ES-7 EC-1200 EC-1600 EC-3600 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 body, and carefully peel off the button panel. (Fig. 1 and 2) L TRO HR CON E ANC ADV OBIC AER OBIC AER GHT WEI HIL S LOS L 1 S ER ATE PR ES TO OP " AL LY MA NU UI CK 2 3 "Q AL ERV INT 1 2 Caution QU 3 Be careful that the blade of the INT HIL AN T NST CO TTA GE WA HR CO NTR cutter does not cause injury to your hands. 2. Clean the adhesive agent, if any, on the control unit before placing a brandnew button panel. Reference Sufficiently press the button panel thus placed. ICK AL ERV T STAR L MO DE OL S NEST FIT TES STOP Control Unit Button Panel EC-1200 3600 Control Unit EC-C400 C400R Fig. 2 Fig. 1 Cateye ergometer Service Manual 50 Button Panel EC-3700 EC-C400 EC-C400R Model ES-8 EC-1200 EC-1600 Replacing the Printer 1. Open the control unit into upper and lower bodies by referring to the Section ES-6 "Replacing the Panel Keyboard (1) & (2)." CN-2 Connector Printer Unit 2. Unit is fixed to the lower body with two screws. Remove these two screws. (Fig. 1) 3. The printer unit can be removed after detaching cable connectors CN-2 and CN-3 of the printer unit. To remove connector CN-2, pull it, lifting the printer unit upward. (Fig. 2) 4. Connect the connector CN-2 of the brandnew printer unit. Then, connect CN-3. For the connection, press it while moving it to right and left side alternatively. Printer Fixing Screws Fig. 1 CN-3 Connector Fig. 2 5. Fix the printer unit with two screws. (Fig. 1) 6. Put the upper and lower bodies together, and fix them with eight screws. 7. Adjust the printing darkness by referring to the Section ES-9 "Adjusting the Printing Darkness." 8. Mount the control unit to the main unit. Cateye ergometer Service Manual 51 EC-3600 EC-3700 EC-C400 EC-C400R Model ES-9 EC-1200 EC-1600 EC-3600 Adjusting the Printing Darkness 1. Remove the control unit from the main unit. (Fig. 1) Upright Type Recumbent Type 2. Loosen four screws on the bottom of the control unit, and remove the cable connector from the unit. (Fig. 1) 3. Remove the black metal base on the bottom of the control unit. (Fig. 2) 4. Provisionally connect the 5P connector on the bottom of the control unit to the main unit. 5. Turn on the power. Check if the printer symbol appears on the LCD panel and the printer is in the operating condition. Control Unit Cable Connector Cable Connector Control Unit Fig. 1 6. Check if the thermal paper is set in position. 7. Adjustment should be done with the control unit positioned horizontally. Press the ADV button on the control panel twice to perform a test printing. A counter-clockwise turn of the potentiometer PR on the bottom of the control unit will decrease the darkness, while a clockwise turn will increase it (Fig. 2). Set it to an appropriate darkness level. (An extreme clockwise turn of the potentiometer may distort the printed characters.) Caution DCV PR Potentiometer PR Fig. 2 Never touch the potentiometer DCV. Cateye ergometer Service Manual 52 EC-3700 EC-C400 EC-C400R Model ES-10 EC-1200 EC-1600 Paper Jamming in Printer 1. Open the control unit into upper and lower bodies by referring to the Section ES-6 "Replacing the Panel Keyboard (1) & (2)." Pincette 2. Remove the jammed paper with a tweezer or the like. (Fig. 1) 3. Assemble the control unit by referring to the Section ES-6 "Replacing the Panel Keyboard (9) & (10)." 4. Set the printer paper. Reference See the Operation Manual. Printer Unit Fig. 1 Cateye ergometer Service Manual 53 EC-3600 EC-3700 EC-C400 EC-C400R Model ES-11 EC-1600 EC-3600 EC-3700 EC-C400 Replacing the Pulse Sensor Jack and Pulse Sensor Jack Board (1) ■Replacing the Pulse Sensor Jack Board 1. Turn off the power and open the control unit which accesses the upper and lower bodies. Reference EC-1200 Pulse Sensor Jack Board Pulse Sensor Jack Board Pulse Sensor Jack Board See the Section D-3 "Decomposition of a Control Unit ". 2. In the case of the three cables (or four in the case of the ES-C400 and ES-C400R) soldered to the board, number the cables so that they can be matched to cable numbers 1 to 4 on the board. (Fig.1) Remove the cables using a soldering iron. Remove the defective board. Cable Cable EC-1200 & EC-3700 EC-1600 & EC-3600 Fig. 1 3. Insert a brand new board and solder the cable in place. Match the cables to the numbered cables on the board. 4. Bring the upper and lower bodies together and fasten them temporarily with the eight screws. 5. Insert the pulse sensor and check whether or not the control unit displays a value. Cable Fig. 2 6. Fasten the eight screws. Cateye ergometer Service Manual 54 EC-C400 & EC-C400R EC-C400R Model ES-11 EC-1200 EC-1600 Replacing the Pulse Sensor Jack and Pulse Sensor Jack Board (2) 7. Mount the control unit on the main unit. Warning Pulse Sensor Jack Be sure to turn off the power before starting work. Particularly, in case of the ECC400 and EC-C400R, the parts indicated in figure 2 are operating at high voltage and may cause electric shock. Furthermore, residual electric current is likely to be present for a little while after the power is turned off. Before restarting work, wait a few moments after the power has been turned off. Solder Fig. 3 ■Replacing Only the Pulse Sensor Jack 1. Turn off the power and open the control unit which accesses the upper and lower bodies. Reference See the Section D-3 "Disassembly of a Control Unit ". 2. Lift the ear sensor jack board but not to the extent that the cable will become taut, and remove the jack with a soldering iron. Excessive solder should be removed using solder remover, etc. 3. Solder a brand new pulse sensor jack in place. (Fig.3) Cateye ergometer Service Manual 55 EC-3600 EC-3700 EC-C400 EC-C400R Model ES-12 EC-1600 EC-3600 EC-3700 Replacing the HR Receiving Board (1) 1. Turn off the power and open the control unit which accesses the upper and lower bodies, Reference EC-1200 Connector HR Receiving Board See the Section D-3 "Disassmbly of a Control Unit ". 2. Remove the connector from the reception board. (Fig.1) 3. Loosen the four screws to remove the board. (Fig.1) 4. Install a brand new board, securing it with four screws. Insert a connector. HR Receiving Board EC-C400 & EC-C400R Connector EC-1600 & EC-3700 Fig. 1 5. Bring the upper and lower bodies together and secure them with eight screws. EC-C400 & EC-C400R EC-1600 & EC-3700 Fig. 2 Cateye ergometer Service Manual 56 EC-C400 EC-C400R Model ES-12 EC-1200 EC-1600 Replacing the HR Receiving Board (2) 6. Install the control unit in the main unit. Warning Be sure to turn off the power before starting work. Particularly, in case of the ECC400 and EC-C400R, the parts indicated in figure 3 are operating at high voltage and may cause electric shock. Furthermore, residual electric current is likely to be present for a little while after the power is turned off. Before restarting work, wait a few moments after the power has been turned off. Caution Fig. 3 The HR reception board is standard in the case of equipment for export while it is optional in the case of equipment sold on the domestic market. For information related to installation (in the case of products sold on the domestic market), follow the instructions in the operation manual of the Reception Board Kit. Be sure the power is turned off. Before restarting work, wait a few moments after the power has been turned off. Cateye ergometer Service Manual 57 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Workload Unit (w/o Flywheel) (1) ■ Removing the Workload Unit 1. Remove the frame cover. Reference Power Supply Board See the Section D-1 "Replacing the Frame Covers." CN-1 Connector 2. Detach the CN-1 connector on the power supply board. 3. Using a nipper or the like, cut the cable holder which fixes the CN-1 connector, while paying attention not to damage the cable. (Fig. 2) EC-1200 Power Supply Board Workload Unit Fig. 1 Cable Holder Fig. 2 4. Remove the crank pulley 1-A set. Reference See the Section MS-8 "Replacing the Crank Pulley 1-A Set." Also, remove the timing belt together with the crank pulley 1-A set. 5. Using a wrench, loosen the nuts, which fix the workload unit reinforcing metal base, on both the workload unit side and the frame side, and remove the metal base. (Fig. 3) Workload Unit Reinforcing Metal Base Workload Unit Workload Unit Fixing Metal Base Fig. 3 Fig. 4 6. Remove the hexagonal head bolts securing the workload unit (four points at the right and left) as well as the bolt securing the workload unit metal base. Lift the entire unit upward and off the base, and then lift it either to the right or left to remove it completely. TitleNo Caution Be careful that your hands are not injured by the copper disk plate when lifting the unit. Be careful not to bend or damage the plate. Cateye ergometer Service Manual 58 Workload Unit Fixing Bolt Model MS-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Workload Unit (w/o Flywheel) (2) ■ Mounting the brand new Workload Unit 1. Assemble a brand new workload unit so that it will engage with the workload unit mounting metal base of the frame. (Fig.1) Caution Be careful that your hands are not injured by the copper disk plate. Be careful not to bend or damage the plate. 2. Tighten the crank bolt by using a cotterless gear crank removing/ fastening tool and a wrench (Figs. 2 and 3). Tightening torque should be 350kg cm to 400kg·cm, and tighten the bolt until the end of the crank shaft can level with the end surface of the bolt. Then, put Workload Unit Workload Unit Fixing Metal Base Cotterless Gear Crank Removing/Fastening Tool Cotterless Gear Crank Removing/Fastening Tool Fig. 1 Fig. 2 Fig. 3 Timing Belt Timing Belt Idler A Set the crank cap with a coin or the like. (Fig. 4) 3. Position the timing belt on the pulley 1-B. (Fig.4) 4. Position idler spring A on the pawl of the idler A set. (Fig.5) Caution Idler Spring A Pulley 1-B Fig. 4 Fig. 5 Be careful that the end of the spring does not cause injury to your hands. 5. Position the timing belt on the pulley 1-A set. The entire timing belt can be positioned by rotating the crank forward (Fig.6) Caution Be careful not to pinch your fingers between the timing belt and crank pulley 1-A set. Cateye ergometer Service Manual 59 Crank Pulley 1-A Set Fig. 6 Model MS-1 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Workload Unit (w/o Flywheel) (3) 6. Adjust the position of the workload unit so that the tension of the timing belt in the loaded area is optimal. Move the workload unit back and forth so that the longer edge of the derailleur fixing metal base is perpendicular to idler spring A. (Fig.7) Caution EC-1200 Be careful that your hands are not injured by the copper disk plate. Be careful not to bend or damage the plate. Workload Unit Reinforcing Metal Base Workload Unit Fixing Metal Base Bolt Idler A Set 90 Lock Nut Workload Unit Fixing Bolt Idler Spring A Fig. 7 Fig. 8 7. Tighten the workload unit fixing bolts securing the workload unit (four points, at the right and left) as well as the bolt for the base with a spanner. (Fig. 8) The tightening torque is 90 kg/cm to 120kg/cm. 8. Assemble the workload reinforcing metal base in between the bolts at the workload side and the frame side, and tighten the bolts with nuts. (Fig. 9) * In case the nut is screwed in at the position where the workload-unit-side workload unit metal base is supposed to be mounted, remove the nut. * The tightening torque at the workload unit side should be 90kg·cm to 120kg·cm, and the nut at the frame side should be provisionally tightened. Cateye ergometer Service Manual 60 Fig. 9 Workload Unit Side Bolt Model MS-1 EC-1200 EC-1600 Replacing the Workload Unit (w/o Flywheel) (4) ■ Checking the Positions of Copper Disk Plate and Solenoid Coil Core Slit ● Regarding the workload unit, positions of copper disk plate and solenoid coil core slit have been adjusted before mounting the frame so that they will not touch each other while the plate is rotating. However, due to positional distortion caused by tightening the bolts while the frame is being mounted, the copper disk plate may touch the core. (Fig. 1) Correct Position Core Slit Copper Disk Plate Core Fig. 1 ● Rotate the copper disk plate slowly to check if it does not touch the core. If it does, it is necessary to eliminate the positional distortion caused by the tightening. Caution When the copper plate is rotating, keep hands away from unit. Reference See the Section ES-4 "Correcting the Position of Solenoid Coil." Cateye ergometer Service Manual 61 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-1 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Workload Unit (w/o Flywheel) (5) Correction Method Correction can be made by tightening the frame-side nuts of the workload reinforcing metal base. Tighten the metal base toward the direction in which the positional correction of the copper disk plate should be made, until the plate comes close to the center of the core slit (Fig. 1). Reference Power Supply Board Workload Unit Reinforcing Metal Base Frame-Side Nut CN-1 Connector Workload-UnitSide Nut See the Section ES-4 "Correcting the Position of Solenoid Coil." 1. After checking the correction direction, use a wrench to tighten the frame-side nut of the workload unit reinforcing metal base. Give the even tightening to both right and left sides. CN-1 Female Connector Fig. 2 Fig. 3 Power Supply Board A 2. As shown in Fig. 3, set a cable for measuring coil current in between the CN-1 female connector and the CN-1 male connector at the side of power supply board, and connect the cable to an voltmeter. 3. Turn on the power switch of the main unit, set the control unit to the manual mode, select the torque at 4.0kg·m, and start the system. Cable for Measuring Coil Current Power Supply Board B I mA COIL LOT No. K6020 Potentiometer Fig. 4 Fig. 5 4. Adjust the volume of the power supply board (Fig. 5 and 6) with a driver until the coil current rate is the same as the value (Fig.4) displayed on the solenoid coil in the workload unit. Example: As shown in Fig. 3, when 630 is indicated, adjust the potentiometer so that the coil current will be 630mA. Cateye ergometer Service Manual 62 Potentiometer Fig. 6 Model MS-1 EC-1200 EC-1600 Replacing the Workload Unit (w/o Flywheel) (6) 5. After having adjusted the coil current, remove the measuring cable, and connect the female connector of the CN-1 cable directly to the male connector at the power supply board side. 6. Fix the cable onto the seat pipe with cable holders. ■ Adjusting the Flywheel 1. Adjust the flywheel by referring to the Section MS-3 "Adjusting the Flywheel." Cateye ergometer Service Manual 63 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-2 EC-1200 EC-1600 EC-3600 EC-3700 Replacing the Workload Unit (w/ Flywheel) (1) ■ Removing the Workload Unit Flywheel 1. Remove the crank pulley 1-A set and the timing belt. Reference See the Items 1 to 4 in Section MS-1 "Replacing the Workload Unit (w/o Flywheel) (1)." 2. Loosen the flywheel fixing nut which is fixed to the flywheel metal base. (Fig. 1) Workload Unit Workload Unit EC-3600 & 3700 C400R ON EC-1600 3. Remove the four bolts which fix the flywheel metal base, and remove the plain belt. (Fig. 2) Caution Flywheel OFF Flywheel Be careful that your hands are not injured by the copper disk plate. Be careful not to bend or damage the plate. Flywheel Fixing Nut Flywheel Metal Base Plain Belt Flywheel Fixing Metal Base 4. Remove the workload unit. Reference See the Items 5 to 6 in Section MS-1 "Replacing the Workload Unit (w/o Flywheel) (1)." Flywheel Fixing Nut Fig. 1 Metal Base Fixing Screw Fig. 2 Cateye ergometer Service Manual 64 EC-C400 EC-C400R Model MS-2 EC-1200 EC-1600 Replacing the Workload Unit (w/ Flywheel) (2) ■ Mounting the brand new Workload Unit 1. Assemble the brand new workload unit so that it will engage with the workload unit mounting metal base of the frame (Fig. 1). Reference See the Item 1 of the Section MS-1 "Replacing the Workload Unit (w/o flywheel) (2)." 2. Hang the plain belt on the flywheel, and fix it to the flywheel metal base with the flywheel fixing nut. 3. Provisionally fasten the metal base fixing screw (4 pieces) to the flywheel fixing metal base and the frame respectively. (Fig. 2) 4. Install the workload unit. Reference See the Items 2 to 8 in Section MS-1 "Replacing the Workload Unit (w/o Flywheel) (2)." ■ Adjusting the Flywheel 1. Adjust the flywheel. Reference See the Section MS-3 "Adjusting the Flywheel." Cateye ergometer Service Manual 65 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-3 EC-1200 EC-1600 EC-3600 Adjusting the Flywheel ■ Adjustment Method of Flywheel Since the plain belt which delivers the rotation of both the workload unit and flywheel requires an adequate tension, a specified tension should be given to the plain belt in the following adjustment procedures. For this adjustment, a commonly available spring scale. Flywheel Metal Base Spring Scale Flywheel Metal Base 1. Set a heavy gauge wire around the flywheel metal base as depicted in Fig. 1, and tie up the both ends outside the frame. Flywheel Metal Base Fixing Screw Wire Fig. 2 2. Hang a commercial spring scale at the top of the wire thus tied up, and lift the scale upward with a pulling force of 5 to 6 kg. 3. Keeping this status, fully tighten the four metal base fixing screws which had been fastened provisionally. (Fig. 2) Metal Base Fixing Screws Fig. 1 Cateye ergometer Service Manual 66 EC-3700 EC-C400 EC-C400R Model MS-4 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Timing Belt (1) 1. Remove the frame cover. Reference See the Sections D-1 & D-2 "Removing the Frame Covers." Idler A Set Crank Pulley 1-A Set Screw 2. Remove the eight fixing screws and then remove the pulley flange. (Fig.1) 3. Remove the timing belt at the upper part of the crank pulley 1-A set first, and then rotate the crank forward to remove the entire timing belt. (Fig.2) 4. Removing idler spring A from the pawl of the idler A set will allow the entire timing belt to be removed. (Fig.3) Pulley Frange Fig. 1 Fig. 2 Fig. 3 Crank Pulley 1-A Set Timing Belt 5. Install a brand new belt on the on pulley 1-B. (Fig.4) 6. Position idler spring A on the pawl of the idler A set. (Fig.3) Caution Be careful that the end of the spring does not injure your hands. Pulley 1-B Fig. 4 Fig. 5 7. Position the timing belt on the crank pulley 1-A set. A forward rotation of the pulley 1-A set allows the timing belt to be set correctly. (Fig.5) Caution Be careful not to pinch your fingers between the timing belt and the crank pulley 1-A set. 8. Secure the flange of the pulley with the fixing screws. Cateye ergometer Service Manual 67 Idler Spring A Timing Belt Model MS-4 EC-1600 Replacing the Timing Belt (2) 9. Adjust the tension of the timing belt. To carry out adjustment, loosen the workload unit fixing screw and adjust the tension while sliding the unit back and forth. (Fig.6) Caution EC-1200 Be careful that the belt is not too tight. Be careful not to injure your hands with the copper disk plate. Be careful not to bend or damage the plate. Workload Unit Fixing Metal Base Bolt Workload Unit Fixing Screw Fig. 6 10. Assemble the frame cover. Reference See the Sections D-1 & D-2 "Removing the Frame Covers." Cateye ergometer Service Manual 68 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-5 EC-1200 EC-1600 EC-3600 Replacing the Pulley 1-B Set 1. Detach the timing Belt. Reference See the Section MS-4 "Replacing the Timing Belt." 2. Hold the D-cut section on the pulley 1-B shaft with a No.13 wrench, and remove the hexagon U-nut. Then, pull off the pulley 1-B set by using a pulley 1-B remover. (Figs. 1 & 2) 3. Mount the brand new pulley 1-B set, and firmly tighten the hexagon nut. Tightening should be done while holding the D-cut section with a No.13 wrench. (Fig. 1) Pulley 1-B Pulley 1-B ON EC-3600 3700 C400R EC-1200 1600 C400 Idler Pulley 1-B 4. Install the timing belt. Reference OFF Timing Belt See the Section MS-4 "Replacing the Timing Belt." D-Cut Section Pulley 1-B Fig. 1 Hexagon U-Nut Fig. 2 Cateye ergometer Service Manual 69 EC-3700 EC-C400 EC-C400R Model MS-6 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Idler A Set 1. Remove the screw of the crank pulley 1-A set to remove the pulley flange. (Fig.1) 2. Remove the timing belt at the upper part of the crank pulley 1-A set first, and then rotate the crank forward to remove the entire belt. (Fig.2) Idler A Set Idler A Set 3. Remove idler spring A from the pawl of the idler A set. (Fig.3) 4. Remove the idler fixing bolt of the idler A set to remove the idler A set. (Fig.4) EC-3600 3700 C400R EC-1200 1600 C400 5. Mount the brand new idler A set with idler fixing bolt. Crank Pulley 1-A Set Screw Idler A Set 6. Position idler spring A on the pawl of the idler A set. Caution Be careful that the end of the spring does not injure your hands. 7. Position the timing belt on the pulley 1-A set. Rotate the pulley set forward to set the belt. Caution Be careful not to pinch your fingers between the timing belt and crank pulley 1-A set. Pulley Frange Fig. 1 Mounting Bolt 8. Mount the pulley flange with screws. Idler A Set Fig. 4 Cateye ergometer Service Manual 70 Idler Spring A Timing Belt Fig. 2 Fig. 3 Model MS-7 EC-1200 EC-1600 EC-3600 Replacing the Idler B Set 1. Remove the frame cover. Reference See the sections D-1 & D-2 "Removing the Frame Covers." Idler B Set Idler B Set 2. Remove the idler B spring from the pawl of the idler metal base. (Fig. 1) 3. Loosen the idler B mounting bolts, and detach the idler B set. (Fig. 2) 4. Mount a brand new idler B set by using an idler mounting bolt. EC-3600 3700 C400R EC-1200 1600 C400 5. Hang the idler B spring on the pawl of the idler Caution Idler B Set Idler B Set to give tension to the belt. Be careful that the end of the spring does not injure your hands. Idler Mounting Bolt Idler Spring B Fig. 1 Fig. 2 Cateye ergometer Service Manual 71 EC-3700 EC-C400 EC-C400R Model MS-8 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Crank Pulley 1-A Set (1) ■ Removing the CrankPulley 1-A Set 1. Remove the frame cover. Reference Crank Pulley 1-A Set See the Sections D-1 & D-2 "Removing the Frame Covers." 2. Detach the timing belt. Reference See the Section MS-4 "Replacing the Timing Belt." 3. Insert a flat had driver into the groove of the crank cap to remove the crank cap. (Fig.2) 4. Use a cotterless gear crank removing/fastening tool and a wrench, rotate the crank bolt to remove it. (Fig. 3) Crank Pulley 1-A Set EC-3600 3700 C400R EC-1200 1600 C400 Crank Pulley 1-A Set Cotterless Gear Crank Removing/Fastening Tool 5. Change the sides of a cotterless gear crank removing/fastening tool, and rotate it clockwise to remove the crank pulley 1-A set from the crank shaft. (Fig. 4) Crank Cap Timing Belt - to be continued to the next page - Fig. 1 Fig. 2 Cotterless Gear Crank Removing/Fastening Tool Fig. 4 Cateye ergometer Service Manual 72 Fig. 3 Model MS-8 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Crank Pulley 1-A Set (2) ■ Assembling the Crank Pulley 1-A Set Cotterless Gear Crank Removing/Fastening Tool 1. Mount the gear crank (crank) to the crank shaft. 2. Securely fasten the crank bolt by using a socket wrench (or by a cotterless gear crank removing/fastening tool and a wrench). (Figs. 1 & 2) Caution Each of the cranks should be positioned relative to each other to form an angle of 180 °against the gear. (Fig.3) 3. Clamp the crank cap. Right-Side Crank Left-Side Crank Cotterless Gear Crank Removing/Fastening Tool Fig. 1 Fig. 2 Crank Pulley 1A Set Fig. 3 Workload Unit Fixing Metal Base Bolt Screw 4. The timing belt should be first positioned on pulley 1-B and then on the upper part of the crank pulley 1-A set. A forward rotation of the crank will allow the belt to be set correctly (Fig.4) Caution Be careful not to pinch your fingers between the timing belt and crank pulley 1-A set. Pulley Flange Pulley 1-B Fig. 4 Fig. 5 5. Mount the pulley flange with screws. 6. Adjust the tension of the timing belt. To carry out adjustment, loosen the screws of the workload unit (four points, at the right and left) as well as the bolt which secures the metal base, and then adjust the tension while sliding the unit back and forth. (Fig.5) Caution Be careful that the timing belt is not too tight. Be careful not to injure your hands with the copper disk plate. Be careful not to bend or damage the plate. Cateye ergometer Service Manual 73 Workload Unit Fixing Screw Fig. 6 Model MS-8 EC-1200 EC-1600 Replacing the Crank Pulley 1-A Set (3) 7. Adjust the clearance between the magnet mounted on the large gear and the CDC sensor, and also adjust the positions of the sensing lines. Reference See the Item (5) of Section ES-5 "Replacing the CDC Sensor (1)." 8. Turn on the power temporarily, and check whether or not the pedal cadence is displayed on the control unit. 9. Reassemble the frame cover. Reference See the Sections D-1 and D-2 "Removing the Frame Covers." Cateye ergometer Service Manual 74 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-9 EC-1200 EC-1600 EC-3600 EC-3700 Replacing the Cartridge BB Set (1) ■ REMOVAL 1. Remove the frame cover. Reference Cartridge BB Set See the Sections D-1 & D-2 "Removing the Frame Covers." 2. Remove the crank pulley 1-A set from the crank shaft (BB Axle). Reference See the Section MS-8 "Replacing the Crank Pulley 1-A Set." 3. Remove the cartridge BB from the left side using a cartridge BB removing tool and a wrench. (Fig.1) Reference Cartridge BB Set Loosen Loosen Cartridge BB Cartridge BB Removing Tool Cartridge BB Removing Tool (SHIMANO TL-UN74S/BB) 4. Remove the BB fixing cup using a cartridge BB removing tool and a wrench. (Fig.2) The CDC sensor (metal base) will be removed at the same time. Caution EC-3600 3700 C400R EC-1200 1600 C400 The BB fixing cup is a left winding screw. To loosen the screw, turn it to the right. Fasten Fasten Cartridge BB Removing Tool Fig. 1 CDC Sensor Fig. 2 Cateye ergometer Service Manual 75 EC-C400 EC-C400R Model MS-9 EC-1200 EC-1600 Replacing the BB Set (2) ■ ASSEMBLING CDC Sensor Metal Base 1. Install the right BB fixing cup. Be sure to install the CDC sensor metal base first, before then installing the fixing cup. 2. Mount cartridge BB. The tightening torque is 400kg/cm. CDC Sensor Approx. 2 mm 3. Install the crank pulley 1-A set. Pulley 1-A Reference See the Section MS-8 "Replacing the Crank Pulley 1-A Set." Magnet Fig. 3 4. Adjust the clearance between the CDC sensor surface and the magnet surface to be approx. 2mm. (Fig. 3) Reference When the specified clearance has not been established, bend the metal base to have the clearance. 5. Turn on the power temporarily, and check whether or not the pedal cadence is displayed on the control unit. 6. Reassemble the frame cover. Reference See the Sections D-1& D-2 "Removing the Frame Covers." Cateye ergometer Service Manual 76 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-10 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Post Spacer ■ REMOVAL 1. Remove the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type." Spacer Spring Lock Nut Post Spacer Adjust Screw Adjust Screw Boss 2. Remove the lock nut located at the side of the frame, and then remove the adjust screw. (Fig. 1) Press in. 3. Pull out the spacer spring. (Fig. 1) 4. The post spacer can be pulled out upward while the boss at the side of the post is being pressed in with a screwdriver (for both right and left sides). (Fig. 2) Lock Nut Fig. 1 Fig. 2 ■ ASSEMBLING 1. Insert a brand new post spacer. 2. Insert the spacer spring, and slightly fasten the adjust screw. (Fig. 3) 3. Insert the seat post (handleber post), and adjust the adjust screw so that the post will drop slowly. 4. Fasten the lock nut to lock the adjust screw. 5. Assemble the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type." Cateye ergometer Service Manual 77 Fig. 3 Model MS-11 EC-1200 EC-1600 Adjusting the Spacer Spring 1. Remove the center cover, by referring to the Section MS-19 "Replacing the Center Cover of Upright Type." Lock Nut Adjust Screw 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 MS-19 "Replacing the Center Cover of Upright Type." Fig. 1 Cateye ergometer Service Manual 78 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-12 EC-1200 EC-1600 EC-3600 EC-3700 Replacing the Inner Pipe Spacer ■ REMOVAL 1. Slide the seat pipe to the utmost back end, and set it at a position where the screw head can be seen through the hole on the top surface of the seat pipe. Inner Pipe Spacer A Stopper Screw Pull out. Inner Pipe 2. Remove the stopper screw. (Fig. 1) 3. Pull out the seat pipe and the inner pipe spacer A, while depressing the two bosses, located at the right and left sides of the seat pipe, at the same time. (Fig. 2) Caution Pulling out the inner pipe will make the machine unstable. As they are heavy, be sure that two persons work together to carry the units. Boss Inner Pipe Seat Pipe Fig. 1 Fig. 2 Inner Pipe Spacer A Inner Pipe Spacer B Inner Pipe Spacer B Insert. 4. Remove the spacer B at the end of the inner pipe. (Fig. 3) Seat Pipe Inner Pipe ■ ASSEMBLING 1. Set a brand new inner pipe spacer B into the seat pipe. (Fig. 4) Caution Inner Pipe Fig. 3 Fig. 4 When installing each unit, be careful not to compact or kink the cord of the pulse sensor. 2. Insert the inner pipe spacer A and B together into the seat pipe. 3. Align the hole on the top surface of the seat pipe with the screw hole, and apply the stopper screw. (Fig. 1) Cateye ergometer Service Manual 79 EC-C400 EC-C400R Model MS-13 EC-1600 EC-3600 Replacing the Vertical Pipe Spacer 1. Remove the seat height lock knob, and pull out the rear support pipe. (Fig. 1) Caution EC-1200 When holding the main body of the unit, be careful when pulling out the seat height locking 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. Seat Height Lock Knob Rear Support Pipe Rear Support Pipe Insertion Area Fig. 1 Rear Support Pipe Spacer 3. Apply and set a brand new rear support pipe spacer with an adhesive tape. (Fig. 2) Adhesive Tape 4. Insert the rear support pipe, and fix it with the seat height lock knob. Fig. 2 Cateye ergometer Service Manual 80 EC-3700 EC-C400 EC-C400R Model MS-14 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 Replacing the Leg Cover ■ REMOVAL 1. Remove the leg pipe from the main body. Also, remove the leveling knob. (Fig. 1) Leg Cover Leveling Knob 2. Apply a screwdriver or the like to the damaged leg cover, and knock the cover off, paying attention not to damage the caster. (Fig. 2) Screwdriver Leg Cover ■ ASSEMBLING 1. Set the leg cover onto the leg, and hammer it in. The use of a wood block is recommended as a buffer. (Fig. 3) Fig. 1 Fig. 2 * A direct hammering of the leg cover may damage the leg cover. Fig. 3 2. Mount the leveling knob and assemble it to the frame. Cateye ergometer Service Manual 81 EC-C400R Model MS-15 EC-1200 EC-1600 EC-3600 Replacing the Caster and Level Adjuster 1. Loosen the screw and remove the front leg with casters (rear leg with level adjuster) from the main unit (leg). 2. The caster (level adjuster) has been pressfitted into the front leg with casters (rear leg with level adjuster). It can be removed by hammering it through a wooden block. (Fig. 1) 3. Press fit a brand new caster (level adjuster) with a hammer and a wood block. (Fig. 2) Front Leg with Casters (Rear Leg with Level Adjuster) Wood Block Wood Block 4. Mount the front leg with casters (rear leg with level adjuster) to the main unit (leg). Front Leg with Casters (Rear Leg with Level Adjuster) Caster (Level Adjuster) Fig. 1 Fig. 2 Cateye ergometer Service Manual 82 EC-3700 EC-C400 EC-C400R Model MS-16 EC-1200 EC-1600 Replacing the Seat Post Knob 1. Pull out the seat post. 2. Remove the seat post knob by rotating and loosening the guide screw in the counterclockwise direction. Seat Post Knob Knob Rubber Base 3. Mount a brand new seat post knob by securely tightening the guide screw. 4. Insert the seat post. Guide Screw Fig. 1 Cateye ergometer Service Manual 83 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-17 EC-1200 EC-1600 Replacing the Lock Pin 1. Remove the lock pin by rotating and loosening the guide screw in the counter-clockwise direction. Lock Pin 2. Mount a brand new lock pin by securely tightening the guide screw. Wrench Guide Screw Fig. 1 Cateye ergometer Service Manual 84 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-18 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 Replacing the Crank Cover ■ REMOVAL 1. Remove both right and left pedals. (Fig. 1) Upright Type Crank 2. Loosen and remove the fixing screw on the surface of the crank cover. The narrow-width area of the crank cover should position in between the frame cover and the crank. (Figs 2 & 3) Recumbent Type No.15 Wrench ON OFF Pedal Crank Cover ■ ASSEMBLING 1. Pass the crank through the hole on the crank cover, and fix the crank cover onto the frame cover with screws. (Figs. 2 & 3) Fig. 1 Fig. 2 Crank Cover 2. Set the right and left pedals. Fig. 3 Cateye ergometer Service Manual 85 EC-C400R Model MS-19 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Center Cover of Upright Type 1. Loosen the four screws on the bottom of the control unit, remove the control unit, and then detach the cable connector. (Fig. 1) Handlebar Post 2. For EC-1600, slide the inner pipe of the handlebar post cover upward, and detach the 5P cable connector (Fig. 2). For EC-1200, remove the cable holder from the handlebar post. 3. Loosen the handlebar post knob, and pull out the handlebar post from the main unit. (Fig. 3) 5P Cable Fig. 1 Handlebar Post Knob 5P Cable Fig. 2 Fig. 3 Seat Post Knob 4. Pull the seat post knob upward, and pull out the seat post from the main unit. (Fig. 4) 5. Loosen and remove the guide screw of the seat post knob. (Fig. 5) Handlebar Post Cover Seat Post Knob Rubber Base Seat Post 6. Remove the rubber base of the seat post knob. (Fig. 6) 7. Slightly loosen the center cover fixing screws (6 pieces), and remove the center cover by pulling it upward. (Fig. 7) Guide Screw Fig. 4 8. The assembling of the center cover can be made in the procedures opposite to the above. Fig. 5 Center Cover Center Cover Fixing Screw Fig. 7 Cateye ergometer Service Manual 86 Fig. 6 Model MS-20 EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R Replacing the Center Cover of Recumbent Type * Remove the pulse rate sensor, if it is connected, before proceeding to the following procedures. Control Unit Inner Pipe 1. Remove the control unit fixing screws (4 pieces) from the main unit. (Fig. 1) 2. Detach the cable connector from the control unit. (Fig. 2) 3. Loosen and remove the inner pipe from the joint metal base. (Fig. 3) Caution Pulling out the inner pipe will make the machine unstable. As they are heavy, be sure that two persons work together to carry the units. Control Unit Fixing Screw Fig. 1 5P Cable Joint Metal Base Fig. 2 Frame Cover Fixing Screw Center Cover Inner Pipe 4. Remove the frame cover fixing screws, and the frame cover will be separated into right and left parts. (Fig. 4) 5. Remove the latch of the center cover from the frame cover, and pull the center cover toward the joint metal base to remove it. (Fig. 5) 6. Assembling of the center cover can be performed in reversed procedure of the above. Caution Joint Metal Base Fig. 3 Frame Cover Joint Fig. 4 Fig. 5 When installing each unit, be careful not to compact or kink the cord of the pulse sensor. Pull the 5P cable connector through the hole in the center cover and secure it provisionally with adhesive tape to prevent it from retracting. (Fig.5) Cateye ergometer Service Manual 87 Model MS-21 EC-1200 EC-3600 Replacing the Handlebar Grip 1. In case the handlebar grip is damaged, cut the grip with a thin cutting knife and peel it off the handlebar. (Fig. 1) Caution EC-1600 Brand new Grip Be careful that the blade of the cutter does not cause injury. 2. Fit a brand new 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) Air Gun, etc. Handlebar Existing Grip (Old) Fig. 2 Fig. 1 * When a compressor is not available, apply a soap water on the handlebar, and insert the grip while twisting and pressing the grip. * When the above replacing work is difficult to achieve, remove the handlebar before the work. Cateye ergometer Service Manual 88 EC-3700 EC-C400 EC-C400R Model MS-22 EC-1600 Replacing the Printer Cover 1. Remove the control unit to separate upper and lower bodies. Reference EC-1200 Printer Cover See the Items (1 & 2) in Section ES-6 "Replacing the Panel Keyboard." 2. Detach the existing printer cover, and mount the brand new printer cover. 3. Bring the upper and lower body together and assemble the control unit as one main unit. Reference See the Items (8 & 9) in Section ES-6 "Replacing the Panel Keyboard." Upper Body of Control Unit Fig. 1 Cateye ergometer Service Manual 89 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-23 EC-1200 EC-1600 Replacing the Paper Cutter 1. Remove the control to separate upper and lower bodies. Reference See the Items (1 & 2) in Section ES-6 "Replacing the Panel Keyboard." Paper Cutter 2. Loosen and remove four screws. Also, remove the spring. (Fig. 1) 3. Remove the existing printer cutter, and mount a brand new paper cutter. Caution Be careful that the paper cutter does not cause injury. Screws Spring Fig. 1 4. Set the spring so that it will fit into the groove of the paper cutter, and fix it with four screws. 5. Bring the upper and lower body together and assemble the control unit as one main unit. Reference See the Items (9 & 10) in Section ES-6 "Replacing the Panel Keyboard." Cateye ergometer Service Manual 90 EC-3600 EC-3700 EC-C400 EC-C400R Model MS-24 EC-1200 EC-1600 EC-3600 Replacing the Handle Stem 1. Turn off the power, loosen the four screws of the handle stem and then remove the control unit. (Fig.1) Handlebar Screw Bolt 2. Remove the cable connector linked to the rear of the control unit. (Fig.1) Handle Stem 3. Leave the handlebar lever loose. (Fig.1) 4. Loosen the bolt and pull the handle stem out from the main unit. (Fig. 2) Caution Be careful not to remove the bolt completely. Handlebar Lever Cable Connector Fig. 1 Fig. 2 5. Install a brand new handle stem and fasten the bolt. 6. Carry out the steps above in reverse order to reassemble handle stem. Cateye ergometer Service Manual 91 EC-3700 EC-C400 EC-C400R Model PNR.780-6100 PNR.780-6101 PNR.780-6106 PNR.780-6102 PNR.780-6107 Unit: pieces EC-1200 Control Unit(J) Ivory EC-1200 Control Unit(E) Ivory EC-1200 Control Unit(E) Black EC-1200 Control Unit(G) Ivory EC-1200 Control Unit(G) Black PNR.780-6108 EC-1200 Control Unit Multi Ivory PNR.780-6109 EC-1200 Control Unit Multi Black unit: pieces HR CON TRO EC-1200 EC-1600 PNR.781-6500 PNR.781-6501 PNR.781-6506 PNR.781-6502 PNR.781-6507 unit: pieces EC-3600 EC-1600 Control Unit(J) Ivory EC-1600 Control Unit(E) Ivory EC-1600 Control Unit(E) Black EC-1600 Control Unit(G) Ivory EC-1600 Control Unit(G) Black EC-3700 EC-C400 EC-C400R PNR.781-5600 EC-3600 Control Unit(J) PNR.781-5601 EC-3600 Control Unit(E) PNR.781-5602 EC-3600 Control Unit(G) unit: pieces L E ANC ADV OBIC AER AER OBIC WEIG HT LOS S HILL 1 E RAT SS PRE TO OPE LLY K" MA NUA UIC 2 3 INTE RVA "Q L 1 2 QU ICK L STA RT VALUE ADJUST DE STOP PNR.781-5900 PNR.781-5901 PNR.781-5916 PNR.781-5902 PNR.781-5917 unit: pieces EC-3700 Control Unit(J) Ivory EC-3700 Control Unit(E) Ivory EC-3700 Control Unit(E) Black EC-3700 Control Unit(G) Ivory EC-3700 Control Unit(G) Black PNR.080-6701 EC-C400 Control Unit(J) PNR.080-6702 EC-C400 Control Unit(E) PNR.080-6703 EC-C400 Control Unit(G) unit: pieces 1 10 ESS FITN T TES MODE ADV MO L MODE RVA RESET HR TRO CON L 1 INTE HIL NT STA E CON TAG WAT 10 3 PNR.780-5160 EC-1600/3700 Panel Keybord unit: sets ADVANCE SOUND ON/OFF PNR.780-6121 EC-1200 Button Panel(J) PNR.780-6120 EC-1200 Button Panel(E) PNR.780-6122 EC-1200 Button Panel(G) unit: sets EC-1600 EC-1200 FITNESS TEST HR CONTROL CONSTANT WATTAGE HILL INTERVAL QUICK MODE START VALUE ADJUST MODE ADVANCE STOP TitleNo SOUND ON/OFF PNR.781-5610 EC-3600 Button Panel(J) PNR.781-5611 EC-3600 Button Panel(E) unit: sets PNR.000-0000 EC-C400/C400R Button Panel(J) PNR.022-5481 EC-C400/C400R Button Panel(E) PNR.022-5482 EC-C400/C400R Button Panel(G) unit: sets PNR.000-0000 PNR.780-6061 PNR.780-6062 PNR.780-6063 unit: sets EC-1200 Decal(J) EC-1200 Decal(E) EC-1200 Decal(G) EC-1200 Decal(F) Cateye ergometer Service Manual 92 PNR.000-0000 PNR.780-6561 PNR.780-6562 PNR.780-6563 unit: sets EC-1600 Decal(J) EC-1600 Decal(E) EC-1600 Decal(G) EC-1600 Decal(F) Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R EC-3700 EC-1200 HILL HR CONTROL 1 ADVANCE AEROBIC 2 3 AEROBIC INTERVAL WEIGHT LOSS 1 2 3 TO OPERATE MANUALLY PRESS "QUICK" PNR.000-0000 EC-3600 Decal(J) PNR.781-5631 EC-3600 Decal(E) PNR.781-5632 EC-3600 Decal(G) unit: sets PNR.000-0000 EC-3700 Decal(J) PNR.781-5921 EC-3700 Decal(E) PNR.781-5922 EC-3700 Decal(G) unit: sets PNR.000-0000 EC-C400/C400R Decal(J) PNR.022-5471 EC-C400/C400R Decal(E) PNR.022-5472 EC-C400/C400R Decal(G) unit: sets PNR.781-5930 EC-3700/C400R Unit Base unit: pieces PNR.722-6501 Thermal Paper unit: sets PNR.736-6000 EC-1600/3700 Printer Unit unit: sets PNR.780-5111 EC-1600/3700 Printer Cover unit: pieces PNR.780-1031 EC-1600/3700 Paper Cutter unit: pieces PNR.780-1020 Paper Case unit: pieces PNR.780-1030 Paper Roller unit: pieces PNR.780-1100 EC-1200/1600 Pluse Sensor Set(1M) PNR.780-1101 EC-3600/3700 Pluse Sensor Set(2M) PNR.780-1102 EC-1200/1600 Pluse Sensor Set(1.5M) unit: sets PNR.780-1110 Pluse Sensor Cover Set unit: sets Cateye ergometer Service Manual 93 TitleNo R Model PNR.780-1200 Sensor Clip unit: pieces PNR.737-5500 PNR.737-5511 PNR.737-5520 PNR.737-5523 unit: sets PNR.703-3101 EC-3600/3700 Recumbent Seat unit: sets PNR.025-0030 EC-1200/1600 HORN TYPE Handlebar Grip PNR.725-0000 EC-1200 Handlebar Grip PNR.780-6470 EC-1600 Handlebar Grip PNR.781-5060 EC-3600/3700 Handlebar Grip unit: pieces AC Adapter (100V) J AC Adapter (120V) UL AC Adapter (220V) EC AC Adapter (240V) UK EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R PNR.781-6140 AC Adapter (100V) J PNR.781-6141 AC Adapter (120V) UL PNR.781-6142 AC Adapter (240V) UK PNR.781-6143 AC Adapter (220V) EC (For EC-C400/C400R/5000) unit: sets PNR.781-9100 Saddle (SMP 1209) unit: sets PNR.724-3410 EC-1200 Handlebar PNR.780-6450 EC-1600 Handlebar unit: pieces PNR.781-9000 EC-1200/1600 Handlebar Set (HORN TYPE) unit: pieces PNR.781-5130 EC-3600/3700 Handlebar unit: pieces PNR.781-3200 Handlebar Cap unit: pieces PNR.781-0210 EC-1200/1600 Handlebar Post unit: pieces PNR.780-6430 EC-1600 Handlebar Post Cover Set unit: sets Cateye ergometer Service Manual 94 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R PNR.758-5000 EC-1200/1600 Handlebar Lever Set PNR.780-6170 EC-1200/1600 Handlebar Stem unit: sets unit: sets PNR.785-1416 Adjusting Knob/Seat Hite Lock Knob PNR.780-6190 EC-1200/1600 Seat Post unit: pieces unit: pieces PNR.780-6050 EC-1200/1600 Post Spacer Set unit: sets PNR.780-9610 EC-1200/1600 Seat Pillar unit: pieces PNR.780-6260 EC-1200/1600/C400 New Seat Pillar PNR.785-1417 EC-1200/1600 Seat Post Knob unit: pieces unit: pieces PNR.781-5120 EC-3600/3700 Lock Pin unit: pieces PNR.780-6040 EC-1200/1600 Rubber Base for Knob unit: pieces PNR.781-5300 EC-3700/3600/C400R Grip unit: pieces Cateye ergometer Service Manual 95 PNR.780-6000 EC-1200/1600 Frame Cover(L/R)Ivory PNR.780-6001 EC-1200/1600 Frame Cover(L/R)Black unit: sets Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R 200 EC-1 EC-1 200 R R PNR.781-5000 EC-3600/3700 Frame Cover(L/R)Ivory PNR.780-6010 EC-1200/1600 Center Cover PNR.781-5001 EC-3600/3700 Frame Cover(L/R)Black unit: pieces unit: sets PNR.781-5500 EC-3600/3700 Center Cover unit: pieces C40 70 -3 EC EC EC EC- 0 0 -3 60 -3 -3 EC EC- 70 0 0 60 16 00 00 R 16 0 R 0 C40 EC- EC- PNR.780-6020 EC-1200 Crank Cover(L,R) Set unit: sets R R PNR.780-6420 EC-1600 Crank Cover(L,R) Set unit: sets PNR.781-5810 EC-3700 Crank Cover(L,R) Set unit: sets PNR.781-8100 EC-C400 Crank Cover(L,R) Set unit: sets PNR.781-5100 Pedal(L,R) unit: sets PNR.024-3700 Pedal Set (LU-214) L,R unit: sets PNR.781-9300 Pedal Belt E-16 (L,R) unit: sets EC -C 4 0 0 R R 0 0 4 -C EC PNR.781-5520 EC-3600 Crank Cover(L,R) Set unit: sets PNR.781-8110 EC-C400R Crank Cover(L,R) Set unit: sets Cateye ergometer Service Manual 96 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R PNR.024-3710 Pedal Belt Set (LU-214) L,R unit: sets PNR.780-6160 EC-1200/1600 Rear Leg with Level Adjuster unit: pieces PNR.780-6160 EC-1200/1600 Mod. Rear Leg unit: pieces PNR.780-0140 EC-1200/1600 Leveler Set unit: sets PNR.724-3950 EC-1200/1600 Levelling Knob unit: pieces PNR.780-6180 EC-1200/1600 Caster Pipe Set unit: sets PNR.780-6550 EC-1600 Vibration-proof Rubber unit: pieces PNR.780-6445 EC-1200/1600 Front Leg with Cover Set unit: sets PNR.781-0140 EC-3600/3700 Leveler Set unit: pieces PNR.787-2409 EC-3600/3700 Caster Pipe Set unit: pieces PNR.780-6446 EC-1200/1600 Front Leg with Cover Set PNR.786-2409 EC-3600/3700 Rear Leg with Level unit: sets Adjuster unit: pieces Cateye ergometer Service Manual 97 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R PNR.781-0150 EC-3600/3700 Caster Set unit: pieces PNR.781-5030 EC-3600/3700 Pipe Spacer Set unit: sets PNR.781-5040 EC3600/3700 Rear Support Pipe Spacer Set unit: sets PNR.780-7050 EC-1200B Workload Unit PNR.780-7060 EC-1600B Workload Unit(w/Flywheel) PNR.781-5581 EC-3700B/3600B Workload Unit (w/Flywheel) unit: pieces PNR.780-2240 Freewheel Set unit: sets PNR.724-4802 Crank Cap unit: sets PNR.718-0450 EC-1200/1600 Workload Unit Reinforcing Metal Base unit: pieces PNR.781-5580 EC-3600/3700 Workload Unit Reinforcing Metal Base unit: pieces PNR.780-7030 Idler A Set unit: sets PNR.780-7040 Idler Spring A unit: pieces PNR.780-2220 Idler Set unit: sets PNR.720-1110 Idler Spring unit: pieces Cateye ergometer Service Manual 98 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R PNR.780-7010 Pulley 1-B unit: pieces PNR.781-9200 Cartrige BB(YST-986A) unit: sets PNR.780-6990 Pulley 1-A Set unit: sets PNR.780-7020 Pulley 2-A Set unit: pieces PNR.780-7000 Pulley Flange unit: pieces PNR.724-1021 EC-1600B/1200B Teethed Timing Belt (P8M15-1192) PNR.724-1022 EC-3700B/3600B Teethed Timing Belt (P8M15-1080) unit: pieces PNR.780-6240 EC-1200/1600 Inlet Metal Base unit: sets PNR.780-6241 EC-3600/3700 Inret Metal Base unit: sets PNR.780-6030 EC-1200/1600 Inlet Cover unit: sets PNR.780-6220 EC-1200 5PCable unit: sets PNR.780-6480 EC-1600 5PCable (Upper) PNR.780-6481 EC-1600 5PCable (Lower) unit: sets PNR.781-5550 EC-3600/3700 5PCable unit: sets Cateye ergometer Service Manual 99 Model PNR.780-6241 CDC Sensor Set unit: sets PNR.780-6210 Power Supply Board unit: sets EC-1200 EC-1600 EC-3600 PNR.729-5010 Cable Clip Small (CV200) unit: pieces TO EC-3700 EC-C400 EC-C400R PNR.729-5025 Cable Clip Large (CV250) unit: pieces P D A MS C Wi rele ss He art Ra te Se nso r P TO T He A MS C Wi rel art Ra te Se nso r ess C A R D PNR.718-5140 EC-1200 Cable Holder unit: pieces PNR.722-4950 Date Card unit: sets PNR.701-7002 Chest-belt & Pulse Sensor Kit (TM-1600) unit: pieces PNR.169-9806 Chest-belt Set unit: pieces PNR.169-9826 Replacement Electrode Belt unit: pieces PNR.169-9816 Mounting Belt unit: pieces PNR.000-0000 Pulse Sensor Kit unit: pieces PNR.166-5150 Lithium Battery CR2032 unit: pieces Cateye ergometer Service Manual 100 Model EC-1200 EC-1600 EC-3600 EC-3700 EC-C400 EC-C400R R 3 R 1 IS -0 0R P 31 0- F-2 00 D C S 0R 50 -1 C E K R2 1 Q DC IN 5V OU T IN PNR.781-5180 EC-3600/3700/C400R Tool kit unit: sets PNR.758-1000 Cotterless Gear Crank Removing/ Fastening Tool unit: sets PNR.781-9210 Cartrige BB Removing Tool unit: sets PNR.758-1010 Freewheel Set Removing Tool unit: sets PNR.758-1080 Pin Face Wrench unit: sets PNR.737-7000 Tester unit: sets PNR.747-8000 Coil Current Measuring Cable unit: sets PNR.780-6110 PNR.780-6111 PNR.780-6112 PNR.780-6113 unit: sets EC-1200 Operating Instructions J EC-1200 Operating Instructions E EC-1200 Operating Instructions G EC-1200 Operating Instructions F PNR.780-6510 PNR.780-6511 PNR.780-6512 PNR.780-6513 unit: sets EC-1600 Operating Instructions J EC-1600 Operating Instructions E EC-1600 Operating Instructions G EC-1600 Operating Instructions F Cateye ergometer Service Manual 101 R R R PNR.701-5700 RS232C Communication Kit (100V) PNR.780-6350 EC-1200/1600/C400 Tool kit PNR.701-5701 RS232C Communication Kit (120V) unit: sets PNR.701-5703 RS232C Communication Kit (220V) unit: sets PNR.781-5700 PNR.781-5701 PNR.781-5702 PNR.781-5703 unit: sets EC-3600 Operating Instructions J EC-3600 Operating Instructions E EC-3600 Operating Instructions G EC-3600 Operating Instructions F Model EC-1200 EC-1600 EC-3600 rg E e 00 ey -C4 nual at EC Ma C ODELuction ¤ M rg E e 00 ey -C4 nual a t EC Ma C ODELuction ¤ str In M R In str o m et er m et o er 00 PNR.781-5990 PNR.781-5991 PNR.781-5992 PNR.781-5993 unit: sets EC-3700 Operating Instructions J EC-3700 Operating Instructions E EC-3700 Operating Instructions G EC-3700 Operating Instructions F PNR.000-0000 PNR.080-6751 PNR.000-0000 PNR.000-0000 unit: sets EC-3700 -C 40 0 RE CU NB EEC N-TC B40I K0ER E BIK T GH I R UP EC EC-12 ON OFF EC-C400 Operating Instructions J EC-C400 Operating Instructions E EC-C400 Operating Instructions G EC-C400 Operating Instructions F PNR.000-0000 PNR.080-6761 PNR.000-0000 PNR.000-0000 unit: sets EC-C400R Operating Instructions J EC-C400R Operating Instructions E EC-C400R Operating Instructions G EC-C400R Operating Instructions F Cateye ergometer Service Manual 102 R EC-3700 EC-C400 EC-C400R Model 1 PNR.752-1085 Hexagon Nut M8-3 unit: pieces 4 PNR.756-1412 Tapping Screw 4x12 with Washer unit: pieces EC-1200 EC-1600 EC-3600 2 EC-3700 EC-C400 EC-C400R 3 PNR.752-1063 Hexagon Nut M6-3 unit: pieces PNR.753-5410 Screw Set M6x12 unit: pieces PNR.750-9616 Screw Set(+) M6x16 unit: pieces PNR.750-1390 Spacing Spring unit: pieces PNR.750-8616 Cross-recessed Head Hexagon Screw M6x16 unit: pieces PNR.750-6810 Seat Post Adjust Screw M8x10 unit: pieces PNR.751-5330 Tapping Screw(2) 3x30 unit: pieces PNR.751-5208 Tapping Screw(2) 2x8 unit: pieces PNR.751-5206 Tapping Screw(2) 2x6 unit: pieces 5 6 PNR.753-6412 Tapping Screw(2) 4x12C unit: pieces Cateye ergometer Service Manual 103 Model EC-1200 EC-1600 7 PNR.752-5600 SW Nut M6 unit: pieces Cateye ergometer Service Manual 104 EC-3600 EC-3700 EC-C400 EC-C400R ® CO.,LTD. 2-8-25, Kuwazu, Higashi-ku, Osaka, 546-0041 JAPAN PHONE: 81-6-6719-7781 FAX: 81-6-6719-2362