Cateye Ergociser EC-1200, Service Manual

Page 1: ...CATEYE ERGOCISER AUTOMATIC TYPE Applicable Models EC 1200 EC 1600 EC 3600 EC 3700 SERVICE MANUAL...

Page 2: ...S 13 Replacing the Vertical Pipe Spacer 50 MS 14 Replacing the Leg Cover 51 MS 15 Replacing the Caster Level Adjuster 52 MS 16 Replacing the Seat Post Knob 53 MS 17 Replacing the Lock Pin 54 MS 18 Rep...

Page 3: ...t 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...

Page 4: ...Knob Adjust Screw Spacer Spring Crank Crank Cap BB Set Post Spacer Lock Nut Adjust Screw Spacer Spring Seat Pipe Timing Belt Inlet Metal Base Power Switch Copper Plate Idler Idler Fixing Bolt M6x16 Id...

Page 5: ...Fixing Screw Leg Pipe Lever Cover Cable Holder Handlebar Post Seat Post Center Cover Frame Cover Crank Cover Workload Unit Fixing Bolt Free Wheel Set Hexagon Head U Nut Solenoid Coil Derailleur Mount...

Page 6: ...d Power Supply Board Fixing Screw Tapping Screw 2 4x12c Post Spacer Lock Nut Adjust Screw M8x10 Spacer Spring Seat Pipe Flywheel Metal Flywheel Fixing Screw SW Nut M6 Flywheel Metal Base Fixing Screw...

Page 7: ...n Nut M6 3 Workload Unit Reinforcing Metal Base Flywheel Mounting Metal Base Power Supply Board Hexagon Head U Nut Free Wheel Set Workload Unit Derailleur Spring Workload Unit Mounting Bolt M6x16 Dera...

Page 8: ...Power Supply Board Fixing Bolt Power Supply Board Crank Crank Nut 5P Cable Connector 5P Cable Set Cable Holder Frame BB Set Copper Plate Timing Belt Idler Idler Metal Base Idler Fixing Bolt Idler Spri...

Page 9: ...Workload Unit Hexagon Head U Nut Free Wheel Set Derailleur Solenoid Coil Derailleur Mounting Bolt Power Supply Board Cable Holder Flywheel Plain Belt Flywheel Fixing Screw Flywheel Metal Base Fixing...

Page 10: ...P8M15 1192 Pulley 2 A Set Idler A Set Idler Spring A Pulley 1 A Set Pulley Flange Pulley 1 B Workload Unit Teethed Timing Belt P8M15 1192 Pulley 2 A Set Pulley 1 B Idler A Set Workload Unit Idler Spri...

Page 11: ...me of Parts for Belt Drive Type Teethed Timing Belt P8M15 1080 Pulley 2 A Set Pulley 1 B Workload Unit Idler A Set Idler Spring A Pulley 1 A Set Pulley Flange Belt Drive EC 3600B EC 3700B Cateye Ergoc...

Page 12: ...g within Frame Switch CN4 Connector 4 DC Power Supply Connector 4 Power Supply Control Circuit for Printer Solenoid Coil Current Control Circuit Power Supply Board Cadence Sensor Magnet 5P Cable to Co...

Page 13: ...sured voltage is 0V or less than 14V the AC adapter will be defective Note Never short circuit the plug of AC adapter This will damage the AC adapter 2 Checking the Wiring within the Frame 1 When the...

Page 14: ...t The wiring within the frame is correct when the measured voltage is in the range of 14V and 19V When the voltage across the electrolytic capacitor on the power supply board is correct the 5P cable w...

Page 15: ...iting is found the 5P cable which connects the power supply board and the control unit is defective When there is no short circuiting proceed to the following check procedures 3 Check the positional r...

Page 16: ...d new one Replace the control unit with a brand new one No Display of Pulse Rate 1 Turn on the power to display the in training screen any exercise program 2 Install a brand new pulse sensor and check...

Page 17: ...ound replace the control unit with a brand new one 5 With the new control unit installed check the printer operation t When the printer works fine the control unit is defective When the printer does n...

Page 18: ...eck if the belt timing belt of the workload unit has not been broken Fig 2 5 Check if the plastic pulley of the workload unit has not been broken Fig 2 Replace the chain with a brand new one See the S...

Page 19: ...for any short circuiting across Terminal 1s and Terminal 4s at both ends of the 5P cable which connects the power supply board and the control unit Fig 3 t When there is no shortcircuit the 5P cable i...

Page 20: ...frame See the Sections D1 D2 Removing the Frame Covers 2 Check if the plain belt of the flywheel has not been detached Fig 1 t No damage on the plain belt t The plain belt is damaged Apply the plain b...

Page 21: ...2 Chain Inner surface of the timing belt mating surface with the plastic pulley 2 Check if the derailleur has been worn out Fig 1 3 Check if the idler has been worn out Fig 2 4 Check if the plain bel...

Page 22: ...Frame Covers t The copper disc plate of the workload unit may touch the solenoid coil Figs 2 3 Use a No 15 wrench and securely fasten the pedal to the crank both sides See the Section ES 4 Correcting...

Page 23: ...ated with a large torque A large sound bang occurs when the pedal is abruptly rotated with a large torque Remove the frame cover and check the inside of frame See the Sections D 1 D 2 Removing the Fra...

Page 24: ...the center cover 5 Loosen the center cover fixing screw a little and lift the center cover upward Do not remove it Fig 4 6 Loosen the four screws on the inlet cover Fig 5 7 Remove the frame cover fixi...

Page 25: ...ed in between the frame cover and the crank Fig 2 3 Remove the leg pipe fixing screws Fig 3 You do not have to remove the leg pipe itself 4 Remove the frame cover fixing screw with a screwdriver befor...

Page 26: ...s 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 th...

Page 27: ...ng portion should be binded with a cable holder Fig 4 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 scre...

Page 28: ...Fig 8 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 See the Section D...

Page 29: ...nit set the control unit to the manual mode set the load display to 4 0kg m and start the system 3 Adjust the potentiometer as shown in Figs 3 and 4 on the power supply board with a blade head screwdr...

Page 30: ...plate contacts the core when the main unit is viewed from the direction as depicted in Fig 3 fasten the frame side nut C Then fasten the frame side nut on the other side until the copper disk plate c...

Page 31: ...nsor 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 5 Perform the following adjustments Figs 3 and 4 T Align the l...

Page 32: ...nel keyboard which is located at the upper body side loosen the nine screws on the substrate and remove them from the upper body Fig 3 4 Since the panel keyboard is fixed to the control unit with sili...

Page 33: ...tting 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 2 Clean the adhesive agent if any on the control...

Page 34: ...removed after detaching cable connectors CN 2 and CN 3 of the printer unit To remove the connector CN 3 just pull it while to remove connector CN 2 the use of tweezer will be recommended Fig 2 4 Conn...

Page 35: ...r Check if the printer symbol appears on the LCD panel and the printer is in the operating condition 6 Check if the thermal paper is set in position 7 Adjustment should be done with the control unit p...

Page 36: ...Printer 1 Open the control unit into upper and lower bodies by referring to the Section ES 6 Replacing the Panel Keyboard 1 2 2 Remove the jammed paper with a tweezer or the like Fig 1 3 Assemble the...

Page 37: ...e paying attention not to damage the cable Fig 2 4 Remove the gear crank by referring to the Section MS 8 Replacing the Crank Set Also remove the chain together with the gear crank 5 Using a wrench lo...

Page 38: ...of the workload unit so that the tension of the chain at the workload unit can be adequate Move the workload unit back and forth so that the longer edge of the derailleur fixing metal base can be posi...

Page 39: ...wrench to tighten the frame side nut of the workload unit reinforcing metal base Give the even tightening to both right and left sides 2 As shown in Fig 2 set a cable for measuring coil current in bet...

Page 40: ...unit so that it will engage with the workload unit mounting metal base of the frame Fig 1 See the Item 1 of the Section MS 1 Replacing the Workload Unit w o flywheel 2 2 Hang the plain belt on the fly...

Page 41: ...ment use commercial tools since no purpose designed tool is not prepared 1 Set a commercial wire around the flywheel metal base as depicted in Fig 1 and tie up the both ends outside the frame 2 Hang a...

Page 42: ...brandnew chain should be hung firstly on the free wheel and then hang it over the upper part of the large gear A forward rotation of the crank will allow complete setting of the entire chain Fig 3 5 A...

Page 43: ...he hexagon U nut Then pull off the free wheel set by using a free wheel remover Figs 1 2 3 Mount the brandnew free wheel set and firmly tighten the hexagon nut Tightening should be done while holding...

Page 44: ...Derailleur Fixing Bolt Derailleur Replacing the Derailleur Set 1 Detach the derailleur spring from the pawl of the derailleur metal base Fig 1 2 Loosen the derailleur fixing bolt with a No 10 socket w...

Page 45: ...Covers 2 Remove the idler spring from the pawl of the idler metal base Fig 1 3 Loosen the idler mounting bolts and detach the idler set Fig 2 4 Mount a brandnew idler set by using an idler mounting b...

Page 46: ...Covers 2 Detach the chain by referring to the Section MS 4 Replacing the Chain Fig 1 3 Detach the crank cap with a coin or the like Fig 2 4 Use a cotterless gear crank removing fastening tool and a w...

Page 47: ...against the gear Fig 3 3 Fasten the crank cap by using a coin etc Fig 4 4 The chain should be first set on the free wheel and then on the upper part of the large gear A forward rotation of the crank...

Page 48: ...se as depicted in Fig 4 3 Mount the gear crank crank by referring to Mounting Items 1 thru 5 Section MS 8 Replacing the Crank Set Also adjust the tension of the chain 4 Adjust the following 1 Align th...

Page 49: ...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 ASSEMBLING 1 Insert a brandnew post spacer 2 Insert the spacer spring and...

Page 50: ...on MS 19 Replacing the Center Cover of Upright Type 2 Slightly loosen the lock nut at the side of the frame Fig 1 3 Fasten the adjust screw so that the seat post handleber post will drop slowly 4 Fast...

Page 51: ...sses located at the right and left sides of the seat pipe at the same time Fig 2 4 Remove the spacer B at the end of the inner pipe Fig 3 ASSEMBLING 1 Set a brandnew inner pipe spacer B into the seat...

Page 52: ...rt pipe Fig 1 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...

Page 53: ...crewdriver or the like to the damaged leg cover and knock the cover off paying attention not to damage the caster Fig 2 ASSEMBLING 1 Set the legcover onto the leg and hammer it in The use of a wood bl...

Page 54: ...casters rear leg with level adjuster from the main unit leg 2 The caster level adjuster has been press fitted into the front leg with casters rear leg with level adjuster It can be removed by hammeri...

Page 55: ...e Seat Post Knob 1 Pull out the seat post 2 Remove the seat post knob by rotating and loosening the guide screw in the counter clockwise direction 3 Mount a brandnew seat post knob by securely tighten...

Page 56: ...0 Applicable Models MS 17 MS 17 Fig 1 Replacing the Lock Pin 1 Remove the lock pin by rotating and loosening the guide screw in the counter clockwise direction 2 Mount a brandnew lock pin by securely...

Page 57: ...ng 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 ASSEMBLING 1 Pass the crank through the hole on th...

Page 58: ...ebar post from the main unit Fig 3 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 6 Remove the rub...

Page 59: ...rame 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 me...

Page 60: ...ar Fig 1 2 Fit a brandnew handlebar grip onto the handlebar utilizing compressed air from a compressor etc Press the grip into the handlebar while applying compressed air at one end Fig 2 When a compr...

Page 61: ...ng the Printer Cover MS 22 MS 22 Printer Cover Fig 1 Upper Body of Control Unit Replacing the Printer Cover 1 See the Items 1 2 Section ES 6 Replacing the Panel Keyboard 2 Detach the existing printer...

Page 62: ...ES 6 Replacing the Panel Keyboard 2 Loosen and remove four screws Also remove the spring Fig 1 3 Remove the existing printer cutter and mount a brandnew paper cutter 4 Set the spring so that it will...

Page 63: ...781 5902 EC 3700 Control Unit G Ivory PNR 781 5916 EC 3700 Control Unit E Black PNR 781 5917 EC 3700 Control Unit G Black unit pieces PNR 780 5160 EC 1600 3700 Panel Keybord unit sets PNR 781 5611 EC...

Page 64: ...523 AC Adepter UK 240V unit sets PNR 781 9100 Saddle SMP1209 unitsets PNR 703 3101 EC 3600 3700 Recumbent Seat unit sets PNR 724 3410 EC 1200 Handlebar PNR 780 6450 EC 1600 Handlebar unit pieces PNR 7...

Page 65: ...R Ivory PNR 781 5001 EC 3600 3700 Frame Cover L R Black unit sets PNR 780 6010 EC 1200 1600 Center Cover unit pieces PNR 781 5500 EC 3600 3700 Center Cover unit pieces PNR 780 6020 EC 1200 Crank Cove...

Page 66: ...s 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 2000 EC 1200 Workload Uni...

Page 67: ...PNR 781 5550 EC 3600 3700 5PCable unit sets PNR 780 6241 CDC Sensor Set unit sets PNR 780 6210 Power Supply Board unit sets PNR 729 5010 Cable Clip Small CV200 unit pieces PNR 729 5025 Cable Clip Larg...

Page 68: ...600B Workload Unit unit pieces PNR 780 7030 Idler A Set unit sets PNR 780 7040 Idler Spring A unit pieces PNR 780 7010 Pulley 1 B unit pieces PNR 780 6990 Pulley 1 A Set unit sets PNR 780 7020 Pulley...

Page 69: ...ut M10x1 25 unit pieces PNR 750 8616 Cross recessed Head Hexagon Screw M6x16 unit pieces PNR 750 6810 Seat Post Adjust Screw M8x10 unit pieces PNR 753 6412 Tapping Screw 2 4x12C unit pieces PNR 751 53...

Page 70: ...sets PNR 780 6111 EC 1200 Operating Instructions E PNR 780 6112 EC 1200 Operating Instructions G PNR 780 6113 EC 1200 Operating Instructions F unit sets PNR 780 6511 EC 1600 Operating Instructions E...

Page 71: ...CO LTD TEL 81 6 6719 2631 FAX 81 6 6719 2363 Copyright Feb 1995 CAT EYE Co Ltd ECSM1E 991007 PDF 2 8 25 Kuwazu Higashi Sumiyoshi ku OSAKA 546 0041 JAPAN...