CATEYE ERGOCISER
AUTOMATIC TYPE
Applicable Models: EC-1200/EC-1600/EC-3600/EC-3700
SERVICE MANUAL
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
How to Use This Service 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
T
R
E
S
E
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.
E
M
O
D
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.
EC- 1
6
0
0
N
O
0
0
7
EC- 3
F
F
O
Cateye Ergociser Series 1000 Service Manual
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Applicable Models: EC-1200
Name of Parts for Upright Type (w/o Flywheel)
Crank
Crank Cap
BB Set
Post Spacer
Lock Nut
Post Spacer
Lock Nut
Adjust Screw
Spacer Spring
9
6
Frame
Adjust Screw
Spacer Spring
9
6
5P Cable
Cable Holder
Seat Pipe
Large Gear
CDC Magnet
Timing Belt
Inlet Metal Base
Power Switch
Connector Cover
5P Cable Connector
CDC Sensor
Copper Plate
Idler
Idler Fixing Bolt [M6x16]
8
Frame
Idler Metal Base
Idler Spring
Wiring within Frame
Leg Cover
Leg Pipe
Leg Pipe Fixing Screw
Plastic Pulley
q SW Nut (M6)
Workload Unit
Solenoid Coil Mounting Base
Caster
Levelling Knob
Power Supply Board
4Workload Unit Mounting Base
Power Supply Board Fixing Screw
[Tapping Screw(2) 4x12c]
Levelling Knob
0
[Screw Set (+) (M6x16)]
Solenoid Coil
Cateye Ergociser Series 1000 Service Manual
4
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Applicable Models:
EC-1200
Handlebar Post
Seat Post
Cable Holder
Center Cover
Frame Cover
Crank Cover
EC-1 2 0 0
5
Tapping Screw (4x12) with Washer
Inlet Metal Base
AC Adapter Inlet
Chain
Crank Nut
9
Workload Unit Reinforcing Metal Base Nut
2
1
Power Supply Board
Workload Unit Reinforcing Metal Base
Hexagon Nut (M8-3)
Derailleur Spring
Leg Pipe Fixing Screw
Leg Pipe
Lever Cover
4
Workload Unit
Fixing Bolt
4
Solenoid Coil
Screw Set(+) (M6x16)
Derailleur Mounting Bolt
Thrust Washer (9x15.5x0.25)
Free Wheel Set
Hexagon Head U Nut
Levelling Knob
3
Derailleur
Cateye Ergociser Series 1000 Service Manual
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Applicable Models: EC-1600
Name of Parts for Upright Type (w/ Flywheel)
5P Cable Connector
Lock Nut
5P Cable
Post Spacer
Adjust Screw
Flywheel Mounting Metal Base
Post Spacer
BB Set
Crank Cap
Lock Nut
9
6
Adjust Screw [M8x10]
Spacer Spring
Crank
Seat Pipe
Cable Holder
Flywheel Metal
Flywheel Fixing Screw [SW Nut(M6)]
q
4
Large Gear
Flywheel Metal Base Fixing Screw
[Screw Set (+) (M6x16)]
CDC Magnet
Inlet Metal Base
Power Switch
CDC Sensor
Frame
Copper Plate
Idler
Idler Mounting Bolt [M6x16]
4
Idler Metal Base
Idler Spring
Timing Belt
Wiring within Frame
Caster
Plastic Pulley
Workload Unit
Leg Pipe Fixing Screw
Leg Pipe
q SW Nut (M6)
Solenoid Coil Mounting Base
Workload Unit Mounting Base
Power Supply Board
Leg Pipe
0
Power Supply Board Fixing Screw
[Tapping Screw(2) 4x12c]
4
[Screw Set (+) (M6x16)]
Levelling Knob
Solenoid Coil
Cateye Ergociser Series 1000 Service Manual
6
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Applicable Models:
EC-1600
Handlebar Post Cover
Seat Post
Center Cover
Flywheel Mounting Metal Base
Frame Cover
Crank Cover
CDC Magnet
Flywheel
Flywheel Fixing Screw
Power Supply Board
Flywheel Metal Base Fixing Screw
Flywheel Metal Base
5 Tapping Screw (4x12) with Washer
AC Adapter Inlet
Inlet Metal Base
Plain Belt
Chain
Workload Unit Reinforcing Nut
[Hexagon Nut (M6-3)]
2
1
Workload Unit Reinforcing Metal Base
Hexagon Nut (M8-3)
7 Crank Nut (M10x1.25)
Derailleur
Spring
Screw Set(+) (M6x16)
4
Solenoid Coil
Workload Unit
Hexagon Head U Nut
Derailleur Mounting Bolt
Thrust Washer (9x15.5x0.25)
3
Workload Unit Mounting
Bolt (M6x16)
4
Free Wheel Set
Derailleur
Cateye Ergociser Series 1000 Service Manual
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Applicable Models: EC-3600 EC-3700
Name of Parts for Recumbent Type (EC-3600 & EC3700)
Crank Nut
7
5P Cable Connector
5P Cable Set
Power Supply Board Fixing Bolt
0
Crank
Power Supply Board
Cable Holder
Wiring within Frame
Frame
BB Set
Flywheel Metal Base Fixing Screw
Flywheel
4
q
Copper Plate
Timing Belt
Flywheel Fixing Screw
Flywheel Metal Base
Idler
Idler Metal Base
Idler Fixing Bolt
8
Plain Belt
Idler Spring
4
Solenoid Coil
Mounting Base
Workload Unit Mounting Base [Screw Set (+) (M6x16)]
Frame Cover
Plastic Pulley
Solenoid Coil
Workload Unit
Center Cover
Crank Cover
Rear Support Pipe
Leg Pipe Fixing Screw
Inner Pipe
Seat Pipe
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-3600 EC-3700
Cable Holder
Chain
Power Supply Board
CDC Magnet
CDC Sensor
Cable Holder
Flywheel
Plain Belt
Screw Set (+) [M6x16]
4
2
Flywheel Fixing Screw
q
Workload Unit Reinforcing Nut
Flywheel Metal Base Fixing Screw
4
Workload Unit Reinforcing Metal Base
O
N
Inlet Metal Base
Workload Unit
O
F
F
Solenoid Coil
3
AC Adapter Inlet
Power Switch
Derailleur
Free Wheel Set
Mounting Bolt
Derailleur
Front Leg with Casters
Hexagon Head U Nut
Caster
Workload Unit Mounting Base
4
[Screw Set (+) (M6x16)]
Cateye Ergociser Series 1000 Service Manual
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Applicable Models: EC-1200B EC-1600B
Belt Drive
EC-1600B
EC-1200B
Teethed Timing Belt (P8M15-1192)
Pulley 1-A Set
Pulley Flange
Teethed Timing Belt (P8M15-1192)
Pulley 1-A Set
Pulley Flange
Pulley 2-A Set
Pulley 2-A Set
Pulley 1-B
Idler A Set
Idler Spring A
Pulley 1-B
Idler A Set
Idler Spring A
Workload Unit
Workload Unit
Cateye Ergociser Series 1000 Service Manual
ADD. 1
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Applicable Models:
EC-3600B/EC-3700B
Pulley 1-A Set
Pulley Flange
Belt Drive
EC-3600B/EC-3700B
Teethed Timing Belt (P8M15-1080)
Pulley 2-A Set
Pulley 1-B
Idler A Set
Workload Unit
Idler Spring A
Cateye Ergociser Series 1000 Service Manual
ADD. 2
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Applicable Models: EC-1200 EC-1600 EC-3600 EC-3700
Circuit Diagram for Automatic Type Cateye Ergociser
AC Adapter
Wiring within Frame
Black Cable (-)
CN4 (Connector 4)
100V AC
12V DC*
–
+
Switch
Red Cable (+)
DC Connector
AC Plug
AC Adapter Inlet
*Fluctuate depending on the electric load
About 16V when the load is zero.
DC Power Supply
CN4
Power Supply Board
CN3
(Connector 4)
+ –
Cadence Sensor
Magnet
C1
–
C2
–
+
R2
+
5P Cable to Control Unit
CN2
R8
Common Line
Cadence Signal
REG
R3
Control Unit Power Supply
VR1
R7
TR2
Solenoid Coil Current Control Signal
Printer Power Supply (+5V)
IC1
TR1
R1
Solenoid Coil Current Control Circuit
Power Supply Control Circuit
for Printer
CN1
D1
Metal Pulley
Timing Belt
Plastic Pulley
Chain
Cadence Sensor
Magnet
Coil
Large Gear
Pedal
Electromagnet
Copper Disk Plate
Free Wheel
Crank
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
No Display on Control Unit after Power ON. (1)
T-1
Check Method of Causes
Repair Method
Explanation Figures
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
Red Cable
DC Connector
1. Detach the plug of AC adapter from the AC adapter inlet of the
main unit.
2. Connect the wall socket plug of the AC adapter to the wall
socket.
Cable Connector
3. Using a tester, measure the voltage at the plug which will be
connected to the main unit. (Fig. 1)
Black Cable
t 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
and 19V.
Fig. 1
Fig. 2
Replace the AC adapter.
t When the measured voltage is 0V, or less than 14V, the
Normal for 14V thru 19V
AC adapter will be defective.
Note: Never short-circuit the plug of AC adapter. This will
damage the AC adapter.
Black Cable
Red Cable
[2] Checking the Wiring within the Frame
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)
Terminal
3 (+)
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.
5P Cable
Terminal 1 (-)
4. Using a tester, measure the voltage across the terminals 1 (-)
and 3 (+) of the 5P cable. (Fig. 3)
Replace the control unit.
Fig. 3
t The main unit side will be working fine if the meter reading
is in the range of 14V and 19V. This means the control unit
will be defective.
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
No Display on Control Unit after Power ON. (2)
T-1
Check Method of Causes
Repair Method
Explanation Figures
[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)
Note: The layout of the power supply board may be different from
lot to lot. (Figs. 5 and 6)
Black Cable
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, which connects the power supply
board and the control unit, may be defective.
Replace the 5P cable. (See the Section ES-2
"Replacing the Frame.")
Red Cable
Replace the Inlet Metal Base Set. (See the Section
ES-1 "Replacing the Wiring within the Frame."
t When the measured voltage is 0V, the wiring within the
Fig. 4
frame is defective.
Power Supply Board B
Power Supply Board A
Replace the power supply board. (See the Section
ES-3 "Replacing the Power Supply Board. "Fig. 4
t When the problem cannot be remedied even if the 5P cable
is replaced, the power supply board may be defective.
Fig. 6
Fig. 5
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
No Display of Cadence (The cadence remains at zero (0) and does not count when the pedal is rotated.)
T-2
Check Method of Causes
Repair Method
Explanation Figures
[1] Checking the Control Unit
1. Turn off the power. Loosen the four screws on the handlebar
stem to remove the control unit.
The case of no short-circuiting
Black Cable
2. Remove the cable connector which is connected to the back of
control unit.
The case a short-circuiting is found. One zero (0)
is detected during one rotation of the pedal.
5
4
3. Slowly rotate the pedal while measuring the resistance across
the connector terminals 1 and 2 of the 5P cable. (Fig. 1)
t When there is one short-circuiting (resistance becomes
zero) during one rotation of the pedal, the control unit is
defective.
3
2
1
Replace the control unit with a brand new one.
Terminal 2
When there is no short-circuiting, proceed to the following check
procedures.
Terminal 1
Red Cable
[2] Checking the Main Unit
1. Remove the frame cover. (See the Section D-1 and D-2
"Removing the Frame Covers.")
5P Cable
Fig. 1
2. Remove the CN-3 connector on the power supply board. (Fig.
2)
Power Supply Board
3. Slowly rotate the pedal while checking shortcircuit across the
two terminals of the CN-3 connector by using a tester to see if
there is one short-circuiting during one rotation of the pedal.
(Fig. 3)
The case of no short-
circuiting
The case a short-circuiting is
found. One zero (0) is detected
during one rotation of the pedal.
t If short-circuiting is found, the 5P cable which connects the
Replace the 5P cable. (See the Section ES-2
"Replacing the 5P Cable.")
Black Cable
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 relation between the CDC sensor and the
magnet of the large gear. (Fig. 4)
Red Cable
1. Align the line on the CDC sensor with the center of the CDC
magnet. (Fig. 5)
CN-3 Connector
2. Secure a gap of about 2mm between the surface of the CDC
sensor and that of the CDC magnet. (Fig. 5)
Check if there is any short-circuiting in the CN-3 connector again.
t When a short-circuiting is found, the positional relation
between the CDC sensor and the CDC magnet of the large
gear is incorrect.
Fig. 3
Fig. 2
Gap of 2mm between CDC Sensor and CDC
Magnet
Line on CDC Sensor
Line on CDC Sensor
t When there is no shortcircuit, the CDC sensor is defective.
Replace the CDC sensor. (See the Section ES-5
"Replacing the CDC Sensor".)
Center of CDC Magnet
Fig. 4
Center of CDC Magnet
Fig. 5
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
No Display of Pulse Rate
T-3
Check Method of Causes
Repair Method
Explanation Figures
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.
t When the pulse rate can be displayed, the pulse sensor is
Replace the pulse sensor with a brand new one.
Replace the control unit with a brand new one.
defective.
t When the pulse rate cannot be displayed, the control unit is
defective.
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1600 EC-3700
No Printer Operation
T-4
Check Method of Causes
Repair Method
Explanation Figures
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
RESET
ON
1. Check that the printer symbol is displayed on the LCD panel
and the printer is in a working status. (Fig. 1)
In case the printer symbol is not indicated on the LCD
panel, press the printer button to have the symbol
indicated.
Printer Symbol
10
10
1
1
1
2
3 4
OFF
TIME
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)
MODE
ADV
Select Switch
3 Check if the thermal paper is not jammed at the printer head.
Control Unit
Fig. 1
Back of Control Unit
t Remove the thermal paper if it is jammed. (Fig. 3)
Fig. 2
4. When no other problems are found, replace the control unit
with a brand new one.
Tweezer
5. With the new control unit installed, check the printer operation.
Printer Cover
t When the printer works fine, the control unit is defective.
When the printer does not operate after the above-stated checks,
Replace the control unit with a brand new one.
proceed to the following procedures:
[2] Checking the Main Unit
Cable Connector
1. Turn off the power, and loosen the four screws on the
handlebar stem to remove the control unit. (Fig. 4)
Paper Cutter
2. Remove the cable connector which is connected to the back of
the control unit. (Fig. 4)
Fig. 3
Fig. 4
3. Remove the frame cover. (See the Section D1 & D2
"Removing the Frame Covers.")
Normal when zero (0)
Power Supply Board
4. Remove the CN-2 connector on the power supply board. (Fig.
5)
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)
Replace the 5P cable. (See the Section ES-2
"Replacing the 5P Cable.")
t When there is no shortcircuit, the 5P cable is disconnected.
t When it is short-circuited, the power supply board is
Replace the power supply board. (See the Section
ES-3 "Replacing the Power Supply Board.")
Connector
Terminal 5
defective.
5P Cable
Fig. 6
Fig. 5
Connector Terminal 5
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
No Loading (Check of mechanical systems)
T-5
Check Method of Causes
Repair Method
Explanation Figures
[1] Checking the Mechanical Systems
Chain
See the Section D1 & D2 "Removing the Frame Covers" to remove
the frame cover, and check the inside of frame.
Replace the chain with a brand new one. (See the
Section MS-4 "Replacing the Chain.")
1. Check if the chain has not been broken. (Fig. 1)
2. Rotate the crank and check if the belt of the workload unit will
rotate. (Fig. 2)
Replace the free wheel with a brand new one. (See
the Section MS-5 "Replacing the Free Wheel Set.")
3. Check if the free wheel set is not idling. (Fig. 2)
Spray CRC into the gap as shown in Fig. 2, and rotate
the pedal in forward and backward directions.
Replace the workload unit. (See the Sections MS-1 &
MS-2 "Replacing the Workload Unit.")
4. Check 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 workload unit. (See the Sections MS-1 &
MS-2 "Replacing the Workload Unit.")
Free Wheel
Crank
Derailleur
Fig. 1
Gap
Timing Belt
Free Wheel
Plastic Pulley
Fig. 2
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
No Loading (Check of Electrical Systems)
T-5
Check Method of Causes
Repair Method
Explanation Figures
Power Supply Board
[2]Checking the Electrical Systems
1. Connect the AC adapter, and turn on the power of the main
unit.
2. Obtain the manual training program, set the pedal torque
setting to 4.0kg·m, and rotate the pedal at the rate of 50 rpm. If
you can rotate it quite easily, no load will be applied.
3. Replace the control unit with a brand new one.
4. Again, check the torque status under the manual training
program.
t When the pedal torque is loaded, the control unit is
Replace the control unit with a brand new one.
defective.
CN-2 Connector
When no torque loading is possible, proceed to the following
Fig. 2
Fig. 1
procedures.
Normal when zero (0)
1. Turn off the power, and loosen the four screws on the
handlebar stem to remove the control unit. (Fig. 1)
2. Remove the cable connector which is connected to the back of
the control unit. (Fig. 1)
3. Remove the frame cover. (See the Sections D1 & D2
"Removing the Frame Covers.")
4. Remove the CN-2 connector on the power supply board. (Fig.
2)
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)
Connector
Terminal 4
CN-1 Connector
Fig. 4
t When there is no shortcircuit, the 5P cable is disconnected.
Replace the 5P cable with a brand new one. (See the
Section ES-2 " Replacing the 5P Cable.")
When it is short-circuited, proceed to the following procedures:
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 and 14Ω,
the connector is all right. (Figs. 4 & 5)
5P Cable
Connector Terminal 4
Fig. 3
Normal for 14V thru 19V
t When the meter reading is exceedingly large, the solenoid
Replace the workload unit. (See the Sections MS-1 &
MS-2 "Replacing the Workload Unit.")
coil is defective.
t When the meter reading is in the acceptable range, the
Replace the power supply board. (See the Section
ES-3 "Replacing the Power Supply Board.")
power supply board may be defective.
Connector
Terminal 2
To Solenoid Coil
Connector Terminal 3
CN-1 Connector
Fig. 5
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1600 EC-3600 EC-3700
No Pedal Rotation (Locked)
T-6
Check Method of Causes
Repair Method
Explanation Figures
1. Remove the frame cover, and check the inside of 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
Apply the plain belt correctly. (See the Section MS-2
"Replacing the Workload Unit (w/ Flywheel).")
t The plain belt is damaged.
Replace the workload unit and free wheel with brand
new ones. (See the Section MS-2 "Replacing the
Workload Unit (w/ Flywheel).")
Plain Belt
Fig. 1
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Unusual Noise (Continuous and Increasing)
T-7-1
Check Method of Causes
Repair Method
Explanation Figures
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).
Chain
[1] Noise is continuous and increasing.
1. Remove the frame cover. (See the Sections D-1 & D-2
"Removing the Frame Covers.")
Apply grease to the following points. (Figs 1 & 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)
When it has been worn out, replace it with a brand
new derailleur set. (See the Section MS-6 "Replacing
the Derailleur Set.")
When it has been worn out, replace it with a brand
new idler set. (See the Section MS-7 "Replacing the
Idler 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.
4. Check if the plain belt has been deviated in position, thus
causing friction.
Derailleur
Fig. 1
Idler
Idler Set
Plain Belt
Timing Belt
Plastic Pulley
Fig. 2
Fig. 3
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EC-1200 EC-1600 EC-3600 EC-3700
Unusual Noise (Periodical)
T-7-2
Check Method of Causes
Repair Method
Explanation Figures
[2] Noise is Periodical.
1. Noise occurs around once per rotation of the pedal.
t The pedal installation may not be perfect. (Fig. 1)
No.15 Wrench
Use a No.15 wrench and securely fasten the pedal to
the crank. (both sides)
2. Sliding noise occurs around 17 times per rotation of the pedal.
Remove the frame cover, and check the inside of frame. (See the
Sections D-1 & D-2 "Removing the Frame Covers.")
Crank
t The copper disc plate of the workload unit may touch the
See the Section ES-4 "Correcting the Position of
Solenoid Coil," and correct the position of the copper
disc plate.
Pedal
solenoid coil. (Figs. 2 & 3)
[If the plate is warped and the position of solenoid coil
cannot be corrected, replace the workload unit. (See
Fig. 1
the Sections MS-1 & MS-2 "Replacing the Workload
Unit.")]
Solenoid Coil
Fig. 2
Core Slit
Core Slit
Copper Disc Plate
Core
Copper Disc Plate
Core
Solenoid Coil
Copper disc plate is in contact with the core.
Solenoid Coil
Correct Position
Fig. 3
Fig. 4
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Unusual Noise (Noise occurs when the pedal is rotated with a large torque.)
T-7-3
Check Method of Causes
Repair Method
Explanation Figures
Idler
[3] Noise occurs when the pedal is rotated with a large torque.
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. (See the
Sections D-1 & D-2 "Removing the Frame Covers.")
Hook the idler spring on the pawl of the idler.
Securely fasten the idler mounting bolt.
1. Check if the idler spring is detached.
2. Check if the idler mounting bolt is detached or loosened.
Idler Mounting Bolt
Idler Spring
dler Metal Base
Fig. 1
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EC-1200 EC-1600
Applicable Models:
Removing the Frame Covers
D-1
Upright Type (EC-1200 & EC-1600)
No. 15 Wrench
When any repair or adjustment of parts within the frame is required,
remove the frame covers in the following procedures.
REMOVAL
1. Remove the pedals at both the left and right sides. (The right
side pedal can be removed by turning it in the clockwise
direction, and the left side pedal can be removed in the
counter-clockwise direction.) (Fig. 1)
Crank
Pedal
O
N
O
F
F
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)
Crank Cover
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.
Fig. 2
Fig. 1
Lift upward.
Leg Pipe Fixing Screw
4. Shift the rubber base at the seat post lock knob away from the
center cover.
O
N
O
F
F
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)
Center Cover
7. Remove the frame cover fixing screw with a screwdriver before
removing the frame cover. (Fig. 6)
Rear
Front
ASSEMBLING
Leg Pipe Fixing Screw
1. Place the frame covers onto the frame at both right and left
sides, paying attention to the position of the crank.
Center Cover Fixing Screw
2. Fix the right and left frame covers with frame cover fixing
screws.
Fig. 3
Fig. 4
Frame Cover
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)
O
N
Four (4)
Screws
O
F
F
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.)
Inlet Cover
Fig. 5
Fig. 6
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Applicable Models:
EC-3600 EC-3700
Removing the Frame Covers
D-2
No. 15 Wrench
Recumbent Type (EC-3600 & EC-3700)
When any repair or adjustment of parts within the frame is required,
remove the frame covers in the following procedures.
Leg Pipe
Fixing Screw
àREMOVAL
Crank
Pedal
1. Remove the pedals at both the left and right sides. (The right
side pedal can be removed by turning it in the clockwise
direction, and the left side pedal can be removed in the
counter-clockwise direction.) (Fig. 1)
Front Leg with
Casters
Crank Cover
Fig. 3
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)
Fig. 1
3. Remove the leg pipe fixing screws. (Fig. 3)
* You do not have to remove the leg pipe itself.
Frame Cover
Center Cover
4. Remove the frame cover fixing screw with a screwdriver before
removing the frame cover. (Fig. 4)
Fig. 2
àASSEMBLING
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.
R
Screw
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.
Fig. 4
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the Wiring within the Frame
ES-1
Power Supply
Board
[A] Removing the Wiring Parts
1. Remove the frame cover. (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)
4. Cut the cable holder with a nipper. (Fig. 3)
[B] Mounting the Brand New Wiring Parts
1. Mount the brand new inlet metal base to the frame with two
screws.
ON
Inlet Metal Base
OFF
Inlet Metal Base
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.
Power Supply Board
EC-3600 & EC-3700
EC-1200 & EC-1600
Inlet Metal Base (for Recumbent Type)
Inlet Metal Base (for Upright Type)
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 and 19V.
ON
Screws
ON
DC Jack
5. Use the cable holder to fix the CDC sensor cable together with
the solenoid coil cable. (Fig. 3)
OFF
Screws
DC Jack
OFF
6. Provisionally connect the control unit, and check the unit works
fine after turning on the power. Then, completely assemble
the frame cover.
Fig. 1
Power Supply Board
Hold the stopper.
Cable Holders
Fig. 2
Fig. 3
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the 5P Cable (1)
Unit-Side Cable Connector
ES-2
Power Supply Board
Procedures are different depending on the type of model as shown
below:
àUpright Type (EC-1200)
T Removing the Existing Cable
Mark this point.
87cm
Cable
Connector
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.
3. Remove the frame cover. (See the Section D-1 "Removing the
Frame Covers.")
4. Remove the CN-2 connector from the power supply board.
(Fig. 2)
Screws
5. Cut the cable holders which fix the 5P cable to the frame, and
remove the 5P cable.
EC-1200
Fig. 1
Fig. 2
Fig. 3
T Mounting the Brand New Cable
Handlebar Pipe
1. Mark the 5P cable at a point approx. 87cm from the unit-side
cable connector (Fig. 3), and connect the leading end of the
CN-2 connector to the power supply board.
Horizontal Frame
2. (1)Using cable holders, fix the 5P cable at the bottom of the
handlaber 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)
(2)
(3)
Inner Handlebar Post Cover
Unplug
Cable
Connector
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. (See the Section D-1 "Removing the
Frame Covers.")
Cable Holders
Screws
EC-1600
Fig. 5
Fig. 6
àUpright Type (EC-1600)
(1)
T Removing the Existing Cable
EC-1200
5P Cable Handleber Post
1. Loosen the four screws which fix the control unit to remove the
control unit. Also, remove the cable connector. (Fig. 4) Slide
the inner handlebar post cover upward, and unplug the cable
connector. (Fig. 5)
Fig. 4
2. Remove the screws of both the handlebar stem and the outer
handlebar post cover to remove the 5P cable. (Fig. 6)
5P Cable within the Frame
5cm
Cable Connector
Cable Holder
1. Remove the frame cover. (See the Section D-1 "Removing the
Frame Covers.")
2. Remove the CN-2 connector at the end of the 5P cable from
the power supply board.
3. Cut the cable holders which fix the 5P cable to the handlebar
pipe, and remove the 5P cable.
Handlebar Stem
Cover
Screws
Fig. 7
To be continued on the next page.
Fig. 8
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the 5P Cable (2)
ES-2
T Mounting the Brand New Cable
10cm
Control Unit
5P Cable
5P Cable within the Handlebar Post
1. Using cable holders, bind the 5P cable, leaving approx. 5cm
portion from the control unit side cable connector, to the
handlebar post. (Fig. 7) Assemble the handlebar post cover
and the handlebar stem cover. (Fig. 6)
2. Connect the cable connector to the control unit, and fix the unit
to the handlebar post by using four screws. (Fig. 5)
(1)
Screws
5P Cable within the Frame
Cable Holders
1. Connect the CN-2 Connector at the end of the 5P cable to the
power supply board.
(3)
2. (1)Using cable holders, fix the 5P cable to the frame, leaving
the extra portion of 10cm 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. 8)
3. Provisionally connect the intermediate cable connector, and
turn on the power. Then, check if the control unit works fine.
Fig. 10
4. Mount the frame cover to restore the original shape. (See the
Section D-1 "Removing the Frame Covers.")
(2)
àRecumbent Type (EC-3600 and EC-3700)
T Removing the Existing Cable
EC-1600
1. Loosen the four screws which fix the control unit to remove the
control unit. Also, remove the cable connector. (Fig. 10)
Fig. 9
2. Remove the frame cover. (See the Section D-2 "Removing the
Frame Covers.")
3. Remove the 5P connector from the power supply board. (Fig.
2)
30cm
Power Supply Board
4. Cut the cable holders which fix the cable to remove the 5P
cable.
Cable Holders
T Mounting the Brand New Cable
1. Leaving approx. 30cm from the end of the frame, fix the 5P
cable to the frame by using cable holders.
2. Connect the 5P cable to the power supply board, and bind the
sagging portion to the point (2) of the frame. (Fig. 11)
3. Provisionally turn on the power, and check if the control unit
works fine.
4. Mount the frame cover. (See the Section D-2 "Removing the
Frame Covers.")
Fig. 11
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the Power Supply Board
ES-3
Power Supply
Board
[1] Replacing the Power Supply Board
1. Remove the frame cover. (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)
4. Securely fix the brand new power supply board by using two
fixing screws.
Power Supply Board
EC-1200 & EC-1600
EC-3600 & EC-3700
5. Connect three connectors, CN-2, CN-3 and CN-4.
[2] Adjustment of Coil Current Value
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 4.0kg m, and start
the system.
Fixing Screws
3. Adjust the potentiometer (as shown in Figs. 3 and 4) on the
power supply board with a blade-head 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.)
Power Supply Board
Example: When the indication is 630 as shown in Fig. 5,
adjust the potentiometer so that the coil current
value will be 630mA.
Cable for Measuring
Coil Current
Fig. 1
Fig. 2
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.
Power Supply Board B
Power Supply Board A
Solenoid
Coil
I
mA
COIL
K６０２０
LOT No.
Location of Coil Current Value Indication
Fig. 4
Fig. 5
Fig. 3
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Correcting the Position of Solenoid Coil
ES-4
Workload Unit
Reinforcing Metal
Base
Perform the positional correction of the core slit section after
detaching the frame cover and turning off the power. (See the
Sections D-1 & D-2 "Removing the Frame Covers.")
Workload Unit
Reinforcing
Metal Base
[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.
2. Adjust the two frame-side nuts of the workload unit reinforcing
metal base in the following procedures. (Fig. 1)
ON
OFF
A. Loosen the nut on the workload unit side, and the nut on the
frame side (Fig. 1).
Solenoid Coil
Solenoid Coil
EC-3600 & EC-3700
EC-1200 & EC-1600
B. If the right side of the copper disk plate contacts the core,
when the main unit is viewed from the direction as depicted
in Fig. 3, fasten the frame-side nut.
Workload-Unit-
Side Nut
Workload Unit Reinforcing
Metal Base
Core Slit
Core Slit
Copper Disk Plate
Core
Copper Disk Plate
Core
C.Then, fasten the frame-side nut on the other side until the
copper disk plate comes close to the center of the core slit
(Fig. 2). [ Rotate the copper disk plate slowly, and check for
any contacts on the entire area of the plate.
D.Fasten the nuts which had been tightened in the above step
A.
[2] In case correction is not possible by the method stated in [1].
I
mA
I
mA
Replace the whole workload unit. (See the Section MS-2 "Replacing
the Workload Unit (w/ Flywheel).")
Frame-Side Nut
Fig. 1
Solenoid Coil
Copper disk plate contacts the core.
Solenoid Coil
Correct Position
Fig. 3
Fig. 2
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the CDC Sensor
ES-5
CDC Sensor
1. Remove the frame cover. (See the Sections D-1 & D-2
"Removing the Frame Covers.")
Power Supply
Board
2. Detach the CN-3 connector from the power supply board. (Fig.
1)
3. Cut the cable holders which fix the CDC sensor cable to the
frame.
CDC Sensor
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 line on the CDC sensor with the center of the line
ON
on the CDC magnet. (Fig. 3)
OFF
Power Supply Board
T Adjust the gap between the surface of CDC sensor and the
EC-3600 & EC-3700
EC-1200 & EC-1600
Power Supply Board
surface of CDC magnet to be approx. 2mm. (Fig. 4)
* If the gap is inadequate, bend the metal base to secure the
specified gap.
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 holders.
(Fig. 5)
9. Assemble the frame cover. (See the Sections D-1 & D-2
"Removing the Frame Covers.")
CDC Sensor
CN-3 Connector
Fig. 1
Fig. 2
Approx. 2mm gap between CDC sensor and
CDC magnet
Line on CDC Sensor
Cable Holders
Center of CDC
Magnet
Center of CDC Magnet
Line on CDC Sensor
Fig. 4
Fig. 5
Fig. 3
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EC-1600 EC-3700
Applicable Models:
Substrate
Fixing Screw
Replacing the Panel Keyboard
ES-6
Substrate
Control Unit
Screw
1. Remove the control unit by loosening four screws. Also
remove the cable connector from the control unit. (Fig. 1)
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.
Cable Connector
3. Remove the connector on the panel 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)
Connector
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)
Fig. 2
Fig. 3
Fig. 1
Control Unit
5. If the silicon remains at the upper body, remove it thoroughly.
Panel Keyboard
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.
Upper Body
7. Apply silicon at two depicted areas to prevent intrusion of
sweat. (Figs. 4 and 6)
8. Mount the substrate and fix it with nine screws, and insert the
connector of the panel keyboard. (Fig. 3)
Fig. 5
9. Put the upper and lower body together, and fix them with eight
screws.
Silicon
10. Connect the cable connector to the control unit, and mount the
unit to the main unit.
Fig. 4
Silicon
Fig. 6
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Applicable Models:
EC-1200 EC-3600
Replacing the Button Panel
ES-7
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)
2. Clean the adhesive agent, if any, on the control unit before
placing a brandnew button panel.
*
Sufficiently press the button panel thus placed.
Button Panel
Control Unit
Fig. 1
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EC-1600 EC-3700
Applicable Models:
Replacing the Printer
ES-8
Printer Unit
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
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 the
connector CN-3, just pull it, while to remove connector CN-2,
the use of tweezer will be recommended. (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.
CN-3 Connector
Printer Fixing Screws
Fig. 2
Fig. 1
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 Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1600 EC-3700
Adjusting the Printing Darkness
Upright Type
Control Unit
Recumbent Type
ES-9
Control Unit
1. Remove the control unit from the main unit. (Fig. 1)
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.
Cable Connector
5. Turn on the power. Check if the printer symbol appears on the
LCD panel and the printer is in the operating condition.
Cable Connector
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.)
Fig. 1
Fig. 2
NOTE: Never touch the potentiometer DCV.
DCV
PR
Potentiometer PR
Fig. 3
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EC-1600 EC-3700
Applicable Models:
Paper Jamming in Printer
ES-10
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. (See the Operation Manual.)
Printer Unit
Fig. 1
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Applicable Models:
EC-1200
Replacing the Workload Unit (w/o Flywheel) (1)
MS-1
àRemoving the Workload Unit
1. Remove the frame cover, by referring to the Sections D-1 & D-
2 "Removing the Frame Covers."
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)
Power Supply
Board
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.
Workload Unit
Power Supply Board
EC-1200
CN-1 Connector
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)
Fig. 1
6. Remove the hexagon head bolts which fix the workload unit
(two bolts on either right and left sides). Lift the entire workload
unit upward until it comes off the workload unit fixing metal
base, and remove the unit by shifting it either in the right or left
side (Fig. 4). Be careful that the copper disk plate does not
touch the frame.
Wrench
Workload Unit
Reinforcing Metal Base
Cable Holder
Fig. 2
Fig. 3
Workload Unit
Workload Unit Fixing Hexagon Head Bolt
Fig. 4
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EC-1200
Applicable Models:
Replacing the Workload Unit (w/o Flywheel) (2)
MS-1
Wrench
Wrench
àMounting the Brandnew Workload Unit
Workload Unit
1. Assemble the brandnew workload unit so that it will engage
with the workload unit mounting metal base of the frame (Fig.
1). Be careful that the copper disk plate will not touch the
frame.
2. Tighten the crank nut 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 nut until the end of the crank shaft can level with the
end surface of the nut. Then, put the crank cap with a coin or
the like. (Fig. 4)
Cotterless Gear Crank Removing/
Fastening Tool
Cotterless Gear Crank
Removing/Fastening Tool
Fig. 3
Fig. 2
Workload Unit Fixing Metal Base
Fig. 1
3. Assemble the chain. Chain should first be set on the free
wheel before setting it to the upper part of the large gear.
Then, a forward rotation of the crank will enable the complete
setting on the large gear. (Fig. 5)
Upper Part of Large Gear
Coin
Derailleur
Spring
Chain
4. Set the derailleur spring to the pawl of the derailleur to give
tension to the chain. (Fig. 6)
5. Adjust the position 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 positioned at a right angle
to the derailleur spring. (Fig. 6)
Derailleur
Crank Cap
Fig. 6
6. Tighten the workload unit fixing screw (two screws on either
right and left sides). (Fig. 7) The tightening torque is 90kg·cm
to 120kg·cm.
Fig. 4
Fig. 5
Workload Unit Reinforcing Metal
Base
7. 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. 8)
* 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.
Workload-Unit-
Side Bolt
* 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.
Frame-Side Bolt
Workload Unit Fixing Screw
Fig. 7
Fig. 8
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Applicable Models:
EC-1200
Correct Position
Core Slit
Replacing the Workload Unit (w/o Flywheel) (3)
MS-1
Copper Disk Plate
Core
à Checking the Positions of Copper Disk Plate and Solenoid Coil
Workload Unit
Reinforcing Metal Base
Core Slit
T 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)
Frame-Side Nut
Workload-Unit-Side Nut
Fig. 1
T 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.
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). (See the Section ES-4 "Correcting the Position of
Solenoid Coil.")
Fig. 2
Power Supply Board
CN-1 Connector
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.
2. As shown in Fig. 2, 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 ammeter.
I
mA
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.
COIL
K 6 0 2 0
LOT No.
4. Using a blade-head screwdriver, adjust the potentiometer on
the power supply board so that the meter reading shows the
coil current which is specified on the solenoid coil of the
workload unit.
Cable for Measuring
Coil Current
Fig. 4
CN-1 Female
Connector
Example:As shown in Fig. 3, when 630 is indicated, adjust the
potentiometer so that the coil current will be 630mA.
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.
Fig. 3
6. Fix the cable onto the seat pipe with cable holders.
àAdjusting the Flywheel
1. Adjust the flywheel by referring to the Section MS-3 "Adjusting
the Flywheel."
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EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the Workload Unit (w/ Flywheel)
MS-2
Flywheel
àRemoving the Workload Unit
1. Remove the gear crank and the chain by referring to Items 1
through 4 of the 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)
Flywheel
3. Remove the four bolts which fix the flywheel metal base, and
remove the plain belt. (Fig. 2)
4. Remove the workload unit by referring to Items 5 and 6 of the
Section MS-1 "Replacing the Workload Unit (w/o flywheel)
(1)."
ON
Workload Unit
EC-1600
Workload Unit
EC-3600 & EC-3700
àMounting the Brandnew Workload Unit
Flywheel Fixing Nut
1. Assemble the brandnew workload 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)."]
Flywheel
Flywheel Metal Base
Flywheel Fixing Nut
Plain Belt
2. Hang the plain belt on the flywheel, and fix it to the flywheel
metal base with the flywheel fixing nut.
Flywheel Fixing Metal Base
Metal Base Fixing
Screw
3. Provisionally fasten the metal base fixing screw (4 pieces) to
the flywheel fixing metal base and the frame respectively. (Fig.
2)
4. Mount the workload unit by referring to Items 2 to 6 of the
Section MS-1 "Replacing the Workload Unit (w/o flywheel)
(2)."
Fig. 1
àAdjusting the Flywheel
Fig. 2
1. Adjust the flywheel by referring to the Section MS-3 "Adjusting
the Flywheel."
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Applicable Models:
EC-1600 EC-3600 EC-3700
Adjusting the Flywheel
MS-3
Spring Scale
àAdjustment Method of Flywheel
Flywheel Metal Base
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, 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.
Flywheel
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.
Metal Base Fixing Screw
Wire
Fig. 2
3. Keeping this status, fully tighten the four metal base fixing
screws which had been fastened provisionally. (Fig. 2)
Metal Base Fixing Screws
Flywheel Metal Base
Fig. 1
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the Chain
MS-4
1. Remove the frame cover by referring to the Sections D-1 & D-
2 "Removing the Frame Covers."
2. Use a screwdriver or the like to remove the derailleur spring
which is hung on the derailleur metal base, thus loosening the
chain.
Chain
Chain
3. First detach the chain at the upper part of the large gear, and
then rotate the crank forward to detach the entire chain. (Fig.
2)
4. The 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)
ON
OFF
5. Adjust the tension of chain. Hang the spring on the derailleur,
loosen the workload fixing screw, and adjust the tension while
sliding the workload unit back and forth. (Fig. 4)
EC-3600 & EC-3700
Crank
EC-1200 & EC-1600
* Be careful not to give excessive tension to the chain.
Large Gear
6. Assemble the frame cover by referring to the Sections D-1 &
D-2 "Removing the Frame Covers."
Derailleur Spring
Derailleur
Fig. 2
Fig. 1
Crank
Large Gear
Approx. 3 to 7mm of slack
Free Wheel
Fig. 3
Fig. 4
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the Free Wheel Set
MS-5
1. Detach the chain. (See the Section MS-4 "Replacing the
Chain.")
2. Hold the D-cut section on the free wheel shaft with a No.13
wrench, and remove the 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 the D-
cut section with a No.13 wrench. (Fig. 1)
4. Set the chain by referring to the Section MS-4 "Replacing the
Chain."
ON
OFF
Free Wheel Set
EC-1200 & EC-1600
Free Wheel Set
EC-3600 & EC-3700
Free Wheel
Idler
Timing Belt
Hexagon U-Nut
Free Wheel
D-Cut Section
Fig. 1
Fig. 2
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the Derailleur Set
MS-6
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 wrench,
and remove the derailleur set. (Fig. 2)
3. Mount the brandnew derailleur set with fixing screws.
4. Set the derailleur spring on the pawl of the metal base to give
tension to the chain.
ON
Derailleur Set
EC-3600 & EC-3700
Derailleur Set
EC-1200 & EC-1600
Derailleur Spring
Derailleur Fixing Bolt
Derailleur
Derailleur
Fig. 2
Fig. 1
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the Idler Set
MS-7
1. Remove the frame cover by referring to the Sections D-1 & D-
2 "Removing the Frame 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 bolt.
5. Hang the idler spring on the pawl of the idler to give tension to
the belt.
Idler Set
Idler Set
EC-1200 & EC-1600
EC-3600 & EC-3700
Idler
Idler
Idler Fixing
Bolt
Idler Spring
Fig. 1
Fig. 2
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the Crank Set (1)
MS-8
Crank Set
àRemoving the Gear Crank (Crank)
Crank Set
1. Remove the frame cover by referring to the Sections D-1 & D-
2 "Removing the Frame 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
wrench, rotate the crank nut to remove it. (Fig. 3)
5. Change the sides of a cotterless gear crank removing/
fastening tool, and rotate it clockwise to remove the gear crank
(crank) from the crank shaft. (Fig. 4)
ON
OFF
- to be continued to the next page -
EC-3600 & EC-3700
EC-1200 & EC-1600
Upper Part of Large Gear
Coin
Chain
Crank Cap
Fig. 1
Fig. 2
Wrench
Wrench
Cotterless Gear Crank
Removing/Fastening Tool
Cotterless Gear Crank
Removing/Fastening Tool
Fig. 4
Fig. 3
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the Crank Set (2)
MS-8
Right-Side
Crank
àAssembling the Gear Crank (Crank)
1. Mount the gear crank (crank) to the crank shaft.
2. Securely fasten the crank nut by using a socket wrench (or by
a cotterless gear crank removing/fastening tool and a wrench).
(Figs. 1 & 2)
Wrench
Wrench
* Respective cranks should be positioned each other to from
Left-Side Crank
Cotterless Gear Crank
Removing/Fastening Tool
an angle of 180° against the gear.(Fig.3)
Cotterless Gear Crank Removing/Fastening Tool
Fig. 1
3. Fasten the crank cap by using a coin, etc. (Fig. 4)
Fig. 2
Fig. 3
4. The chain should be first set on the free wheel, and then on the
upper part of the large gear. A forward rotation of the crank will
enable the complete setting of the gear. (Fig. 5)
Upper Part of Large Gear
5. Adjust the tension of chain. Loosen the workload fixing screw
[two screws at each right and left side (Fig. 6)], and adjust the
tension while sliding the workload unit. The tension of chain
should be adjusted as illustrated in Fig. 7.
Coin
* Be careful not to give excessive tensioning to the chain.
6. Adjust the clearance between the magnet mounted on the
large gear and the CDC sensor, and also adjust the positions
of the indication lines, by referring to Item (5) Section ES-5
"Replacing the CDC Sensor."
Crank Cap
Chain
7. Provisionally turn on the power, and check if the pedal
cadence is displayed on the control unit.
Fig. 4
8. Assemble the frame cover by referring to the Sections D-1 & D-
2 "Removing the Frame Covers."
Fig. 5
Approx. 3 to 7mm of Slack
Workload Unit Fixing Screw
Fig. 6
Fig. 7
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EC-1200 EC-1600 EC-3600 EC-3700
Applicable Models:
Replacing the BB Set
MS-9
BB Set
àREMOVAL
1. Remove the frame cover, by referring to the Sections D-1 & D-
2 "Removing the Frame Covers."
2. Remove the gear crank/crank from the crank shaft(BB axle),
by referring to the Section MS-8 "Replacing the Crank Set."
3. Remove the BB cup locking with a hanger rotating jig. (Fig. 1)
4. Remove the BB adjusting cup, by using a pin face wrench.
(Fig. 2)
5. Remove the crank shaft(BB axle).
6. Remove the BB fixing cup, by using the hanger rotating jig.
(Fig. 3) The CDC sensor metal base will be removed at the
same time.
BB Set
àASSEMBLING
EC-3600 & EC-3700
BB adjusting cup
EC-1200 & EC-1600
1. Check if no retainer remains within the hanger, and mount the
BB fixing cup. Be sure that the CDC sensor metal base should
first be mounted before mounting the BB fixing cup.
Hanger Rotating
Jig
2. Assemble the crank shaft(BB axle), retainer, BB fixing cup, BB
adjusting cup, BB cup locking and CDC sensor metal base 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.
Hanger Rotating
Jig
Pin Face Wrench
BB fixing cup
4. Adjust the following:
1. Align the line on the CDC sensor with the center of the line
on the magnet. (Fig. 5)
BB cup locking
CDC Sensor Metal
Base
2. Adjust the clearance between the CDC sensor surface and
the magnet surface to be approx. 2mm. (Fig. 6)
Fig. 1
Fig. 3
Fig. 2
* When the specified clearance has not been established,
bend the metal base to have the clearance.
Approx. 2mm Clearance between CDC
Sensor and Magnet
Retainer
CDC Magnet
5. Provisionally turn on the power, and check if the pedal
cadence is displayed on the control unit.
CDC Sensor Metal Base
BB fixing cup
Line
CDC
Magnet
6. Assemble the frame cover, by referring to the Sections D-1 &
D-2 "Removing the Frame Covers."
CDC
Sensor
BB adjusting cup
Hanger Pipe
BB cup locking
Retainer
Line
Center
Crank Shaft
(BB axle)
Center
CDC Sensor
Fig. 4
Fig. 6
Fig. 5
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Applicable Models:
EC-1200 EC-1600
Replacing the Post Spacer
MS-10
Spacer Spring
Adjust Screw
àREMOVAL
1. Remove the center cover, by referring to the Section MS-19
"Replacing the Center Cover of Upright Type."
2. Remove the lock nut located at the side of the frame, and then
remove the adjust screw. (Fig. 1)
Post Spacer
Boss
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
Press in.
àASSEMBLING
1. Insert a brandnew post spacer.
Fig. 2
2. Insert the spacer spring, and slightly fasten the adjust screw.
(Fig. 3)
Fig. 1
3. Insert the seat post (handleber post), and adjust the adjust
screw so that the post will drop slowly.
Lock Nut
4. Fasten the lock nut to lock the adjust screw.
Adjust Screw
5. Assemble the center cover, by referring to the Section MS-19
"Replacing the Center Cover of Upright Type."
Fig. 3
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Applicable Models:
EC-1200 EC-1600
Adjusting the Spacer Spring
MS-11
Lock Nut
1. Remove the center cover, by referring to the Section 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. 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."
Adjust Screw
Fig. 1
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Applicable Models:
EC-3600 EC-3700
Replacing the Inner Pipe Spacer
MS-12
àREMOVAL
Stopper Screw
Inner Pipe Spacer A
1. Slide the seat pipe to the utmost back end, and set it at a posi-
tion where the screw head can bee seen through the hole on
the top surface of the seat pipe.
Inner Pipe
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)
Boss
Seat Pipe
Fig. 1
4. Remove the spacer B at the end of the inner pipe. (Fig. 3)
àASSEMBLING
Fig. 2
1. Set a brandnew inner pipe spacer B into the seat pipe. (Fig. 4)
2. Insert the inner pipe spacer A and B together into the seat pipe.
Inner Pipe Spacer A
Inner Pipe Spacer B
Insert.
3. Align the hole on the top surface of the seat pipe with the screw
hole, and apply the stopper screw. (Fig. 1)
Inner Pipe Spacer B
Seat Pipe
Inner Pipe
Inner Pipe
Fig. 3
Fig. 4
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Applicable Models:
EC-3600 EC-3700
Replacing the Vertical Pipe Spacer
MS-13
Seat Hite Lock Knob
1. Remove the seat hite lock knob, and pull out the rear support
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.
Rear Support Pipe
3. Apply and set a brandnew rear support pipe spacer with an
adhesive tape.(Fig. 2)
4. Insert the rear support pipe, and fix it with the seat hite lock
knob.
Fig.1
Rear Support Pipe
Insertion Area
Rear Support Pipe Spacer
Fig.2
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Applicable Models:
EC-1200 EC-1600
Replacing the Leg Cover
MS-14
Leg Cover
àREMOVAL
1. Remove the leg pipe from the main body. Also, remove the
levelling knob. (Fig. 1)
Levelling 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
àASSEMBLING
1. Set the legcover onto the leg, and hammer it in. The use of a
wood block is recommended as a buffer. (Fig. 2)
*
A direct hammering of the leg cover may damage the
legcover.
2. Mount the levelling knob and assemble it to the frame.
Fig. 2
Fig. 1
Leg Cover
Fig. 3
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Applicable Models:
EC-3600 EC-3700
Replacing the Caster and Level Adjuster
MS-15
Front Leg with Casters (Rear Leg
with 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 press-fitted 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 brandnew caster (level adjuster) with a hammer and
a wood block. (Fig. 2)
4. Mount the front leg with casters (rear leg with level adjuster) to
the main unit (leg).
Wood Block
Wood Block
Front Leg with Casters (Rear Leg
with Level Adjuster)
Caster (Level Adjuster)
Fig. 1
Fig. 2
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Applicable Models:
EC-1200 EC-1600
Replacing the Seat Post Knob
MS-16
Knob Rubber Base
1. Pull out the seat post.
Seat Post Knob
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 tightening the
guide screw.
4. Insert the seat post.
Guide Screw
Fig. 1
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Applicable Models:
EC-3600 EC-3700
Replacing the Lock Pin
MS-17
1. Remove the lock pin by rotating and loosening the guide screw
in the counter-clockwise direction.
Lock Pin
2. Mount a brandnew lock pin by securely tightening the guide
screw.
Wrench
Guide Screw
Fig. 1
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the Crank Cover
MS-18
Upright Type
àREMOVAL
No.15 Wrench
1. Remove both right and left pedals. (Fig. 1)
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)
àASSEMBLING
Crank
Pedal
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)
O
N
O
F
F
2. Set the right and left pedals.
Crank Cover
Fig. 2
Fig. 1
Recumbent Type
Crank Cover
Fig. 3
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Applicable Models:
EC-1200 EC-1600 EE
Replacing the Center Cover of Upright Type
MS-19
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.
Handlebar Post Cover
5P Cable
5P Cable
3. Loosen the handlebar post knob, and pull out the handlebar
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)
Handlebar Post Knob
Fig. 2
Fig. 1
Fig. 3
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)
Seat Post Knob
8. The assembling of the center cover can be made in the
procedures opposite to the above.
Seat Post
Seat Post Knob
Rubber Base
Guide Screw
Fig. 5
Fig. 6
Fig. 4
Center Cover
Center Cover
Fixing Screws
Fig. 7
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Applicable Models:
EC-3600 EC-3700
Replacing the Center Cover of Recumbent Type
Control Unit
MS-20
* Remove the pulse rate sensor, if it is connected, before
proceeding to the following procedures.
1. Remove the control unit fixing screws (4 pieces) from the main
unit. (Fig. 1)
Inner Pipe
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)
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)
Joint Metal Base
Control Unit Fixing Screw
5P Cable
6. Assembling of the center cover can be performed in reversed
procedure of the above.
Fig. 2
Fig. 3
Fig. 1
*
Pull the 5P cable connector out of the center cover through
the hole on the cover, and tentatively hold it with an
adhesive tape so that it may not be retracted.
Frame Cover
Fixing Screw
Center Cover
EC
-
3 6 0 0
Frame Cover
Joint
Fig. 5
Fig. 4
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Applicable Models:
EC-1200 EC-1600 EC-3600 EC-3700
Replacing the Handlebar Grip
MS-21
1. In case the handlebar grip is damaged, cut the grip with a thin
cutting knife and peel it off the handlebar.(Fig. 1)
Brandnew Grip
2. Fit a brandnew handlebar grip onto the handlebar, utilizing
compressed air from a compressor, etc. Press the grip into the
handlebar while applying compressed air at one end.(Fig. 2)
*
When a compressor is not available, apply a soap water on
the handlebar, and insert the grip while twisting and
pressing the grip.
Air Gun,etc
*
When the above replacing work is difficult to achieve,
remove the handlebar before the work.
Handlebar
Existing Grip(Old)
Fig.1
Fig.2
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Applicable Models:
EC-1600 EC-3700
Replacing the Printer Cover
MS-22
Printer Cover
1. See the Items (1 &2), Section ES-6 "Replacing the Panel
Keyboard."
2. Detach the existing printer cover, and mount the brandnew
printer cover.
3. See the Item (8 & 9), Section ES-6 "Replacing the Panel
Keyboard."
Upper Body of Control Unit
Fig.1
Cateye Ergociser Series 1000 Service Manual
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Applicable Models:
EC-1600 EC-3700
Replacing the Paper Cutter
MS-23
1. See the Items (1 &2), Section 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.
Paper Cutter
4. Set the spring so that it will fit into the groove of the paper
cutter, and fix it with four screws.
5. See the Item (8 & 9), Section ES-6 "Replacing the Panel
Keyboard."
Screws
Spring
Fig. 1
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
PNR.780-6101 EC-1200 Control Unit(E) Ivory
PNR.780-6102 EC-1200 Control Unit(G) Ivory
PNR.780-6106 EC-1200 Control Unit(E) Black
PNR.780-6107 EC-1200 Control Unit(G) Black
unit: pieces
PNR.780-6108 EC-1200 Control Unit Multi Ivory
PNR.780-6109 EC-1200 Control Unit Multi Black
unit: pieces
PNR.780-6501 EC-1600 Control Unit(E) Ivory
PNR.780-6502 EC-1600 Control Unit(G) Ivory
PNR.780-6506 EC-1600 Control Unit(E) Black
PNR.780-6507 EC-1600 Control Unit(G) Black
unit: pieces
PNR.781-5601 EC-3600 Control Unit(E) Ivory
PNR.781-5602 EC-3600 Control Unit(G) Ivory
PNR.781-5606 EC-3600 Control Unit(E) Black
PNR.781-5607 EC-3600 Control Unit(G) Black
unit: pieces
VALUE ADJUST
VALUE ADJUST
MODE
ADVANCE
MODE
ADVANCE
SOUND ON/OFF
SOUND ON/OFF
PNR.781-5901 EC-3700 Control Unit(E) Ivory
PNR.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.780-6120 EC-1200 Button Panel(E)
PNR.780-6121 EC-1200 Button Panel(G)
unit: sets
PNR.781-5611 EC-3600 Button Panel(E)
PNR.781-5610 EC-3600 Button Panel(G)
unit: sets
EC- 1
6
0
0
EC- 3
7
0
0
EC- 1
2
0
0
EC- 1
2
0
0
PNR.000-0000 EC-1200 Decal(E)
PNR.000-0000 EC-1200 Decal(G)
PNR.000-0000 EC-1200 Decal(F)
unit: sets
PNR.000-0000 EC-1600 Decal(E)
PNR.000-0000 EC-1600 Decal(G)
PNR.000-0000 EC-1600 Decal(F)
unit: sets
PNR.000-0000 EC-3600 Decal(E)
PNR.000-0000 EC-3600 Decal(G)
PNR.000-0000 EC-3600 Decal(F)
unit: sets
PNR.000-0000 EC-3700 Decal(E)
PNR.000-0000 EC-3700 Decal(G)
PNR.000-0000 EC-3700 Decal(F)
unit: sets
R
PNR.000-0000 EC-3700 Unit Base
unit: pieces
PNR.722-6502 Thermal Paper(E)
unit: sets
PNR.736-6000 EC-1600/3700 Printer Unit
unit: sets
PNR.780-5111 EC-1600/3700 Printer Cover
unit: pieces
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
PNR.780-1031 EC-1600/3700 Paper Cutter
unit: pieces
PNR.780-1020 Paper Case
unit: pieces
PNR.780-1100 EC-1200/1600 Pluse Sensor Set (1M)
PNR.780-1102 EC-1200/1600 Pluse Sensor Set (1.5M)
PNR.780-1101 EC-3600/3700 Pluse Sensor Set (2M)
unit: sets
PNR.780-1030 Paper Roller
unit: pieces
PNR.780-1200 Sensor Clip
unit: pieces
PNR.780-1110 Pluse Sensor Cover Set
unit: sets
PNR.737-5500 AC Adepter J (100V)
PNR.737-5511 AC Adepter UL (120V)
PNR.737-5520 AC Adepter EC (220V)
PNR.737-5523 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.781-9000 Sporty Handlebar Set (HB-100)
unit: pieces
PNR.781-5130 EC-3600/3700 Handlebar
unit: pieces
PNR.725-0000 EC-1200 Handlebar Grip
PNR.780-6470 EC-1600 Handlebar Grip
PNR.781-5060 EC-3600/3700 Handlebar Grip
unit: pieces
PNR.781-3200 Handlebar Cap
unit: pieces
PNR.781-0210 EC-1200/1600 Hadlebar Post
unit: pieces
PNR.780-6430 EC-1600 Hadlebar Post Cover Set
unit: sets
PNR.758-5000 EC-1200/1600 Hadlebar Lever Set
unit: sets
PNR.780-6170 EC-1200/1600 Hadlebar Stem
unit: sets
PNR.785-1416 Adjusting Knob/Seat Hite Lock Knob
unit: pieces
PNR.780-6190 EC-1200/1600 Seat Post
unit: pieces
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
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 New Seat Pillar
unit: pieces
PNR.785-1417 EC-1200/1600 Seat Post Knob
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.780-6000 EC-1200/1600 Frame Cover(L/R) Ivory PNR.781-5000 EC-3600/3700 Frame Cover(L/R) Ivory
PNR.780-6001 EC-1200/1600 Frame Cover(L/R) Black PNR.781-5001 EC-3600/3700 Frame Cover(L/R) Black
unit: sets
unit: sets
0
0
2
0
6
0
0
1
0
-
0
0
C
6
E
E
C
-
1
C
-
1
E C -
1
2
E
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 Cover(L,R)Set
unit: sets
PNR.780-6420 EC-1600 Crank Cover(L,R)Set
unit: sets
R
R
R
R
PNR.781-5520 EC-3600 Crank Cover(L,R)Set
unit: sets
PNR.781-5810 EC-3700 Crank Cover(L,R)Set
unit: sets
PNR.781-5100 Pedal(L,R)
unit: sets
PNR.781-9300 Pedal Belt E-16 (L,R)
unit: sets
PNR.780-6160 EC-1200/1600 Rear Leg with Level Adjuster PNR.780-6160 EC-1200/1600 Mod. Rear Leg
unit: pieces unit: pieces
PNR.780-0140 EC-1200/1600 Leveler Set
unit: sets
PNR.724-3950 EC-1200/1600 Levelling Knob
unit: pieces
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
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/EC-1600 Front Leg with
Cover Set
unit: sets
PNR.780-6446 EC-1200/EC-1600 Rear Leg with
Cover Set
unit: sets
PNR.786-2409 EC-3600/3700 Rear Leg with Level
PNR.781-0140 EC-3600/3700 Leveler Set
unit: pieces
PNR.787-2409 EC-3600/3700 Caster Pipe Set
unit: pieces
PNR.781-0150 EC-3600/3700 Caster Set
unit: pieces
Adjuster
unit: pieces
PNR.781-5030 EC-3600/3700 Pipe Spacer Set
unit: sets
PNR.781-5040 EC3600/3700 Rear Support Pipe
PNR.780-2000 EC-1200 Workload Unit
PNR.780-2240 Freewheel Set
Spacer Set
PNR.780-6310 EC-1600/1200G Workload Unit (w/Flywheel) unit: sets
PNR.781-5580 EC-3600/3700 Workload Unit (w/Flywheel)
unit: pieces
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.780-2200 Derailleur Set
unit: set
PNR.720-1110 Derailleur Spring
unit: set
PNR.780-2220
unit: sets
Idler Set
PNR.720-1110 Idler Spring
unit: pieces
PNR.780-2240
unit: sets
Freewheel Set
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
PNR.780-6250 Crank Set
unit: sets
PNR.780-6240 EC-1200/1600 Inlet Metal Base
unit: sets
PNR.780-6230 EC-1200/1600 Chain
PNR.781-5570 EC-3600/3700 Chain
unit: pieces
PNR.781-9200 Cartridge BB (YST-986A)
unit: sets
PNR.780-6241 EC-3600/3700 Inlet 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
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
T
R
A
N
S
M
I
T
T
E
R
T
M
R
-
1
0
0
0
D
A
T
A
C
A
R
D
PNR.729-5025 Cable Clip Large(CV250)
unit: pieces
PNR.718-5140 EC-1200 Cable Holder
unit: pieces
PNR.722-4950 Date Card
unit: sets
PNR.701-6701 Wireless Heart Rate Senaor Kit (TM-
1000)
unit: sets
R3
R1
E
C
-1
K
I
S
-
5
0
0
0
R
C
0
0
0
-
0
R
S
DF-231
P
T
2
R
R
A
N
1
Q
S
M
IT
T
E
R
T
M
R
-
1
0
0
0
D
C
IN
V
5
O
U
T
IN
PNR.701-6801 Wireless Heart Rate Receiving Circuit
unit: sets
PNR.000-0000 Wireless Heart Rate Senaor
unit: sets
PNR.000-0000 HR Senaor Belt
unit: sets
PNR.701-5701 RS232C Communication Kit
PNR.701-5703 RS232C Communication Kit (220V)
unit: sets
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200B EC-1600B EC-3600B EC-3700B
Belt Drive
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.780-7050 EC-1600B/1200B Workload Unit
PNR.781-5581 EC-3700B/3600B Workload Unit
unit: pieces
PNR.780-6990 Pulley 1-A Set
unit: sets
PNR.780-7020 Pulley 2-A Set
unit: sets
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
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
1
3
2
PNR.752-1085 Hexagon Nut M8-3
unit: pieces
PNR.752-1063 Hexagon Nut M6-3
unit: pieces
PNR.723-2080 Thrust Washer 9x15.5x0.25
unit: pieces
PNR.753-5410 Screw Set M6x12
unit: pieces
4
5
6
7
PNR.750-9616 Screw Set(+) M6x16
unit: pieces
PNR.750-1390 Spacer Spring
unit: pieces
PNR.756-1412 Tapping Screw 4x12 with Washer
unit: pieces
PNR.724-4803 Crank Nut M10x1.25
unit: pieces
8
9
0
PNR.750-8616 Cross-recessed Head Hexagon Screw
PNR.750-6810 Seat Post Adjust Screw M8x10
unit: pieces
PNR.753-6412 Tapping Screw(2) 4x12C
unit: pieces
PNR.751-5330 Tapping Screw(2) 3x30
unit: pieces
M6x16
unit: pieces
q
PNR.751-5208 Tapping Screw(2) 2x8
unit: pieces
PNR.751-5206 Tapping Screw(2) 2x6
unit: pieces
PNR.752-5600 SW Nut M6
unit: pieces
Cateye Ergociser Series 1000 Service Manual
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Applicable Models
EC-1200 EC-1600 EC-3600 EC-3700
PNR.780-6350 EC-1200/1600 Tool Kit
unit: sets
PNR.781-5180 EC-3600/3700 Tool Kit
unit: sets
PNR.758-1000 Cotterless Gear Crank Removing /
Fastening Tool
unit: sets
PNR.781-9210 Cartridge 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
R
R
R
R
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
PNR.780-6512 EC-1600 Operating Instructions G
PNR.780-6513 EC-1600 Operating Instructions F
unit: sets
PNR.781-5701 EC-3600 Operating Instructions E
PNR.781-5702 EC-3600 Operating Instructions G
PNR.781-5703 EC-3600 Operating Instructions F
unit: sets
PNR.781-5991 EC-3700 Operating Instructions E
PNR.781-5992 EC-3700 Operating Instructions G
PNR.781-5993 EC-3700 Operating Instructions F
unit: sets
Cateye Ergociser Series 1000 Service Manual
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CO.,LTD.
®
2-8-25, Kuwazu, Higashi Sumiyoshi-ku, OSAKA, 546-0041 JAPAN
TEL: 81-6-6719-2631 FAX: 81-6-6719-2363
Copyright © Feb. 1995 CAT EYE Co., Ltd.
ECSM1E-991007-PDF
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